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BACKGROUND OF THE INVENTION
This invention relates to web coating apparatus such as is used, for example, to coat paper for magazines. More specifically, this invention relates to a new type of holder to mount the rotating metering rod in the so-called"rod coater" type coating apparatus.
Rod coaters are well known in the papermaking industry as exemplified by U.S. Pat. Nos. 3,143,438; 3,179,083 and 3,683,851. Typical rod holders used in rod coating apparatus are exemplified by U.S. Pat. Nos. 3,683,851 and 3,701,335.
In existing rod coater equipment, as shown in the above cited patent apparatus, the rod is inserted into the rod holder longitudinally from one end which necessitates a bench assembly since the rod is inserted with a press or interference fit. The rod holder with inserted rod then in turn is mounted longitudinally in the coating apparatus which requires the coater to be "down", or in an inoperative status.
In addition, existing types of rod holders have no capability for having the size of the rod cavity adjusted to accommodate wear during the course of operation. In all rod coaters, the relatively abrasive coating materials containing various types of oxides and carbonates, wear away the surface of the rod holder cavity bearing against the rotating rod. Eventually, the gap between the rod and rod holder becomes so large that lubricating water escapes to deleteriously affect the coating applied to the web. Further, localized differences in the wear of the rod holder caused by variations in the distribution of the coating material which is picked up by the rod and carried into the cavity cause uneven wear which results in more water escaping in those localized places to delute the coating and thereby cause streaking in the web.
In order to extend the life of prior rod holders in rod coaters, the cylindrical cavity, or bore, formed in the rod holder was made smaller than the diameter of the rod, such as, for example, a 0.003 inch interference fit, so that the rod holder could accommodate additional wear before the gap between the rod and rod holder become too large to prevent an excessive amount of water to escape and mark the web being coated. Perhaps because of the interference fits, rods on existing coaterscommonly last only from ten days to two weeks before their chrome plating wears off. In addition, the wear of the cylindrical cavity in the rod holder of prior rod coaters becomes excessive (i.e. lubricating water begins to leak) typically after about two to three weeks of operation at which time the coater must be shut down to replace the rod holder. Naturally, this is very costly both from a standpoint of coater down time as well as the cost of replacing rods and rod holders.
Besides the short life of existing types of rod hodlers, their operation requires high initial torque to turn the rod due to the interference fit with the rod holder. As the rod holder cavity wears and becomes larger, the amount of lubricating water carried on the rod's surface and transferred to the coating increases and this may vary so much from the initial amount of water carried on the rod as to noticeably affect the appearance of the coating compared with its appearance when the rod holder is new.
SUMMARY OF THE INVENTION
This invention mitigates the deficiencies and problems associated with prior art rod coaters and even obviates some of the problems in their structure and operation. Operating uniformity and adjustability is provided by the utilization of two pressure tubes. The first pressure tube is positioned between a backing bar on a bracket mounted between the pivoted arm assemblies and a loading surface on the rod holder opposite the rod cavity. The first pressure tube operates to profile the nip line of the rod as desired. It can also be used to load the rod against the paper web on the backing roll.
The rod holder of this invention includes a lip extending substantially radially from one side of the rod cavity and longitudinally along the rod holder. An air inflatable, expandable second pressure tube coextends with the lip portion of the holder longitudinally of the holder body and parallel to the rod cavity. The second pressure tube operates to engage the lip and exert a uniform force along the length of the lip which causes that side of the rod cavity to uniformly deform and bear against the rod. Effectively, movement of the lip changes the diameter of the rod cavity to adjust for wear. This selectively variable deformation of the rod cavity is facilitated by making the rod holder of a plastic material, such as high density polyethylene.
Thus, as the rod holder cavity becomes larger with wear, the air pressure in the second pressure tube is gradually increased to move the lip and tighten the fit between the rotating rod and cavity so that the fit remains very much the same and the lubricating water carried on the rod surface is correspondingly uniform. This results in uniform metering of the coating which is very desirable.
The lip portion of the rod holder also permits the rod cavity to be enlarged, or opened, slightly so that the rod can be removed and a new rod installed from the front instead of the ends. The ability to adjust the size of the rod cavity opening permits rods to be changed without removing the rod holder from the machine as well as permitting longer life of both rod and rod holder. Rod holder life is increased from about 2-3 weeks on prior rod holders to an expected 3 months with this adjustable rod holder, although life will naturally vary according to operating conditions and with different materials.
Accordingly, it is an object of this invention to provide an improved rod holder for a metering rod on a coating apparatus wherein the rod holder cavity is adjustable in size to accommodate wear.
Another object of the invention is to provide a rod holder wherein the rod can be removed and installed from the front without forcing or deforming the lips.
Still another object is to provide a rod holder which is capable of adjusting the pressure with which it grips the rotating rod and thereby regulate the amount of lubricating water carried on the rod into the coating material.
Yet another object is to provide a rod holder which has an extended usable life greater than about three weeks.
A feature of this rod holder is the utilization of two pressurized air tubes to align or profile the rod and adjust the effective diameter of the rod cavity.
These and other objects, features and advantages of the invention will become readily apparent to those skilled in the art when the attached drawings of the preferred embodiment are viewed in conjunction with the following description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, partially in section, of the rod holder assembly shown in operating position against the coater backing roll.
FIG. 2 is a front view of the rod holder.
FIGS. 3, 3A, B and C are cross sectional views of the rod holder and illustrate how the rod cavity is adjusted for wear.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, a coater backing roll 10 is rotating in direction of arrow 11 while supporting a paper web 12 on which a film of coating 14 has been deposited by coating apparatus which is not shown. A metering rod 18 is rotatably mounted in a cylindrical cavity, or bore, 20 extending longitudinally in a rod holder 16 and is positioned against the paper web on the backing roll with the axes of rotation of the rod and backing roll being parallel. A drive motor 50 is operably linked to the rod to rotate the rod in the direction opposite to that of the backing roll as indicated by directional arrow 19.
The rod holder is mounted on a bar 40 with a clamp 42 between a pair of arm assemblies 54, one on either side of the coater. The arm assemblies are pivotally mounted in the coater framework to pivot about an axis 52 against and away from the backing roll in the direction of two headed arrow 60. The arm assembly 54 on either side of the coating apparatus is engaged by an air spring 56 which provides force in the direction of arrow 58 against each arm assembly 54 to move the rod into and out of engagement of the paper web against the backing roll.
On the rod holder 16, at a location behind the rod cavity, a load surface 22 is formed against which the first pressure tube 28 is positioned. The first pressure tube is mounted in a plurality of abutting, axially extending segments of a backing bar 41, each of which segments is about 6 inches long. Each backing bar segment has an adjustment screw 46 extending rearwardly thereof through the back side of an adaptor 43 mounted on the bar 40. Each adjustment screw 46 extends through a corresponding adjustment nut 44, each of which rests in a slot, open at the top, in the adaptor 43. Holding the backing bars 41 and the knurled adjustment nut 44 in place is a clamp 48.
A first air supply source 32 is connected to the first pressure tube 28, and a second air supply source 34 is connected to a second pressure tube 30 which will be described in more detail later.
As shown more clearly in FIG. 2, a pair of conduits 36, 38 extend longitudinally along the cavity 20 in the rod holder. A pressurized water source 62 is connected to one conduit 36 at one end of the rod holder while a second source of pressurized water 64 is connected to conduit 38 on the opposite end of the rod holder. Conduits 36, 38 are fluidly linked with bore 20 by a plurality of spaced passages 37, 39, respectively. The flow of water through the conduit and passages thus operate to provide cross flow to promote removal of the coating material uniformly along the length of the rod. The water also lubricates the rod.
In operation, a pair of air springs 56, one operating against the end of arm assembly 54 on either side of the coating apparatus, are actuated to pivot the rod holder apparatus towards the paper web 12 supported on the backing roll 10. A drive motor 50 rotates the rod within the rod holder in a direction indicated by arrow 19 which is opposite to the direction 11 of the paper being carried on the backing roll. The speed with which rod 18 turns is variable and controlled by the machine operator. Usually, the rod rotational speed varies from about 60 rpm to about 120 rpm, depending on other factors, such as backing roll speed and coating composition, as will be explained shortly. Normally, a rather heavy amount of coating 14 (i.e. about 10 lbs/1000 ft 2 ) is applied to the paper web downstream of the location where rod 18 nips the web on the backing roll. This rod nip pressure typically varies from about 8 pli to about 18 pli and can be provided in either of two ways. The most common, and preferred, way is by means of the air springs 56 operating against the extensions 54 of the arm assemblies on either side of the coating apparatus. The rod nip pressure against the backing roll is then dependent on the air pressure in the air springs 56. However, if desired, the air springs 56 can be used to rotate the whole rod assembly about the pivot axis 52 against stops on the coating apparatus framework (not shown) so that rod 18 just barely touches the web surface on which the coating is to be metered. There is little, or no, nip load. Then, the first pressure tube 28 is pressurized to provide a uniform force against the loading surface 22 along the back side of the rod holder 16 to urge rod 18 into nipping engagement with the web at the desired nip load.
Regardless of the manner used to load rod 18 against the traveling web, the metering action of rod counter rotating against the coating carried on the traveling web reduces the coating weight to about 2 lbs/1000 ft 2 of web area.
It is very important that the coating applied to the web be applied uniformly over the entire web area. Ideally, of course, this would mean that the horizontal nip on the cylindrical rod surface be perfectly straight as it extends longitudinally in the cross machine direction. However, due to various irregularities in the machinery and web forming process, the web itself almost invariably is not of a uniform profile, or caliper, in the cross machine direction. Quite simply stated, this means that somewhere along the width of the web, there will be a bulge or depression in the web of perhaps several ten thousandths, or even thousandths, of an inch variation in caliper. In order to coat such a web as uniformly as possible, it is desirable to profile the nip line of contact of the rod to match, as closely as possible, the contour of the web in the cross machine direction. This is accomplished by providing a segmented backing bar 41 against which the first pressure tube 28 bears to provide the nip loading force to the metering rod 18. Backing bar 41 is made up of a plurality of segments, each of which is about 6 inches long, as desired, and which are disposed in end abutting relationship for the entire longitudinal operating length of pressure tube 28.
In the center of each segment of backing bar 41, a threaded adjustment screw 46 is mounted to extend out of the back of adaptor 43. Each adjustment screw is mounted through a threaded adjustment nut 44 which is knurled. By turning the adjustment nut 44 on the appropriate segment of the backing bar 41, the corresponding portion of the pressure tube 28, which is mounted in a longitudinally extending groove in the forward side of each segment, is moved slightly forward or backward, as desired, from the load surface 22 on the back side of the rod holder so that the rod surface at that location is urged to conform to the profile of the paper web at that location on the backing roll to operate to meter the coating to provide an equal thickness of coating along the entire web width. Construction of the adjustment nut 44 and adapter 43 is such that the adjustment nut 44 is captured in a slot in adapter 43. Thus when adjustment nut 44 is turned, either forward or backward movement of the adjustment screw 46 is produced. Those adjustment nuts 44 that are not turned hold their respective adjustment screws stationary. This arrangement allows for selective adjustment of backing bar segments.
As the rod rotates in the rod holder cavity, the cavity begins to wear away and enlarge under the abrasive action of the coating material which is carried into the interface between the rod and holder cavity. The normally cylindrical bore may become non-cylindrical upon enlargement. In prior types of rod holders, which have cylindrical rod cavities of a fixed diameter, it has been found that when the wear on the rod and rod holder creates a gap of 0.002 inch or more, the quantity of water carried by the rotating rod from the lubricating slot becomes sufficiently large to dilute the coating to an extent which deleteriously marks the web. Typically, this occurs after about 10 days to 3 weeks of operation. Since the rods in prior types of coaters must be installed from the end of the holder with an interference fit to increase operating life, the coater had to be shut down and the rod holder removed to install a new rod.
In the apparatus of this invention, the rod 18 and its cylindrical rod cavity 20 are designed to be mounted with substantially a normal press fit. As an example, the rod would have a chrome plated surface with a finish dimension of 0.378/0.377 inch diameter. The rod cavity would have a finish diameter of 0.377/0.378 inch.
As the cylindrical cavity surface wears away during operation, the side of the cavity, or bore wall, from which the lip portion 24 of the rod holder extends is designed to turn or close inwardly towards the axis of the rotating rod for a distance of about 0.015 inch, although this distance is really a function of many factors, such as the size of the rod holder, the rod cavity, the length of lip portion 24 and the material used in its construction and can therefore be made greater or smaller as desired. As shown in FIGS. 3A, 3B and 3C, this movement of essentially one side of the cavity wall is accomplished by the lip 24 being pivotally turned by the uniform force against the second surface 26 by increasing the pressure within second pressure tube 30. In FIG. 3B, the cavity has enlarged to a greater size as indicated by numeral 20a. The enlarged cavity 20a may no longer be cylindrical. As shown in FIG. 3C, the force designated by arrow 66, which is supplied by inflating second pressure tube 30, has turned lip portion 24 a distance "D" which has caused the associated part of cavity 20a to turn inwardly to effectively decrease the diameter of cavity 20a. The locations of lip portion 24, before pressure is applied, and enlarged cavity 20a are shown in dashed lines in FIG. 3C. Depending on the air pressure supplied to pressure tube 30 by the second source 34 of air supply, such as an air compressor, the size of cavity 20a can be reduced slightly or effectively returned to the size of original cavity 20. This allows the sealing pressure of the rod holder cavity wall to be maintained against the rod surface as desired and, concomitantly, it maintains the desired fit between the rod and rod holder cavity. Movement of the lip portion does not necessarily return the bore to its original, cylindrical shape, but this isn't necessary. Maintaining the fit between rod and rod holder as constant as possible and preventing excessive water leakage around the rod is the goal. By doing this, the torque required by drive motor 50 to turn the rod will also remain nearly constant and the rod will operate more uniformly to smooth the coating. A uniform fit also enhances the quality of the coating process because the film of water carried by the rotating rod from the lubricating slots 36, 38 onto the coating, as the rod meters the coating to the desired weight, is also controlled thereby to ensure that it does not become so great to cause streaking or otherwise lessen the appearance of the coating.
The rod speed is increased or decreased within a range of, for example, about 60 to about 120 rpm, to prevent a pattern from forming on the metered coating on the web due to film splitting. Film splitting is a phenomenon which occurs when liquid coating material is present between two surfaces which are moving in different directions. A typical example occurs when a web on which coating has been deposited is passed between a pair of nipped rolls. Both the web and either or both of the roll surfaces contact the coating. The web and the roll surface diverge on the off-going side of the nip. The coating material is literally split into two films, one of which stays on the web while the other remains on the roll surface. As the coating splits into two films, the interface consists of a multitude of thread-like portions of liquid coating material, each of which has one end contacting one of the diverging surfaces. These portions are sometimes referred to as "stickies" in the trade. When the thread-like portions eventually break, the material that returns to each surface causes some marking on the film formed on the web which is undesirable because it blemishes the just previously coated surface.
The rod speed is adjusted by the machine operator as a function of backing roll speed, coating weight and type as well as other factors, such as humidity or temperature which might affect the coating process. The rod rotating in a direction counter to the direction of the coated paper web operates to lay the "stickies" of the split film back down onto the web so that no pattern or blemish is imparted to the web which would otherwise be caused when the split film carried by the rod is pulled away from the split film which remains on the traveling web.
The rod is chrome plated to provide a smooth surface that won't contaminate the coating material. When the chrome coating on the rod has worn away, or when the rod holder cavity has become so large that the second pressure tube can no longer provide the force necessary to maintain the desired fit due to the increased distance the lip must turn, rod 18 can be removed from the face of the rod holder by depressing second pressure tube 30 and simply pushing lip 24 inwardly to allow the rod to be popped out of the front of the rod holder and a new rod installed. In the case where the chrome plating of the rod has worn away, a new rod of the same size is installed. In the case where the cavity has enlarged beyond its desired size, a larger diameter rod may be installed. In either case, the rod can be replaced without removing the rod holder from the coater, thus saving a considerable amount of time.
While the preferred embodiment of this rod coating apparatus has been set forth in detail, it is contemplated that various changes in the apparatus and substitutions made in the materials for the components parts can be made without departing from the spirit and scope of the appended claims. For example, while polyethylene is preferred material for the rod holder, other materials, such as polypropylene, vinyl and Teflon may be used with satisfactory results. The essential aspect is that the material forming the bore wall in the rod holder be made of a stiff, resiliently deformable material so that it can hold the rotating rod and yet be capable of being selectively moved to effectively change the bore diameter responsive to movement of the lip portion. Obviously, the most natural, and preferred, way of accomplishing this is to make the entire rod holder of a suitable plastic material, such as polyethylene. However it is contemplated that not all of the rod holder per se need to be made of the same material in order for the rod holder to function according to the principles set forth. For example the lip portion of the rod holder could be made of metal and the rod holder could still operate to change the size of the cavity, as desired.
Also, the tolerances for the rod diameter and rod holder cavity opening as well as the degree of permissible wear in the rod holder before replacement is desired are intended to be illustrative rather than representing limits on their relationships.
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A holder for rotatably mounting the metering rod in a rod-type web coating apparatus, such as used to coat paper, is made of a rigid but yieldably deformable material, such as a plastic. The holder includes a plurality of longitudinally extending conduits for carrying water to lubricate the rotating rod and removing coating particles which are carried by the rod from the web surface and into the rod cavity. The holder has a surface opposite the rod cavity for receiving a uniformly applied load along the longitudinal length of the rod holder for aligning the rod surface and/or applying a uniform nipping load between the rod and surface of the web being coated. A second surface also extends longitudinally for the length of the holder along a lip portion which protrudes from one side of the cylindrical rod cavity. The second surface on the lip portion is adapted to receive a second uniformly applied load to urge the rod cavity to assume a smaller effective diameter to maintain the desired sealing engagement with the rod.
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The U.S. Government may have rights in this invention pursuant to contract DE-AC11-76PN00014 between the U.S. Department of Energy and Westinghouse Electric Corporation.
FIELD OF THE INVENTION
The present invention relates generally to the purification of water in a nuclear power plant fuel pool, and more particularly to a portable and submersible fuel pool water purification system which allows simple waste disposal of collected radioactive contaminants.
BACKGROUND OF THE INVENTION
Nuclear power plants and other nuclear facilities typically store fuel rods or other radioactive materials in large pools of water. These water pools provide both cooling and shielding for the radioactive materials. Typically, such pools use a centralized water purification system which is permanently mounted in a dry equipment or auxiliary room. Because such systems concentrate radioactive contaminants which are present in the pool water, high radiation areas develop which significantly increase personnel exposure during required periodic operation and maintenance.
An alternative to these types of systems which was used in the past consisted of submersible concrete vaults which contained six 6.3 cubic foot resin tanks connected in parallel with the flow provided by a 2.5 horsepower submersible pump. Such a system produced a minimal flow rate (50 to 60 GPM), required excessive floor space (22.3 square feet), and produced excessive radioactive waste due to the integral concrete shield vault (waste packaged volume to expended resin volume ratio of 4.1:1). Such systems were also difficult to dispose of due to the high levels of radioactive contamination built up on the rough concrete surfaces.
A method and apparatus for purifying fluids containing radioactive impurities is disclosed in U.S. Pat. No. 4,107,044 (Levendusky). This apparatus includes a vessel having appropriate radiation shielding thereabout. Inside the vessel is a means for the filtration of undissolved solids and ion exchange removal of dissolved solids. The radioactive shielding is designed to be sufficient to preclude the emission of radiation from within the vessel upon the complete expenditure of the filter apparatus and demineralizing material. The apparatus is designed to be portable in order to be brought to a plant, utilized, and then carted away for disposal.
Other water purification systems have also been disclosed in the prior art. For example, in U.S. Pat. No. 3,276,458, (Iverson et al) an ultra pure water recirculating system including a filter, an ultra violet lamp sterilizer and an ion exchange resin in the circulating system is disclosed. A similar system which produces hydrogen-free water by the addition of ozone is also disclosed in U.S. Pat. No. 4,548,716 (Boeve).
A process for decontaminating water, and in particular for removing fission products and other radioisotopes from radioactively contaminated water, is disclosed in U.S. Pat. No. 2,752,309 (Emmons et al). In this process, the water is fed through a first column including a layer of glass wool, a layer of steel wool, a layer of burned clay, and a layer of moist activated carbon. Then, the water is fed through a second column containing an anion exchange resin and a cation exchange resin. An apparatus which utilizes ultraviolet radiation in the purification of water is also disclosed in U.S. Pat. No. 4,438,337 (Forrat).
SUMMARY OF THE INVENTION
In accordance with the present invention, a portable, submersible water purification system for use in a pool of water containing radioactive contamination is provided. The system includes a prefilter means contained in a submersible watertight container for filtering particulates from the water. An ion-exchange means contained in a submersible watertight tank is also provided for removal of remaining dissolved, particulate, organic, and colloidal impurities from the prefiltered water of the prefilter means. A sterilizing means is also provided for sterilizing the water. The sterilizing means is provided in a watertight housing which is located out of the pool. A circulating means is provided for circulating the water in the pool through the prefilter means, ion-exchange means, and sterilizing means.
In a preferred embodiment, the circulating means includes a pump and a base is provided to which the pump, prefilter means, and ion-exchange means are all commonly mounted. The tank containing the ion-exchange means preferably includes a top and a bottom. The base is mounted to the top of the tank so that the base is located above the tank and the bottom of the tank forms a stand for the tank and for the prefilter means, pump, and base. Preferably, the base is detachably mounted to the tank and a connecting means is provided for detachably connecting fluidly the prefilter means and the ion-exchange means. The base is also preferably provided with handles for lifting the base and the tank also preferably includes handles for lifting the tank so that the base and tank could be lifted as a unit or separately. In order to drain the tank, a drain valve is provided at the bottom.
In the preferred embodiment, the pump includes an inlet through which water in the pool is drawn and an outlet fluidly connected to the inlet of the prefilter means. The outlet of the prefilter means is then fluidly connected to the inlet of the ion-exchange means. The outlet of the ion-exchange means is fluidly connected to the inlet of the sterilizing means, and the outlet of the sterilizing means returns the water to the pool. The circulating means preferably includes a length of piping between the outlet of the ion-exchange means and a top of the pool where the inlet to the sterilizing means is located. Thus, the base is located adjacent to the bottom of the pool and the sterilizing means is located adjacent the surface of the pool.
The circulating means advantageously includes a throttle valve means for controlling the flow of water through the pump, and hence through the system. A flow sensing means is also provided adjacent the outlet of the tank for sensing the flow of water therethrough.
In the preferred embodiment, the prefilter means filters particles greater than about 60 microns and the ion-exchange means includes ion-exchange resins and activated carbon in the tank. The sterilizing means includes an ultraviolet radiation source.
The purification system of the present invention preferably also includes a sample means for taking samples of the water entering the prefilter means and samples of the water exiting both the prefilter means and the filter means. Two control means are also provided for monitoring system pressure and flowrate and for controlling the operation of the sterilizing means. The control means are located at an appropriate position out of the pool.
It is an advantage of the present invention that the system operates on the floor of the fuel pool and is shielded by the pool water. This location eliminates centralized system flow piping and resultant development of radioactive hot spots and personnel exposure.
It is also an advantage of the present invention that the system is totally self-contained and transportable. This allows complete remote operation of the system which is provided at any desired location of the fuel pool. In addition, the transportability of the present invention allows treatment of isolated fuel pool zones as desired, or treatment of areas that require enhanced water purification in the pool.
It is a further advantage of the present invention that the system requires a minimum of floor space due to a vertical, stacked design while still achieving a significant flow rate.
Still another advantage of the present invention is that the tank containing the ion-exchange means is usable as a disposal container, eliminating the need for transfer of the depleted resin discharge from the tank. A drain at the bottom of the tank allows water in the tank to be drained therefrom, allowing resin shipment. The remainder of the system is then used with a new ion-exchange means.
Yet another advantage of the present invention is the minimum radioactive waste package volume per cubic foot of depleted resin due to the elimination of resin vessel shielding and the detachment and reuse of support components. It is contemplated that temporary, reusable transport shielding may be used for disposal shipment of the tank as needed.
Another advantage of the present invention is that the system is totally operated and maintained by remote manual control at the surface. Maintenance--including prefilter replacement, pump replacement, flow control, and sampling--are all performed by personnel at the surface on the submerged system so that the personnel are shielded by the water at all times.
Other features and advantages of the invention are stated in or apparent from a detailed description of a presently preferred embodiment of the invention found hereinbelow.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE is a schematic perspective view of the present invention with a portion broken away of the ion-exchange means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawing in which like numerals represent like elements, a portable, submersible water purification system 10 is schematically depicted. Purification system 10 is particularly adapted for purifying the water contained in a nuclear fuel pool or the like in which the water contains radioactive contaminants. A circulation means 11 is used to circulate water from the pool through purification system 10. Circulation means 11 includes a pump 12 such as a ten horsepower Prosser Pump which is held to a base 14. Water is drawn into pump 12 through a suction adaptor 16 having an inlet 18 as shown. Pump 12 includes an outlet 20 to which a piping 22 is connected by means of a quick disconnect coupling 24. Disposed in piping 22 is a pump throttle valve means 26. Pump throttle valve means 26 is adjusted by a stem 28 which is adapted to be remotely actuated from the surface by a suitable connecting tool or the like.
Piping 22 is connected by a quick disconnect coupling 30 to a prefilter means 32. Prefilter means 32 is designed to remove particulates greater than about 60 microns. Preferably, prefilter means 32 is a Ronningen-Petter prefilter available commercially. Attaching prefilter means 32 to base 14 is a suitable mounting means 31. Prefilter means 32 includes a filter bag (not shown) which is provided inside of a submersible container 33. The design of container 33 with a removable end 34 allows changing of the filter bag by technicians at the surface of the pool. The outlet of prefilter means 32 is connected by a piping 36 having a quick disconnect coupling 38 to an inlet 40 of an internal distribution system 109 inside ion-exchange means 43. This distribution system 109 provides a uniform imput of water inside the ion-exchange means 43 including a resin tank 42. Resin tank 42 is preferably a submersible stainless steel ten gauge tank holding approximately 80 cubic feet of ion exchange resins and activated carbon 44. As shown, resin tank 42 includes a bottom which forms a stand 46 for resin tank 42. At the top of resin tank 42, a standard lifting brace 48 is included to which base 14 is suitably attached by clamps 50. It should be appreciated that the clamps attaching base 14 to lifting brace 48 are suitably located so that clamps 50 may be removed or inserted from the surface by technicians without interference of the remainder of the structure of purification system 10.
As shown by the broken away portion of resin tank 42, collection arms 52 are disposed at the bottom of resin tank 42 to collect water passing through ion exchange resins and activated carbon 44 and to direct this water to a central collection chamber 54. Collection chamber 54 is fluidly connected to an outlet 56 of resin tank 42 by a pipe 58. Below collection chamber 54, a drain valve 60 and drain outlet 62 are provided. Drain valve 60 is remotely actuatable by an extended stem 64 which extends through the side of stand 46 and thus can be actuated by the technicians at the surface of the pool. It should be appreciated that drain valve 60 is closed during operation of the system.
Connected to outlet 56 of resin tank 42 is a piping 66. Piping 66 includes a quick disconnect coupling 68 for attachment to outlet 56. Piping 56 includes an outlet 70 to which a flexible piping 72 is attached by use of a quick disconnect coupling 74. Flexible piping 72 is of sufficient length to reach to the top of the pool in which purification system 10 is located.
Flexible piping 72 is connected by a U-shaped pipe 76 having quick disconnect couplings 78 at each end to an inlet 82 of a sterilizing means 80. Sterilizing means 80 includes a water tight housing 81 in which is contained an ultraviolet light sterilizer such as manufactured by Ultraviolet Purification System, Inc. which contains 12 germicidal lamps. Thus, sterilizing means 80 kills all microorganisms in the water passing through housing 81. Sterilizing means 80 also includes an outlet 84, to which a U-shaped pipe 86 is connected having quick disconnect couplings 88. An outlet tube 89 is attached at the other end to U-shaped pipe 86 to discharge water passing through purification system 10 back into the top of the pool of water. As an alternative to discharging the water into the pool, the outlet tube 89 can be replaced by a connection to equipment that requires a source of purified water. It should be appreciated that sterilizing means 80 is maintained at the surface of the pool by a suitable means such as a support or float from which U-shaped pipes 76 and 86 hang.
In order to control pump means 12, a control panel 90 is provided at a suitable location out of the pool. Control panel 90 is suitably connected to pump means 12 as shown schematically. Preferably, a flow sensing means 92 is provided in piping 66 to sense the flow of water through piping 66. Flow sensing means 92 is preferably monitored at control panel 90 by use of a suitable connection thereto.
As mentioned above, base 14 is removably attached to lifting brace 48 of resin tank 42. In order to lift base 14 from lifting brace 48, a central handle 94 extends above base 14. In addition, side handles 96 are provided at each end of base 14 to assist in the remote positioning of base 14.
Purification system 10 also preferably includes a sampling means 100. Sampling means 100 is used to sample the water prior to passing through prefilter means 32, and after passing through prefilter means 32 and ion-exchange means 43. Thus, sampling means 100 includes a line 102 for sampling the water entering prefilter means 32, a line 104 for sampling the water about to leave prefilter means 32 and enter ion-exchange means 43, and a line 106 for sampling the water leaving ion-exchange means 43 in piping 66. Line 102 and line 104 each include a pressure gauge (not shown) at sampling means 100 to monitor the pressure drop across the prefilter. The pressure gauges are used to determine when the filter bag (not shown) must be replaced. As shown, lines 102, 104, and 106 are connected to a sample panel 108 which is conveniently located above the surface of the pool and which is accessible to the technicians at a suitable location.
The sterilizing means 80 is controlled by a control panel 110 as schematically shown. The control panel 110 is conveniently located remote from the pool for easy access.
In operation, purification system 10 functions in the following manner. Upon actuation of pump 12 and sterilizing means 80 by control panels 90 and 110, water in the pool is drawn into inlet 18 of suction adaptor 16 by the operation of pump 12. This water is then pumped through throttle valve means 26 to prefilter means 32. In prefilter means 32, particulates greater than about 60 microns are removed from the water in order to extend the life of the ion exchange resins and activated carbon 44 contained in ion-exchange means 43. After prefiltering, the water passes through piping 36 into internal distribution system 40. Distribution arms 109 direct the water into ion-exchange means 43 containing ion exchange resins and activated carbon 44. After passing through ion exchange resins and activated carbon 44, the water enters collection arms 52 and passes back up through resin tank 42 through pipe 58. The water then passes through piping 66 and flexible piping 72 to sterilizing means 80 where the water is sterilized before being passed back into the pool of water at the top of the pool through outlet tube 89.
During operation, it should be appreciated that the flow through piping 66 is sensed by flow sensing means 92. If the flow is not as desired, pump throttle valve means 26 is suitably adjusted by rotation of stem 28. In addition, if it is desired to test the operation of purification system 10, sampling means 100 is used to sample the water at various positions in purification system 10. The samples can be compared to determined the effectiveness of purification system 10 in removing radioactive contaminants from the water. The pressure gauges in sampling means 100 are used to determine when filter bag must be replaced.
It should be appreciated that purification system 10 is portable within the pool to any desired location by suitably attaching lifting means to eyelets 98. In addition, the stacked design of purification system 10 allows the placement of purification system 10 wherever there is sufficient floor space for stand 46.
It should also be appreciated that purification system 10 is specifically designed to contain an inlet 18 adjacent the bottom of the pool, or rather which is spaced from the bottom of the pool only by the height of resin tank 42. Thus, both prefilter means 32 and filter means 43 which collect radioactive contaminants are located as far away as possible from the top of the pool to provide the maximum shielding for personnel. This location of inlet 18 adjacent the bottom of the pool is further designed to be distant from the position of outlet tube 89 located adjacent the top of the pool. By locating outlet tube 89 adjacent the top of the pool, uncontaminated (and hence safer) water is discharged adjacent the top of the pool where personnel are likely to be located. On the other hand, contaminated water which has contaminants which tend to drift to the bottom of the pool is maintained at the bottom of the pool, near where inlet 18 is located.
It should further be appreciated that it is possible to adjust throttle valve means 26 while pump 12 is submerged by using an appropriate tool which attaches to stem 28 and which is manipulated by personnel at the surface of the pool. Similarly, the filter bag in prefilter means 32 can also be changed by removal of end 34 by personnel at the top of the pool while prefilter means 32 is submerged and the personnel are shielded.
When the resins in ion-exchange means 43 become expended, it should further be appreciated that resin tank 42 then serves as a transport vessel for ion exchange resins and activated carbon 44. This is accomplished by disconnecting base 14 from lifting brace 48 by suitably unlatching quick disconnect couplings 68 and 38, and removal of clamps 50 while resin tank 42 rests on the floor of the pool. Base 14 and the associated elements attached thereto can be removed from resin tank 42 by lifting of central handle 94. Side handles 96 are used to remotely position base 14. Outlet 56 is sealed by a suitable cap and a cap with a one way breather valve is placed on inlet 40. The breather valve is required to assist in subsequent draining. Next, resin tank 42 is lifted above the pool and drain valve 60 is opened remotely by use of extended stem 64. This allows the water remaining in resin tank 42 to drain therefrom to allow shipping of resin tank 42. A shielded transport vessel may be used during operation of drain valve 60 and subsequent transfer to a disposal facility to provide personnel shielding.
After draining, drain valve 60 is closed. As resin tank 42 will be radioactive to some extent, auxiliary shielding will probably be necessary for resin tank 42. However, once transported to the dump site, resin tank 42 is simply suitably buried or the like and the shielding is reusable. As soon as resin tank 42 is removed, a new resin tank 42 is lowered into the pool and base 14 attached thereto together with quick disconnect couplings 38 and 68. Thus, purification system 10 is again ready for operation in a very short time.
With purification system 10, a minimum radioactive waste package volume per cubic foot of depleted resin (1.3:1 ratio) is achieved due to the elimination of the resin tank shielding and the detachment and reuse of sterilizing means 80 and the components attached to base 14. It is contemplated that a purification system 10 according to the present invention will utilize a minimum of floor space (twelve square feet), which is very small for a system having a purification flow rate of approximately 150 gallons per minute. In addition, the small size and self-contained nature of the present invention allows treatment of isolated fuel pool zones or areas, as desired, which may require enhanced water purification.
Although a presently preferred embodiment of the present invention has been described above, it will be understood by those of ordinary skill in the art that variations and modifications can be effected within the scope and spirit of the invention.
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A portable, submersible water purification system for use in a pool of water containing radioactive contamination includes a prefilter for filtering particulates from the water. A resin bed is then provided for removal of remaining dissolved, particulate, organic, and colloidal impurities from the prefiltered water. A sterilizer then sterilizes the water. The prefilter and resin bed are suitably contained and are submerged in the pool. The sterilizer is water tight and located at the surface of the pool. The water is circulated from the pool through the prefilter, resin bed, and sterilizer by suitable pump or the like. In the preferred embodiment, the resin bed is contained within a tank which stands on the bottom of the pool and to which a base mounting the prefilter and pump is attached. An inlet for the pump is provided adjacent the bottom of the pool, while the sterilizer and outlet for the system is located adjacent the top of the pool.
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BACKGROUND
1. Field of the Invention
The present invention relates to cover assemblies, and more particularly to a cover assembly for a storage device.
2. Description of Related Art
An electronic apparatus, such as a typical desktop computer, tower computer, server, or the like, usually includes storage devices, such as compact disk read-only memory (CD-ROM) drives, digital video disc (DVD) drives, floppy disk drives, and the like. A panel of the electronic apparatus typically defines an opening for receiving the corresponding storage device, and a cover is typically installed on the panel sheltering the opening for preventing dust entering therein. The cover forms pivots at opposite ends thereof to pivotably connect the cover to the panel. A spring is connected between the cover and the panel to restore the cover after the cover is opened relative to the panel. However, because the pivots are formed at ends of the cover, when the size of the cover is larger than that of the opening of the panel, the panel should define other recesses communicating with the opening to fit the cover. It is troublesome, and the connection of cover to the panel is awkward.
What is needed, therefore, is a cover assembly to conveniently and agilely shelter an opening of a panel.
SUMMARY
An exemplary cover assembly includes a panel defining an opening therein for allowing a storage device in or out therethrough, a cover shielding the opening, a connecting member, and an elastic member. The connecting member is pivotably connected to the panel through a first pivoting mechanism formed therebetween along a first axis, and is pivotably connected to the cover through a second pivoting mechanism formed therebetween along a second axis separate from and parallel with the first axis. The elastic member is arranged between the cover and the connecting member, for restoring the cover to shield the opening of the panel.
Other advantages and novel features will become more apparent from the following detailed description of embodiments when taken in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded, isometric view of a cover assembly in accordance with an embodiment of the present invention, the cover assembly includes a panel, a connecting member, and a cover;
FIG. 2 is an enlarged isometric view of the connecting member of FIG. 1 , but viewed from another aspect;
FIG. 3 is an enlarged isometric view of the cover of FIG. 1 , but viewed from another aspect;
FIG. 4 is an assembled view of FIG. 1 , the cover is opened relative to the panel; and
FIG. 5 is an assembled view of FIG. 1 , the cover is closed to the panel.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2 , a cover assembly is provided in accordance with an embodiment of the present invention for shielding an opening of an electronic apparatus. The cover assembly includes a panel 10 , a connecting member 20 , an elastic member 30 , and a cover 40 . In this embodiment, the elastic member 30 is a torsion spring.
The panel 10 is mounted on a front of the electronic apparatus. The panel 10 defines an opening 11 for allowing a tray of a compact disk read-only memory (CD-ROM) drive in or out. The panel 10 forms two opposite sidewalls 13 bounding two sides of the opening 11 therebetween. Each sidewall 13 defines a pivoting hole 132 , and a slanted surface 133 adjoining the pivoting hole 132 is formed on a joint of the sidewall 133 and the front portion of the panel 10 . Two spaced latching portions 15 are formed on a section of the panel 10 above the opening 11 . Each latching portion 15 defines a recess 153 .
The connecting member 20 includes an elongated main body 21 . The connecting member 20 includes two opposite end surfaces perpendicular to a longitudinal axis of the main body 21 . Two generally L-shaped arms 22 extend outward and then upward from upper portions of the end surfaces of the main body 21 respectively. A first pivot 223 parallel with the longitudinal axis of the main body 21 extends from a free end of each arm 22 . A second pivot 24 perpendicularly extends from a lower portion of each end surface of the main body 21 . A bottom portion of the main body 21 defines a receiving slot 26 . A post 27 extends from a portion of the main body 21 bounding the receiving slot 26 into the receiving slot 26 . The post 27 is oriented generally along a longitudinal axis of the receiving slot 26 and is for the elastic member 30 to be placed therearound.
Referring to FIG. 3 , the cover 40 is larger than the opening 11 of the panel 10 . Two spaced arcuate protrusions 41 protrude from a backside of the cover 40 . An elongated plate 43 extends backward from a bottom portion of the cover 40 , and two spaced fixing plates 44 each defining a fixing hole 445 are formed on the plate 43 adjoining the backside of the cover 40 . A positioning portion 45 is formed on a lower portion of the backside of the cover 40 between the fixing plates 44 . The positioning portion 45 is generally C-shaped with the open part 453 facing away from the cover 40 , and the fixing holes 445 are coaxial to the open part 453 of the C-shape positioning portion 45 . A hook 42 protrudes from the backside of the cover 40 above the positioning portion 45 . Two spaced blocks 47 protrude from an upper portion of the backside of the cover 40 , corresponding to the latching portions 15 of the panel 10 .
Referring further to FIG. 4 , in assembly, the elastic member 30 is placed around the post 27 of the connecting member 20 . One of the second pivots 24 is inserted into the fixing hole 445 of the corresponding one of the fixing plates 44 of the cover 40 . The connecting member 20 is rotated to make the post 27 align with the open part 453 of the positioning portion 45 of the cover 40 . The other fixing plate 44 of the cover 40 is pulled outward, the connecting member 20 is pressed to squeeze the post 27 to be received in the open part 453 of the positioning portion 45 , and the other second pivot 24 aligns with the corresponding fixing hole 445 of the other fixing plate 44 . Releasing the other fixing plate 44 , the other second pivot 24 engages in the corresponding fixing hole 445 of the other fixing plate 44 , thereby the connecting member 20 is pivotably connected to the backside of the cover 40 . One end of the elastic member 30 is fixed to the connecting member 20 , and a hooking portion 32 extending from the other end of the elastic member 30 catches the hook 42 of the cover 40 . Thereafter, the connecting member 20 is pushed toward the panel 10 . The first pivots 223 of the arms 22 slide along the slanted surfaces 133 respectively, and then engage in the pivoting holes 132 of the panel 10 respectively. Thereby the connecting member 20 together with the cover 40 is pivotably connected to the panel 10 . Generally, the cover 40 covers the opening 11 of the panel by the elastic force of the elastic member 30 , and the blocks 47 of the cover 40 engage in the recesses 153 of the latching portions 15 of the panel 10 respectively.
When the tray of the CD-ROM drive is extended out from the electronic apparatus, the tray pushes the protrusions 41 of the cover 40 outward. The cover 40 is rotated away from the panel 10 around the second pivots 24 of the connecting member 20 . The elastic member 30 deforms, and the connecting member 20 is rotated together with the cover 40 , with the first pivots 223 of the connecting member 20 pivoting in the pivoting holes 132 of the panel 10 respectively, until the tray is completely extended from the opening 11 of the panel 10 .
When the tray of the CD-ROM drive is retracted into the electronic apparatus, the elastic member 30 is restored to pull the cover 40 to rotate toward the panel 10 around the second pivots 24 of the connecting member 20 . The connecting member 20 is rotated together with the cover 40 , with the first pivots 223 of the connecting member 20 pivoting in the pivoting holes 132 of the panel 10 respectively, until the tray is completely received in the electronic apparatus, and the blocks 47 of the cover 40 engage in the recesses 153 of the latching portions 15 of the panel 10 respectively. Thereby, the cover 40 is closed to the panel 10 .
In this embodiment, the first pivots 223 of the connecting member 20 cooperate with the pivoting holes 132 of the panel 10 to form a first pivoting mechanism, for pivotably connecting the connecting member 20 to the panel 10 ; the second pivots 24 of the connecting member 20 cooperate with the fixing holes 445 of the fixing plates 44 of the cover 40 to form a second pivoting mechanism, for pivotably connecting the cover 40 to the connecting member 20 .
In other embodiments, in the first pivoting mechanism, positions of the first pivots 223 and the pivoting holes 132 may be exchanged with each other; in the second pivoting mechanism, positions of the second pivots 24 and the fixing holes 445 may be exchanged with each other, or the fixing plates 44 of the cover 40 may be replaced by L-shaped pivots respectively.
It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the invention.
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A cover assembly includes a panel defining an opening therein for allowing a storage device to move in or out therethrough, a cover shielding the opening, a connecting member, and an elastic member. The connecting member is pivotably connected to the panel through a first pivoting mechanism formed therebetween along a first axis, and is pivotably connected to the cover through a second pivoting mechanism formed therebetween along a second axis separate from and parallel with the first axis. The elastic member is arranged between the cover and the connecting member, for restoring the cover to shield the opening of the panel.
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BACKGROUND OF THE INVENTION
1. Field of the Invention:
The present invention relates to a multicolor fluid jet loom which in operation carries out a cutting blow, and more particularly, to a device for preventing the cutting of a weft yarn which need not be cut on such a multicolor fluid jet loom.
2. Description of the Prior Art:
In a multicolor fluid jet loom, a plurality of weft yarns are picked sequentially in a predetermined order, and the picked weft yarn is cut with a cutter provided on the picking side of the multicolor fluid jet loom. While the picked weft yarn is cut with the cutter, the free ends of the rest of the weft yarns, namely, the standby weft yarns, are extending outside of their corresponding picking nozzles. In case the free end of the standby weft yarn nears the picked weft yarn, the cutter erroneously cuts the free end of the stanby weft yarn. As a result, the free end of the thus cut standby weft yarn is blown towards a shed of a warp yarn by a cutting blow and inserted into a fabric.
The term "cutting blow" refers to a cutting blow system provided with multicolor fluid jet looms. The cutting blow is a small amount of fluid which is continuously jetted from a picking nozzle during the period of operation of the jet loom other than a picking period. Alternatively, a small amount of fluid may be jetted from the picking nozzle just before an/or just after a cutting operation. These small jets of fluid ensure that a picked weft yarn is extended and prevented from slipping off of or being extracted from its picking nozzle after the picked weft yarn has been cut by the cutter. Faulty cutting occurs frequently when hard yarns, such as hard twist yarns or glass yarns, are used as weft yarns. When such stiff yarns are used as weft yarns, the fluid is jetted continuously at a moderate rate from the picking nozzles to prevent the standby weft yarns from slipping off from the picking nozzles. The free end of the hard twist yarn is untwisted and extended by the jet of fluid to enter the operating zone of the cutter. When the glass yarn is used as a weft yarn, a portion of the picked glass yarn is slackened between the weft yarn storage device and the cutter used to cut the glass yarn, because the glass yarn is stiff. Then, a slack free end of a standby glass yarn is extended by the fluid being continously jetted from the picking nozzle and thereby the free end of the standby glass yarn reaches the cutting position of the cutter entailing erroneous weft yarn cutting. Accordingly, the multicolor fluid jet loom must be equipped with a standby weft yarn cutting prevention device.
Japanese Utility Model Publication No. 51-5570 discloses a weft yarn withdrawing device, which withdraws the free end of the standby weft yarn with a lever from the picked weft yarn to avoid the entanglement of the free end of the standby weft yarn with the picked weft yarn. This known weft yarn withdrawing device is capable of surely preventing erroneous weft yarn cutting. Nevertheless, the weft yarn withdrawing device is a complicated mechanism and inevitably applies an excessive tension to the weft yarn in withdrawing the weft yarn by hooking the weft yarn with the lever, often damaging the weft yarn. Thus, the weft yarn withdrawing device is not an effective solution of the problem from the viewpoint of maintaining the quality of the fabric.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a standby weft yarn cutting preventing device for a multicolor fluid jet loom, capable of avoiding the erroneous cutting of the free end of a standby weft yarn in cutting a picked weft yarn.
To achieve the object of the invention, the present invention provides a standby weft yarn cutting prevention device having an air current generating device which blows air in an air current in a direction other than the picking direction to positively separate the free end of the standby weft yarn from the picked weft yarn so that the free end of the standby weft yarn will not approach the operating zone of the cutter when the cutter cuts the picked weft yarn. The air current generating device is provided commonly for a plurality of picking nozzles or individually for each of a plurality of picking nozzles to apply an air current only to the standby weft yarn when the cutter cuts the picked weft yarn.
Thus, according to the present invention, erroneous cutting of the weft yarn can surely be avoided by a simple air current generating device preventing the detrimental insertion of the erroneously cut piece of the weft yarn into the fabric. Since the device of the present invention does not employ any mechanical restraining device, the standby weft yarn or yarns will never be damaged, and hence does not cause any defects in the fabric and does not deteriorate the quality thereof.
When the loom is provided with a control valve capable of controlling an air supply for a cutting blow, the standby weft yarn cutting preventing device of the present invention can be completed by simply providing the loom with the air current generating device. Therefore, the standby weft yarn cutting preventing device of the present invention can readily be incorporated into an existing loom as well as into a new loom.
The above and other objects, features and advantages of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration showing a standby weft yarn cutting preventing device for a multicolor fluid jet loom of a first embodiment according to the present invention; and
FIG. 2 is a diagrammatic illustration showing a standby weft yarn cutting preventing device for a multicolor fluid jet loom of a second embodiment according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is described herein below with reference to two preferred embodiments of a multicolor fluid jet loom employing a cutting blow system, wherein a small amount of fluid, i.e. a weak air current, is jetted from a picking nozzle during the period of time other than a picking period.
First Embodiment (FIG. 1)
FIG. 1 shows a standby weft yarn cutting preventing device 2 of the present invention incorporated into a multicolor fluid jet loom 1. In this case, the multicolor fluid jet loom 1 is a two-color fluid jet loom.
The multicolor fluid jet loom 1 is provided with two picking nozzles 31 and 32 held by a nozzle holder 4. The picking nozzles 31 and 32 are operated selectively in a predetermined sequence to jet a fluid, for example, air, so that two kinds of weft yarns 51 and 52 are picked selectively in a predetermined sequence into the shed 7 of warp yarn 6. The picked weft yarns 51 and 52 are cut by a cutter 8 disposed between the picking nozzles 31 and 32 and the selvage of the fabric on the picking side. The picking nozzles 31 and 32 are connected respectively through control valves 101 and 102 by pipes 91 and 92 to a tank 11, which in turn is connected to a compressed air source 12.
The standby weft yarn cutting preventing device 2 has a single air current generating unit 13 is common for both the picking nozzles 31 and 32, and a plurality of control valves, in this embodiment two control valves 141 and 142. The air current generating unit 13 is connected to one end of a pipe 153. The other end of the pipe 153 is branched into two branches, which are connected respectively to the control valves 141 and 142. The control valves 141 and 142 are connected respectively through pressure regulating valves 161 and 162 by pipes 151 and 152 to the tank 11. The air current generating unit 13 blows compressed air in an air current in a direction other than the picking direction, for example, in a direction across the picking direction. In this embodiment, the respective outlet ports of the control valves 141 and 142 are connected also respectively to the respective inlet ports of the picking nozzles for a cutting blow, which is described in Japanese Patent Publication No. 59-44419. The control valves 141, 142 may be electromagnetic On-Off valves for controlling simultaneously the cutting blow fluid and cutting prevention fluid and controlled by the output from a weft yarn selecting unit 17. Since the selection order of the weft yarns is predetermined, the weft yarn selecting unit 17 releases the control valve 101 or 102 at the picking time on the basis of the selection order, while the weft yarn selecting unit 17 opens simultaneously the control valve 141 or 142 at the time of cutting of weft yarns 51, 52 by the cutter 8. Alternatively, control valves 141 and 142 may be mechanical On-Off valves. When mechanical on-off valves are employed as the control valves 141 and 142, the control valves 141 and 142 are operated by cams or the like in synchronism with the weaving operation of the loom. When electromagnetic on-off valves are employed as the control valves 141 and 142, the control valves 141 and 142 are operated by electric signals provided by the weft yarn selecting unit 17. The pressure regulating valves 161 and 162 regulate the pressure of air supplied to the air current generating unit 13 and air supplied to the picking nozzles 31 and 32 for the cutting blow below the pressure of air supplied to the picking nozzles 31 and 32 for picking. Regulating valves 161, 162 may be manually preset prior to operation to regulate the air pressure.
The multicolor fluid jet loom 1 opens the control valves 101 and 102 selectively one at a time according to a predetermined picking order to pick the weft yarns 51 and 52 selectively into the shed 7 of the warp yarns 6 respectively with the picking nozzles 31 and 32. The picked weft yarns 51 and 52 are cut by the cutter 8 disposed between the picking nozzles 31 and 32 and the selvage on the picking side.
During the operation of the cutter 8, the control valves 141 and 142 are opened selectively to operate the air current generating unit 13.
When the picking nozzle 31 is operated to pick the weft yarn 51 and the picked weft yarn 51 is cut by the cutter 8 as shown in FIG. 1, the control valve 141 is opened to supply compressed air to the air current generating unit 13 to blow the free end of the weft yarn 52 away from the operating zone of the cutter 8 by the air current generating unit 13, and to the picking nozzle 31 for the cutting blow to urge the picked weft yarn 51 in the picking direction by a small force so that the cutter 8 never cuts the free end of the weft yarn 52. Since the picked weft yarn 51 is held by the warp yarns and the picking nozzle 31 prior to the cutting operation of the cutter 8, the picked weft yarn 51 will not be blown outside the operating zone of the cutter 8 by a weak air current blown by the air current generating unit 13, and hence the cutter 8 never fails to cut the picked weft yarn 51. Accordingly, the cutter 8 cuts only the picked weft yarn 51. Since the control valve 141 is controlled so that the weft yarn 51 is exposed to an air current blown at a moderate pressure through the picking nozzle 31 also after the same has been cut, the free end of the weft yarn 51 is not pulled back and hence will not slip off the picking nozzle 31.
Second Embodiment (FIG. 2)
FIG. 2 shows a standby weft yarn cutting preventing device 2 of a second embodiment according to the present invention, incorporated into a two-color fluid jet loom 1. The standby weft yarn cutting preventing device in the second embodiment is substantially the same in constitution as the standby weft yarn cutting preventing device in the first embodiment, except that the former is provided with two air current generating units 131 and 132 individually for the picking nozzles 31 and 32, and the control valves 141 and 142 are associated respectively with the air current generating units 131 and 132. The air current generating units 131 and 132 are actuated selectively so as to blow air only while the associated weft yarns 51 and 52 are on standby. A guide plate 16 provided between the respective extremities of the picking nozzles 31 and 32 prevents the interference of the picked weft yarn with air currents blown by the air current generating units 131 and 132 to further ensure the function of the air current generating units 131 and 132. According to the present embodiment the control valves 101, 102, 141, 142 may be controlled by the weft yarn selecting unit 17 as in the previous embodiment. However, the control valves 101, 102, 141, 142 may also be of the mechanically operated type, wherein the valves would be independently rotatably driven by a known cam mechanism in response to the picking order. Note that according to the present embodiment, the control valves 141, 142 act respectively for controlling the cutting blow of the picking nozzles 31, 32, but the mechanism for providing the cutting blow could be alternatively provided independently of the control valves 141, 142.
The air current generating units 13, 131 an 132 may be air blowers or negative pressure generating units which generate a negative pressure by the agency of jet of compressed air on the principle of a vaporizer.
Although the invention has been described in its preferred form with a certain degree of particularity, it is to be understood that many variations and changes are possible in the invention without departing from the scope thereof.
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A standby weft yarn cutting preventing device is provided for a multicolor fluid jet loom, such as a multicolor air jet loom. In cutting a picked weft yarn among a plurality of weft yarns with the cutter of the loom, the standby weft yarn cutting preventing device drives away the free ends of the rest of the weft yarns from the operating zone of the cutter to prevent the free ends of the weft yarns on standby from being cut together with the picked weft yarn.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to control of a multi-chamber heat-pump type air conditioner in which a plurality of room units are connected to one heat source unit, and cooling and heating can be effected selectively for each room unit, and cooling can be effected by one room unit and heating can be simultaneously effected by another.
2. Description of Prior Art
A description will be given hereafter of the prior art of the present invention.
FIG. 13 is an overall schematic diagram of an air conditioner in accordance with a prior art example relating to the present invention, centering on a refrigerant system. In addition, FIGS. 14 to 16 show states of operation during cooling and heating operation in accordance with the prior art example shown in FIG. 13, in which FIG. 14 is a diagram of the state of operation during only cooling or heating, while FIGS. 15 and 16 show diagrams of states of the simultaneous operation of cooling and heating, FIG. 15 being a diagram of a state of operation in which heating is mainly performed (a case where the capacity for heating operation is greater than that for cooling operation), and FIG. 16 being a diagram of a state of operation in which cooling is mainly performed (a case where the capacity for cooling operation is greater than that for heating operation).
It should be noted that in this example a description will be given of a case where three room units are connected to one heat source unit, but it also similarly applies to cases where two or more room units are connected thereto.
In FIG. 13, reference numeral 1 denotes a heat source unit, and numerals 1, 2 and 4 denote room units which are connected in parallel with each other, as will be described later, and the same arrangement is used for the respective units. Numeral 5 denotes a relay unit which incorporates a first branching section 6, a second flow-rate controller 7, a second branching section 8, a gas-liquid separator 9, heat exchanger 10, 11, 12, 13, 14, a third flow-rate controller 15, and a fourth flow-rate controller 16, as will be described later.
In addition, numeral 17 denotes a compressor; 18, a four-way changeover valve for changing over the direction of circulation of a refrigerant of the heat source unit; 19, a heat source unit-side heat exchanger; and 20, an accumulator which is connected to the compressor 17 via the four-way changeover valve 18. The heat source unit 1 is comprised of these units.
In addition, numeral 21 denotes a room unit-side heat exchanger provided for each of the three room units 2, 3, 4; 22, a large-diameter first connecting pipe for connecting together the four-way changeover valve 18 of the heat source unit 1 and the relay unit 5 via a fourth check valve 23 which will be described later; numerals 24, 25, 26 denote room unit-side first connecting pipes which respectively connect the room unit-side heat exchanger 21 of the room units 2, 3, 4 to the relay unit 5 and correspond to the first connecting pipe 22; and 27 denotes a second connecting pipe having a diameter smaller than that of the aforementioned first connecting pipe and used for connecting together heat source unit-side heat exchanger 19 of the heat source unit 1 and the relay unit 5 via a third check valve 28 which will be described later.
In addition, numerals 29, 30, 31 respectively denote room unit-side second connecting pipes for connecting together the room unit-side heat exchanger 21 of the room units 2, 3, 4 and the relay unit 5 via first flow rate controllers 36, and corresponding to the second connecting pipes 27.
Numeral 33 denotes a first valve for allowing the room unit-side first connecting pipes 24, 25, 26 to communicate with the first connecting pipe 22; 34, a second valve for allowing the room unit-side first connecting pipes 24, 25, 26 to communicate with the second connecting pipe 27; and 35, a third valve for bypassing inlet and outlet ports of the first valve 33.
Numeral 36 denotes a first flow-rate controller which is connected in the vicinity of the room unit-side heat exchanger 21 and is controlled by a superheated amount at the outlet of the room unit-side heat exchanger 21 during cooling and by a subcooled amount thereat during heating, the first flow-rate controllers 36 being connected to the room unit-side second connecting pipes 29, 30, 31.
Numeral 6 denotes the first branching section which includes the first valves 33 and the second valves 34 for selectively connecting the room unit-side first connecting pipes 24, 25, 26 to the first connecting pipe 22 or the second connecting pipe 27, as well as the third valves 35 for bypassing the inlet and outlet ports of the first valves 33.
Numeral 8 denotes the second branching section which includes the room unit-side second connecting pipes 29, 30, 31 and the second connecting pipe 27.
Numeral 9 denotes the gas-liquid separator disposed in a midway position of the second connecting pipe 27, and its vapor phase portion is connected to the second valves 34 at the first branching section, while its liquid phase portion is connected to the second branching section 8.
Numeral 7 denotes the second flow-rate controller (here, an electric expansion valve) which can be opened or closed freely and is connected between the gas-liquid separator 9 and the second branching section 8.
Numeral 37 denotes a bypass pipe for connecting together second branching section 8 and the first connecting pipe 22; 15, the third flow-rate controller (here, an electric expansion valve) disposed in a midway position of the bypass pipe 37; and 10, the second heat-exchange portion which is disposed downstream of the third flow-rate controller 15 disposed in the midway position of the bypass pipe 37 and effects heat exchange at a converging portion of the respective room unit-side second connecting pipes 29, 30, 31 in the second branching section 8.
Numerals 11, 12, 13 respectively denote the third heat-exchange portions which are disposed downstream of the third flow-rate controller 15 disposed in the midway position of the bypass pipe 37, and effect heat exchange with the respective room unit-side second connecting pipes 29, 30, 31 in the second branching section 8.
Numeral 14 denotes the first heat exchanger which is disposed downstream of the third flow-rate controller 15 of the bypass pipe 37 and downstream of the second heat-exchange portion 10, and effects heat exchange with the pipe connecting the gas-liquid separator 9 and the second flow-rate controller 7; and numeral 16 denotes the fourth flow-rate controller (here, an electric expansion valve) which can be opened or closed freely and is connected between the second branching section 8 and the first connecting pipe 22.
Meanwhile, numeral 28 denotes the third check valve which is disposed between the heat source unit-side heat exchanger 19 and the second connecting pipe 27, and allows circulation of the refrigerant only from the heat source unit-side heat exchanger 19 to the second connecting pipe 27.
Numeral 23 denotes the fourth check valve which is disposed between the four-way changeover valve 18 of the heat source unit 1 and the first connecting pipe 22, and allows circulation of the refrigerant only from the first connecting pipe 22 to the four-way changeover valve 18.
Numeral 38 denotes a fifth check valve which is disposed between the four-way changeover valve 18 of the heat source unit 1 and the second connecting pipe 27, and allows circulation of the refrigerant only from the four-way changeover valve 18 to the second connecting pipe 27.
Numeral 39 denotes a sixth check valve which is disposed between the heat source unit-side heat exchanger 19 and the first connecting pipe 22, and allows circulation of the refrigerant only from the first connecting pipe 22 to the heat source unit-side heat exchanger 19.
The aforementioned third, fourth, fifth, and sixth check valves 28, 23, 38, 39 constitute a channel-changeover device 40.
Numeral 41 denotes a first pressure-detecting means disposed between the first branching section 6 and the second flow-rate controller 7; and 42 denotes a second pressure-detecting means disposed between the second flow-rate controller 7 and the fourth flow-rate controller 16.
Next, a description will be given of the operation. First, a description will be given of the case of cooling operation only, with reference to FIG. 14. As indicated by the solid-line arrows in the drawing, a high-temperature high-pressure refrigerant gas discharged from the compressor 17 passes through the four-way changeover valve 18, undergoes heat exchange with heat source water in the heat source unit-side heat exchanger 19, and is thereby condensed. The condensed refrigerant then passes through the third check valve 28, the second connecting pipe 27, the gas-liquid separator 9, and the second flow-rate controller in that order, further passes through the second branching section 8 and the room unit-side second connecting pipes 29, 30, 31, and flows into the respective room units 2, 3, 4.
The refrigerant which has entered the room units 2, 3, 4 is made to undergo decompression to a low pressure by the first flow-rate controllers 36 controlled by the superheated amounts at the outlets of the room unit-side heat exchanger 21. The refrigerant then undergoes heat exchange with the air within the rooms by means of the room unit-side heat exchanger 21, whereupon the refrigerant evaporates and gasifies, thereby cooling the interior of the rooms.
The refrigerant in this gaseous state forms a circulation cycle in which it passes through the room unit-side first connecting pipes 24, 25, 26, the first valves 33, the third valves 35, the first connecting pipe 22, the fourth check valve 23, the four-way changeover valve 18 of the heat source unit 1, and the accumulator 20, and is then sucked by the compressor 17, so as to effect the cooling operation.
At that time, the first valves 33 and the third valves 35 are open, while the second valves 34 are closed. In addition, since the first connecting pipe 22 is held under a low pressure and the second connecting pipe 27 under a high pressure at that time, the refrigerant naturally flows to the third check valve 28 and the fourth check valve 23.
In addition, during this cycle, part of the refrigerant which has passed through the second flow-rate controller 7 enters the bypass pipe 37 and is decompressed to a low pressure by the third flow-rate controller 15. The decompressed refrigerant is then subjected to heat exchange with the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the third heat-exchange portions 11, 12, 13, and with the converging portion of the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the second heat-exchange portion 10, and further with the refrigerant flowing into the second flow-rate controller 7 by the first heat-exchange portion 14, and is thereby evaporated. The evaporated refrigerant enters the first connecting pipe 22 and the fourth check valve 23, passes through the four-way changeover valve 18 of the heat source unit 1 and the accumulator 20, and is sucked in by the compressor 17.
Meanwhile, the refrigerant at the second branching section 8, which has been cooled after being subjected to heat exchange at the first, second and third heat-exchange portions 14, 10, 11, 12, 13 and provided sufficiently with subcooling, flows into the room units 2, 3, 4 to be cooled.
Referring now to FIG. 14, a description will be given of the case of heating operation only. Namely, as indicated by the dotted-line arrows in the drawing, the high-temperature high-pressure refrigerant gas discharged from the compressor 17 passes through the four-way changeover valve 18, passes through the fifth check valve 38, the second connecting pipe 27, and the gas-liquid separator 9, passes consecutively through the second valves 34 and the room unit-side first connecting pipes 24, 25, 26, and flows into the respective room units 2, 3, 4, where the refrigerant undergoes heat exchange with the air within the rooms, and condenses and liquefies, thereby heating the interior of the rooms.
The refrigerant in this liquid state is controlled by the subcooled amounts at the outlets of the room unit-side heat exchanger 21, passes through the first flow-rate controllers 36 in the substantially open state, flows into the second branching section 8 from the room unit-side second connecting pipes 29, 30, 31 and converges, and further passes through the fourth flow-rate controller 16.
Here, the refrigerant is decompressed to a low-pressure gas-liquid two-phase state by either the first flow-rate controllers 36 or the third and fourth flow-rate controllers 15, 16.
The refrigerant decompressed to a low pressure forms a circulation cycle in which the refrigerant passes through the first connecting pipe 22, flows into the sixth check valve 39 of the heat source unit 1 and the heat source unit-side heat exchanger 19, where the refrigerant exchanges heat with the heat source water, evaporates and assumes a gaseous state, and is sucked in by the compressor 17 through the four-way changeover valve 18 of the heat source unit 1 and the accumulator 20, so as to effect the heating operation.
At that time, the second valves 34 are open, while the first valves 33 and the third valves 35 are closed. In addition, since the first connecting pipe 22 is held under a low pressure and the second connecting pipe 27 under a high pressure at that time, the refrigerant naturally flows to the fifth check valve 38 and the sixth check valve 39.
It should be noted that at that time the second flow-rate controller 7 is normally set in a state of being open by a predetermined minimum amount.
Referring now to FIG. 15, a description will be given of the case where heating is mainly carried out in the simultaneous operation of cooling and heating. As indicated by the dotted-line arrows in the drawing, the high-temperature high-pressure refrigerant gas discharged from the compressor 17 passes through the four-way changeover valve 18, passes through the fifth check valve 38 and the second connecting pipe 27, is supplied to the relay unit 5, passes through the gas-liquid separator 9, passes consecutively through the second valves 34 and the room unit-side first connecting pipes 24, 25, and flows into the respective room units 2, 3, 4 to be heated, where the refrigerant undergoes heat exchange through the room unit-side heat exchanger 21, and condenses and liquefies, thereby heating the interior of the rooms.
This condensed and liquefied refrigerant is controlled by the subcooled amounts at the outlets of the room unit-side heat exchanger 21, passes through the first flow-rate controllers 36, where it is slightly decompressed and flows into the second branching section 8.
Part of this refrigerant passes through the room unit-side second connecting pipe 31, enters the room unit 4 to be cooled, enters the first flow-rate controller 36 controlled by the superheated amount at the outlet of the room unit-side heat exchanger 21. After the refrigerant is decompressed, the refrigerant enters the room unit-side heat exchanger 21 where it undergoes heat exchange, evaporates and assumes the gaseous state to cool the interior of the room. The refrigerant then passes through the first connecting pipe 26 at the room unit-side, and flows into the first connecting pipe 22 via the first valve 33 and the third valve 35. Meanwhile, a remaining portion of the refrigerant passes through the fourth flow-rate controller 16 which is controlled such that a pressure difference between the pressure detected by the first pressure-detecting means 41 and the pressure detected by the second pressure-detecting means 42 is set in a predetermined range. The refrigerant then converges with the refrigerant which has passed through the room unit 4 to be cooled, passes through the large-diameter first connecting pipe 22, flows into the sixth check valve 39 of the heat source unit 1 and the heat source unit-side heat exchanger 19, and undergoes heat exchange with the heat source water, and thereby evaporates and assumes the gaseous state.
This refrigerant forms a circulation cycle in which the room unit passes through the four-way changeover valve 18 of the heat source unit 1 and the accumulator 20 and is sucked in by the compressor 17, so as to effect the operation in which heating is mainly performed.
At that time, the pressure difference between the low pressure of the room unit-side heat exchanger 36 of the room unit 4 for effecting cooling and the pressure of the heat source unit-side heat exchanger 19 becomes small since the line is changed over to the large-diameter first connecting pipe 22.
In addition, at that time, the second valves 34 connected to the room units 2, 3 are open, while the first valves 33 and the third valves 35 connected thereto are closed. The first valve 33 and the third valve 35 connected to the room unit 4 are open, while the second valve 34 connected thereto is closed.
In addition, since the first connecting pipe 22 is held under a low pressure and the second connecting pipe 27 under a high pressure at that time, the refrigerant naturally flows to the fifth check valve 38 and the sixth check valve 39.
During this cycle, part of the liquid refrigerant enters the bypass pipe 37 from the converging portion of the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8, and is decompressed to a low pressure by the third flow-rate controller 15. The decompressed refrigerant is then subjected to heat exchange with the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the third heat exchanger 11, 12, 13, and with the converging portion of the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the second heat-exchange portion 10. The evaporated refrigerant passes through the first connecting pipe 22 and the sixth check valve 39, enters the heat source unit-side heat exchanger 19 where it undergoes heat exchange with the heat source water and is evaporated. Subsequently, the evaporated refrigerant passes through the four-way changeover valve 18 of the heat source unit 1 and the accumulator 20, and is sucked in by the compressor 17.
Meanwhile, the refrigerant at the second branching section 8, which has been cooled after being subjected to heat exchange at the second and third heat-exchange portions 10, 11, 12, 13 and provided sufficiently with subcooling, flows into the room unit 4 to be cooled.
It should be noted that at that time the second flow-rate controller 7 is normally set in a state of being open by a predetermined minimum amount.
Referring now to FIG. 16, a description will be given of the case where cooling is mainly carried out in the simultaneous operation of cooling and heating. As indicated by the dotted-line arrows in the drawing, the high-temperature high-pressure refrigerant gas discharged from the compressor 17 passes through the four-way changeover valve 18, flows into the heat source unit-side heat exchanger 19 where the refrigerant undergoes heat exchange with the heat source water, and is thereby set in a gas-liquid two-phase high-temperature high-pressure state.
Subsequently, the refrigerant in this two-phase high-temperature high-pressure state passes through the third check valve 28 and the second connecting pipe 27, and is supplied to the gas-liquid separator 9 of the relay unit 4.
Here, the refrigerant is separated into the gaseous refrigerant and the liquid refrigerant, and the separated gaseous refrigerant passes consecutively through the second valve 34 and the room unit-side first connecting pipe 26, and flows into the room unit 5 to be heated, where the refrigerant undergoes heat exchange with room air through the room unit-side heat exchanger 21, and condenses and liquefies, thereby heating the interior of the room.
This condensed and liquefied refrigerant is controlled by the subcooled amount at the outlet of the room unit-side heat exchanger 21, passes through the first flow-rate controller 36, where it is slightly decompressed and flows into the second branching section 8.
Meanwhile, a remaining portion of the liquid refrigerant passes through the second flow-rate controller 7 which is controlled the pressure detected by the first pressure-detecting means 41 and the pressure detected by the second pressure-detecting means 42. The refrigerant then converges with the refrigerant which has passed through the room unit 4 to be heated.
The refrigerant consecutively passes through the second branching section 8 and the room unit-side second connecting pipes 29, 30, and flows into the respective room units 2, 3. The refrigerant which has entered the room units 2, 3 is decompressed to a low pressure by the first flow-rate controllers 36 which is controlled by superheated amounts at the outlets of the room unit-side heat exchanger 21. The refrigerant then flows into the room unit-side heat exchanger 21, undergoes heat exchange with room air, and evaporates and gasifies, thereby cooling the interior of the rooms.
The refrigerant in this gaseous state forms a circulation cycle in which the room unit passes through the room unit-side first connecting pipes 24, 25, the first valves 33, the third valves 35, the first connecting pipe 22, the fourth check valve 23, the four-way changeover valve 18 of the heat source unit 1, and the accumulator 20, and is sucked in by the compressor 17, so as to effect the operation in which cooling is mainly performed.
In addition, at that time, the first valves 33 and the third valves 35 connected to the room units 2, 3 are open, while the second valves 34 connected thereto are closed. The second valve 34 connected to the room unit 4 is open, while the first valve 33 and the third valve 35 connected thereto are closed.
Since the first connecting pipe 22 is held under a low pressure and the second connecting pipe 27 under a high pressure at that time, the refrigerant naturally flows to the third check valve 28 and the fourth check valve 23.
During this cycle, part of the liquid refrigerant enters the bypass pipe 37 from the converging portion of the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8, and is decompressed to a low pressure by the third flow-rate controller 15. The decompressed refrigerant is then subjected to heat exchange with the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the third heat exchanger 11, 12, 13, and with the converging portion of the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the second heat-exchange portion 10, and further with the refrigerant flowing into the second flow-rate controller 7 by the first heat-exchange portion 14. The evaporated refrigerant passes through the first connecting pipe 22 and the fourth check valve 23, and further passes through the four-way changeover valve 18 of the heat source unit 1 and the accumulator 20, and is sucked in by the compressor 17.
Meanwhile, the refrigerant at the second branching section 8, which has been cooled after being subjected to heat exchange at the first, second and third heat-exchange portions 14, 10, 11, 12, 13 and provided sufficiently with subcooling, flows into the room units 2, 3 to be cooled.
Since the conventional multi-chamber heat-pump type air conditioner is arranged as described above, there has been a problem in that, in the case of totally cooling operation and mainly cooling operation when the temperature of the heat source water is high, the air conditioner stops due to an abnormality in high-level pressure and an abnormality in discharge temperature as a result of an increase in the condensation pressure. In addition, there has been another problem in that, in the case of totally heating operation and mainly heating operation of a small-capacity room unit when the room air temperature is high, the air conditioner similarly stops due to an abnormality in high-level pressure and abnormality in discharge temperature as a result of an increase in the condensation pressure. Furthermore, there has been still another problem in that, in the case of totally heating operation and mainly heating operation when the heat source temperature is high, the low-level pressure deviates from an allowable range of operation of the compressor due to a rise in evaporation pressure, thereby adversely affecting the reliability of the compressor. It should be noted that Japanese Patent Application Laid-Open (Kokai) Hei-1-118372/(1989) is known as a similar technique.
The present invention has been devised to overcome the above-described problems, and its object is to provide a multi-chamber heat-pump type air conditioner in which a plurality of room units are connected to one heat source unit, cooling and heating can be effected selectively for each room unit, and cooling can be effected by one room unit and heating can be simultaneously effected by another, wherein the high-level pressure or low-level pressure is controlled from rising high as compared to the time of normal operation, and the reliability of the compressor is not impaired.
To attain the above object, there is provided an air conditioner wherein a heat source unit-side heat exchanger which includes a compressor, a four-way changeover valve, a plurality of heat exchanger connected in parallel with each other and each having a fourth and a fifth valve at inlet and outlet ports thereof, and an accumulator, and a plurality of room units each including a room unit-side heat exchanger, a first flow-rate controller, and a room blower, are connected to each other via a first connecting pipe and a second connecting pipe, a second flow-rate controller being interposed between, on the one hand, a first branching section having a first valve and a second valve for allowing one ends of the room unit-side heat exchanger of the plurality of room units to communicate selectively with the first connecting pipe or a gas-side output port of a gas-liquid separator disposed in a room unit-side pipe end of the second connecting pipe and, on the other, a second branching section in which other ends of the plurality of room unit-side heat exchanger are connected to the second connecting pipe via the first flow-rate controllers, the second branching section and the first connecting pipe being connected to each other via a fourth flow-rate controller, there being provided a bypass pipe having one end connected to the second branching section and another end connected to the first connecting pipe via a third flow-rate controller, there being provided a heat-exchange portion for effecting heat exchange with a pipe connecting together the second connecting pipe and the first flow-rate controller, a relay constituted by the first branching section, the second branching section, the second flow-rate controller, the third flow-rate controller, the fourth flow-rate controller, the heat-exchange portion, and the bypass pipe is interposed between the room unit and the plurality of room units, characterized in that a gas side of one of the heat exchanger of the heat source unit-side heat exchanger and a discharge side of the compressor are connected to each other via a sixth valve, that a liquid side of that heat exchanger and an inlet port of the accumulator are connected to each other via a capillary tube and a seventh valve, and that there are provided pressure-detecting means for detecting the pressure within a discharge-side pipe of the compressor and a control circuit for controlling such that when the pipe pressure is below a predetermined pressure, the sixth valve and the seventh valve are closed, and when the pipe pressure exceeds the predetermined pressure, the sixth valve and the seventh valve are opened.
Alternatively, an arrangement may be provided such that a gas side of one of the heat exchanger of the heat source unit-side heat exchanger and a discharge side of the compressor are connected to each other via a sixth valve, that a liquid side of that heat exchanger and an inlet port of the accumulator are connected to each other via a capillary tube and a seventh valve, and that there are provided temperature-detecting means for detecting the temperature of the discharge side of the compressor and a control circuit for controlling such that when the discharge temperature is below a predetermined temperature, the sixth valve and the seventh valve are closed, and when the discharge temperature exceeds the predetermined temperature, the sixth valve and the seventh valve are opened.
Alternatively, an arrangement may be provided such that a gas side of one of the heat exchanger of the heat source unit-side heat exchanger and a discharge side of the compressor are connected to each other via a sixth valve, that a liquid side of that heat exchanger and an inlet port of the accumulator are connected to each other via a capillary tube and a seventh valve, and that there are provided pressure-detecting means for detecting the pressure within an inlet port-side pipe of the accumulator and a control circuit for controlling such that when the pipe pressure is below a predetermined pressure, the sixth valve and the seventh valve are closed, and when the pipe pressure exceeds the predetermined pressure, the sixth valve and the seventh valve are opened.
Alternatively, an arrangement may be provided such that a gas side of one of the heat exchanger of the heat source unit-side heat exchanger and a discharge side of the compressor are connected to each other via a sixth valve, that a liquid side of that heat exchanger and an inlet port of the accumulator are connected to each other via a capillary tube and a seventh valve, that a liquid side of that heat source unit-side heat exchanger and an inlet port of the accumulator are connected to each other by means of an evaporation-temperature detecting circuit, and that there are provided temperature-detecting means for detecting the an evaporation temperature in the evaporation-temperature detecting means and a control circuit for controlling such that when the evaporation temperature is below a predetermined temperature, the sixth valve and the seventh valve are closed, and when the evaporation temperature exceeds the predetermined temperature, the sixth valve and the seventh valve are opened.
OPERATION
The air conditioner according to the present invention is arranged as follows: The gas side of one of the heat source unit-side heat exchanger and the discharge side of the compressor are connected to each other via a sixth valve, the liquid side of that heat exchanger and the inlet port of the accumulator are connected to each other via a capillary tube and a seventh valve. Pressure-detecting means for detecting the pressure within the discharge-side pipe of the compressor and a control circuit for controlling these valves are provided. When a high-level pressure detected by a third pressure-detecting means is below a first set pressure, the sixth and seventh valves are closed, while when the high-level pressure rises above the first set pressure, the sixth and seventh valves are opened. Accordingly, it is possible to control an excessive rise in the high-level pressure.
Alternatively, temperature-detecting means for detecting the temperature of the discharge side of the compressor and a control circuit for controlling these valves are provided. When the discharge temperature detected by the temperature-detecting means is below a first predetermined temperature, the sixth and the seventh valves are closed, while when the discharge temperature rises above the first set temperature, the sixth and seventh valves are opened. Accordingly, it is possible to control an excess rise in the discharge temperature.
Alternatively, pressure-detecting means for detecting the pressure within an inlet port-side pipe of the accumulator and a control circuit for controlling these valves are provided. When the low-level pressure detected by a fourth pressure-detecting means is below a second set pressure, the sixth and seventh valves are closed, while when it rises above the second set pressure, the sixth and seventh valves are opened. Accordingly, it is possible to control an excessive rise in the low-level pressure.
Alternatively, the liquid side of the heat source unit-side heat exchanger and an inlet port of the accumulator are connected to each other by means of an evaporation-temperature detecting circuit, and a control circuit for controlling these valves is provided. When the evaporation temperature detected by the evaporation-temperature detecting means is below a second predetermined temperature, the sixth and seventh valves are closed, while when the evaporation temperature rises above the second set temperature, the sixth and seventh valves are opened. Accordingly, it is possible to control an excessive rise in the evaporation temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall schematic diagram of an air conditioner in accordance with a first embodiment of the invention, centering on a refrigerant system;
FIG. 2 is a circuit diagram of the refrigerant illustrating the state of operation of only cooling or heating by the air conditioner in accordance with the first embodiment of the present invention;
FIG. 3 is a circuit diagram of the refrigerant illustrating the state of operation of mainly heating by the air conditioner in accordance with the first embodiment of the present invention;
FIG. 4 is a circuit diagram of the refrigerant illustrating the state of operation of mainly cooling by the air conditioner in accordance with the first embodiment of the present invention;
FIG. 5 is a block diagram illustrating a configuration of a control system of a first controller of the air conditioner in accordance with the first embodiment of the present invention;
FIG. 6 is a flowchart of the control system of the first controller of the air conditioner in accordance with the first embodiment of the present invention;
FIG. 7 is a block diagram illustrating a configuration of a control system of a second controller of the air conditioner in accordance with a second embodiment of the present invention;
FIG. 8 is a flowchart of the control system of the second controller of the air conditioner in accordance with the second embodiment of the present invention;
FIG. 9 is a block diagram illustrating a configuration of a control system of a third controller of the air conditioner in accordance with a third embodiment of the present invention;
FIG. 10 is a flowchart of the control system of the third controller of the air conditioner in accordance with the third embodiment of the present invention;
FIG. 11 is a block diagram illustrating a configuration of a control system of a fourth controller of the air conditioner in accordance with a fourth embodiment of the present invention;
FIG. 12 is a flowchart of the control system of the fourth controller of the air conditioner in accordance with the fourth embodiment of the present invention;
FIG. 13 is an overall schematic diagram of an air conditioner in accordance with a prior art example relating to the invention, centering on the refrigerant system;
FIG. 14 is a circuit diagram of the refrigerant illustrating the state of operation of only cooling or heating by the air conditioner in accordance with the prior art example relating to the present invention;
FIG. 15 is a circuit diagram of the refrigerant illustrating the state of operation of mainly heating by the air conditioner in accordance with the prior art example relating to the present invention; and
FIG. 16 is a circuit diagram of the refrigerant illustrating the state of operation of mainly cooling by the air conditioner in accordance with the prior art example relating to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
Hereafter, a description will be given of an embodiment of the present invention.
FIG. 1 is an overall schematic diagram of an air conditioner in accordance with an embodiment of the present invention, centering on a refrigerant system. FIGS. 2 to 4 are diagrams illustrating states of operation during cooling and heating operation in the first embodiment, in which FIG. 2 is a diagram of a state of operation of only cooling or heating, FIG. 3 is a diagram of a state of operation in which heating is mainly performed (a case where the capacity for heating operation is greater than that for cooling operation) in the simultaneous operation of cooling and heating, and FIG. 4 is a diagram of a state of operation in which cooling is mainly performed (a case where the capacity for cooling operation is greater than that for heating operation) in the simultaneous operation of cooling and heating.
It should be noted that in this first embodiment a description will be given of a case where three room units are connected to one heat source unit, but it also similarly applies to cases where two or more room units are connected thereto.
In FIG. 1, reference numeral 1 denotes a heat source unit, and numerals 2, 3 and 4 denote room units which are connected in parallel with each other, as will be described later, and the same arrangement is used for the respective units. Numeral 5 denotes a relay unit which incorporates a first branching section 6, a second flow-rate controller 7, a second branching section 8, a gas-liquid separator 9, heat exchange-portions 10, 11, 12, 13, 14, a third flow-rate controller 15, and a fourth flow-rate controller 16, as will be described later.
In addition, numeral 17 denotes a compressor; 18, a four-way changeover valve for changing over the direction of circulation of a refrigerant of the heat source unit; 19, a heat source unit-side heat exchanger consisting a plurality of heat exchanger which are connected in parallel with each other and each having a fourth valve 43 and a fifth valve 44 at inlet and outlet ports thereof; and 20, an accumulator which is connected to the compressor 17 via the four-way changeover valve 18. Numeral 45 denotes a sixth valve connected to a bypass pipe for connecting the gas side of one of the aforementioned heat source unit-side heat exchanger 19 and the discharge side of the compressor 17. Numeral 46 denotes a seventh valve connected to a bypass pipe for connecting the liquid side of that heat exchanger and an inlet of the accumulator 20 via a capillary tube 47. Numeral 48 denotes a third pressure-detecting means disposed between the compressor 17 and the four-way changeover valve 18.
In addition, numeral 21 denotes a room unit-side heat exchanger provided for each of the three room units 2, 3, 4; 22, a large-diameter first connecting pipe for connecting together the four-way changeover valve 18 of the heat source unit 1 and the relay unit 5 via a fourth check valve 23 which will be described later; numerals 24, 25, 26 denote room unit-side first connecting pipes which respectively connect the room unit-side heat exchanger 21 of the room units 2, 3, 4 to the relay unit 5 and correspond to the first connecting pipe 22; and 27 denotes a second connecting pipe having a diameter smaller than that of the aforementioned first connecting pipe and used for connecting together heat source unit-side heat exchanger 19 of the heat source unit 1 and the relay unit 5 via a third check valve 28 which will be described later.
In addition, numerals 29, 30, 31 respectively denote room unit-side second connecting pipes for connecting together the room unit-side heat exchanger 21 of the room units 2, 3, 4 and the relay unit 5, and corresponding to the second connecting pipes 27.
Numeral 33 denotes a first valve for allowing the room unit-side first connecting pipes 24, 25, 26 to communicate with the first connecting pipe 22; 34, a second valve for allowing the room unit-side first connecting pipes 24, 25, 26 to communicate with the second connecting pipe 27; and 35, a third valve for bypassing inlet and outlet ports of the first valve 21.
Numeral 36 denotes a first flow-rate controller which is connected in the vicinity of the room unit-side heat exchanger 21 and is controlled by a superheated amount at the outlet of the room unit-side heat exchanger 21 during cooling and by a subcooled amount thereat during heating, the first flow-rate controllers 36 being connected to the room unit-side second connecting pipes 29, 30, 31.
Numeral 6 denotes the first branching section which includes the first valves 33 and the second valves 34 for selectively connecting the room unit-side first connecting pipes 24, 25, 26 to the first connecting pipe 22 or the second connecting pipe 27, as well as the third valves 35 for bypassing the inlet and outlet ports of the first valves 33.
Numeral 8 denotes the second branching section which includes the room unit-side second connecting pipes 29, 30, 31 and the second connecting pipe 27.
Numeral 9 denotes the gas-liquid separator disposed in a midway position of the second connecting pipe 27, and its vapor phase portion is connected to the second valves 34 at the first branching section, while its liquid phase portion is connected to the second branching section 8.
Numeral 7 denotes the second flow-rate controller (here, an electric expansion valve) which can be opened or closed freely and is connected between the gas-liquid separator 9 and the second branching section 8.
Numeral 37 denotes a bypass pipe for connecting together second branching section 8 and the first connecting pipe 22; 15, the third flow-rate controller (here, an electric expansion valve) disposed in a midway position of the bypass pipe 37; and 10, the second heat-exchange portion which is disposed downstream of the third flow-rate controller 15 disposed in the midway position of the bypass pipe 37 and effects heat exchange at a converging portion of the respective room unit-side second connecting pipes 29, 30, 31 in the second branching section 8.
Numerals 11, 12, 13 respectively denote the third heat-exchange portions which are disposed downstream of the third flow-rate controller 15 disposed in the midway position of the bypass pipe 37, and effect heat exchange with the respective room unit-side second connecting pipes 29, 30, 31 in the second branching section 8.
Numeral 14 denotes the first heat exchanger which is disposed downstream of the third flow-rate controller 15 of the bypass pipe 37 and downstream of the second heat-exchange portion 10, and effects heat exchange with the pipe connecting the gas-liquid separator 9 and the second flow-rate controller 7; and numeral 16 denotes the fourth flow-rate controller (here, an electric expansion valve) which can be opened or closed freely and is connected between the second branching section 8 and the first connecting pipe 22.
Meanwhile, numeral 32 denotes the third check valve which is disposed between the heat source unit-side heat exchanger 19 and the second connecting pipe 27, and allows circulation of the refrigerant only from the heat source unit-side heat exchanger 19 to the second connecting pipe 27.
Numeral 23 denotes the fourth check valve which is disposed between the four-way changeover valve 18 of the heat source unit 1 and the first connecting pipe 22, and allows circulation of the refrigerant only from the first connecting pipe 22 to the four-way changeover valve 18.
Numeral 38 denotes a fifth check valve which is disposed between the four-way changeover valve 18 of the heat source unit 1 and the second connecting pipe 27, and allows circulation of the refrigerant only from the four-way changeover valve 18 to the second connecting pipe 27.
Numeral 39 denotes a sixth check valve which is disposed between the heat source unit-side heat exchanger 19 and the first connecting pipe 22, and allows circulation of the refrigerant only from the first connecting pipe 22 to the heat source unit-side heat exchanger 19.
The aforementioned third, fourth, fifth, and sixth check valves 28, 23, 38, 39 constitute a channel-changeover device 40.
Numeral 41 denotes a first pressure-detecting means disposed between the first branching section 6 and the second flow-rate controller 7; and 42 denotes a second pressure-detecting means disposed between the second flow-rate controller 7 and the fourth flow-rate controller 16.
Numeral 45 denotes the sixth valve connected to a pipe for connecting the compressor 17 and the heat source unit-side heat exchanger 19, and numeral 46 denotes the seventh valve provided in the pipe for connecting the accumulator 20 and the heat source unit-side heat exchanger 19, together with a capillary tube 47.
Next, a description will be given of the operation. First, a description will be given of the case of cooling operation only, with reference to FIG. 2. As indicated by the solid-line arrows in the drawing, a high-temperature high-pressure refrigerant gas discharged from the compressor 17 passes through the four-way changeover valve 18, undergoes heat exchange with heat source water in the heat source unit-side heat exchanger 19, and is thereby condensed. The condensed refrigerant then passes through the third check valve 28, the second connecting pipe 27, the gas-liquid separator 9, and the second flow-rate controller in that order, further passes through the second branching section 8 and the room unit-side second connecting pipes 29, 30, 31, and flows into the respective room units 2, 3, 4.
The refrigerant which has entered the room units 2, 3, 4 is made to undergo decompression to a low pressure by the first flow-rate controllers 36 controlled by the superheated amounts at the outlets of the room unit-side heat exchanger 21. The refrigerant then undergoes heat exchange with the air within the rooms by means of the room unit-side heat exchanger 21, whereupon the refrigerant evaporates and gasifies, thereby cooling the interior of the rooms.
The refrigerant in this gaseous state forms a circulation cycle in which it passes through the room unit-side first connecting pipes 24, 25, 26, the first valves 33, the third valves 35, the first connecting pipe 22, the fourth check valve 23, the four-way changeover valve 18 of the heat source unit 1, and the accumulator 20, and is then sucked by the compressor 17, so as to effect the cooling operation.
At that time, the first valves 33 and the third valves 35 are open, while the second valves 34 are closed. In addition, since the first connecting pipe 22 is held under a low pressure and the second connecting pipe 27 under a high pressure at that time, the refrigerant naturally flows to the third check valve 28 and the fourth check valve 23.
In addition, during this cycle, part of the refrigerant which has passed through the second flow-rate controller 7 enters the bypass pipe 37 and is decompressed to a low pressure by the third flow-rate controller 15. The decompressed refrigerant is then subjected to heat exchange with the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the third heat-exchange portions 11, 12, 13, and with the converging portion of the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the second heat-exchange portion 10, and further with the refrigerant flowing into the second flow-rate controller 7 by the first heat-exchange portion 14, and is thereby evaporated. The evaporated refrigerant enters the first connecting pipe 22 and the fourth check valve 23, passes through the four-way changeover valve 18 of the heat source unit 1 and the accumulator 20, and is sucked in by the compressor 17.
Meanwhile, the refrigerant at the second branching section 8, which has been cooled after being subjected to heat exchange at the first, second and third heat-exchange portions 14, 10, 11, 12, 13 and provided sufficiently with subcooling, flows into the room units 2, 3, 4 to be cooled.
Referring now to FIG. 2, a description will be given of the case of heating operation only. Namely, as indicated by the dotted-line arrows in the drawing, the high-temperature high-pressure refrigerant gas discharged from the compressor 17 passes through the four-way changeover valve 18, passes through the fifth check valve 38, the second connecting pipe 27, and the gas-liquid separator 9, passes consecutively through the second valves 34 and the room unit-side first connecting pipes 24, 25, 26, and flows into the respective room units 2, 3, 4, where the refrigerant undergoes heat exchange with the air within the rooms, and condenses and liquefies, thereby heating the interior of the rooms.
The refrigerant in this liquid state is controlled by the subcooled amounts at the outlets of the room unit-side heat exchanger 21, passes through the first flow-rate controllers 36 in the substantially open state, flows into the second branching section 8 from the room unit-side second connecting pipes 29, 30, 31 and converges, and further passes through the fourth flow-rate controller 16.
Here, the refrigerant is decompressed to a low-pressure gas-liquid two-phase state by either the first flow-rate controllers 36 or the third and fourth flow-rate controllers 15, 16.
The refrigerant decompressed to a low pressure forms a circulation cycle in which the refrigerant passes through the first connecting pipe 22, flows into the sixth check valve 39 of the heat source unit 1 and the heat source unit-side heat exchanger 19, where the refrigerant exchanges heat with the heat source water, evaporates and assumes a gaseous state, and is sucked in by the compressor 17 through the four-way changeover valve 18 of the heat source unit 1 and the accumulator 20, so as to effect the heating operation.
At that time, the second valves 34 are open, while the first valves 33 and the third valves 35 are closed. In addition, since the first connecting pipe 22 is held under a low pressure and the second connecting pipe 27 under a high pressure at that time, the refrigerant naturally flows to the fifth check valve 38 and the sixth check valve 39.
It should be noted that at that time the second flow-rate controller 7 is normally set in a state of being open by a predetermined minimum amount.
Referring now to FIG. 3, a description will be given of the case where heating is mainly carried out in the simultaneous operation of cooling and heating. As indicated by the dotted-line arrows in the drawing, the high-temperature high-pressure refrigerant gas discharged from the compressor 17 passes through the four-way changeover valve 18, passes through the fifth check valve 38 and the second connecting pipe 27, is supplied to the relay unit 5, passes through the gas-liquid separator 9, passes consecutively through the second valves 34 and the room unit-side first connecting pipes 24, 25, and flows into the respective room units 2, 3, to be heated, where the refrigerant undergoes heat exchange through the room unit-side heat exchanger 21, and condenses and liquefies, thereby heating the interior of the rooms.
This condensed and liquefied refrigerant is controlled by the subcooled amounts at the outlets of the room unit-side heat exchanger 21, passes through the first flow-rate controllers 36, where it is slightly decompressed and flows into the second branching section 8.
Part of this refrigerant passes through the room unit-side second connecting pipe 31, enters the room unit 4 to be cooled, enters the first flow-rate controller 36 controlled by the superheated amount at the outlet of the room unit-side heat exchanger 21. After the refrigerant is decompressed, the refrigerant enters the room unit-side heat exchanger 21 where it undergoes heat exchange, evaporates and assumes the gaseous state to cool the interior of the room. The refrigerant then passes through the room unit-side first connecting pipe 26, and flows into the first connecting pipe 22 via the first valve 33 and the third valve 35.
Meanwhile, a remaining portion of the refrigerant passes through the fourth flow-rate controller 16 which is controlled such that a pressure difference between the pressure detected by the first pressure-detecting means 41 and the pressure detected by the second pressure-detecting means 42 is set in a predetermined range. The refrigerant then converges with the refrigerant which has passed through the room unit 4 to be cooled, passes through the large-diameter first connecting pipe 22, flows into the sixth check valve 39 of the heat source unit 1 and the heat source unit-side heat exchanger 19, and undergoes heat exchange with the heat source water, and thereby evaporates and assumes the gaseous state.
This refrigerant forms a circulation cycle in which the room unit passes through the four-way changeover valve 18 of the heat source unit 1 and the accumulator 20 and is sucked in by the compressor 17, so as to effect the operation in which heating is mainly performed.
At that time, the pressure difference between the low pressure of the room unit-side heat exchanger 21 of the room unit 4 for effecting cooling and the pressure of the heat source unit-side heat exchanger 19 becomes small since the line is changed over to the large-diameter first connecting pipe 22.
In addition, at that time, the second valves 34 connected to the room units 2, 3 are open, while the first valves 33 and the third valves 35 connected thereto are closed. The first valve 33 and the third valve 35 connected to the room unit 4 are open, while the second valve 34 connected thereto is closed.
In addition, since the first connecting pipe 22 is held under a low pressure and the second connecting pipe 27 under a high pressure at that time, the refrigerant naturally flows to the fifth check valve 38 and the sixth check valve 39.
During this cycle, part of the liquid refrigerant enters the bypass pipe 37 from the converging portion of the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8, and is decompressed to a low pressure by the third flow-rate controller 15. The decompressed refrigerant is then subjected to heat exchange with the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the third heat exchanger 11, 12, 13, and with the converging portion of the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the second heat-exchange portion 10. The evaporated refrigerant passes through the first connecting pipe 22 and the sixth check valve 39, enters the heat source unit-side heat exchanger 19 where it undergoes heat exchange with heat source water and is evaporated. Subsequently, the evaporated refrigerant passes through the four-way changeover valve 18 of the heat source unit 1 and the accumulator 20, and is sucked in by the compressor 17.
Meanwhile, the refrigerant at the second branching section 8, which has been cooled after being subjected to heat exchange at the second and third heat-exchange portions 10, 11, 12, 13 and provided sufficiently with subcooling, flows into the room unit 4 to be cooled.
It should be noted that at that time the second flow-rate controller 7 is normally set in a state of being open by a predetermined minimum amount.
Referring now to FIG. 4, a description will be given of the case where cooling is mainly carried out in the simultaneous operation of cooling and heating.
As indicated by the solid-line arrows in the drawing, the high-temperature high-pressure refrigerant gas discharged from the compressor 17 passes through the four-way changeover valve 18, flows into the heat source unit-side heat exchanger 19 where the refrigerant undergoes heat exchange with the heat source water, and is thereby set in a gas-liquid two-phase high-temperature high-pressure state.
Subsequently, the refrigerant in this two-phase high-temperature high-pressure state passes through the third check valve 28 and the second connecting pipe 27, and is supplied to the gas-liquid separator 9 of the relay unit 5.
Here, the refrigerant is separated into the gaseous refrigerant and the liquid refrigerant, and the separated gaseous refrigerant passes consecutively through the second valve 34 and the room unit-side first connecting pipe 26, and flows into the room unit 4 to be heated, where the refrigerant undergoes heat exchange with room air through the room unit-side heat exchanger 21, and condenses and liquefies, thereby heating the interior of the room.
This condensed and liquefied refrigerant is controlled by the subcooled amount at the outlet of the room unit-side heat exchanger 21, passes through the first flow-rate controller 36, where it is slightly decompressed and flows into the second branching section 8.
Meanwhile, a remaining portion of the liquid refrigerant passes through the second flow-rate controller 7 which is controlled the pressure detected by the first pressure-detecting means 41 and the pressure detected by the second pressure-detecting means 42. The refrigerant then converges with the refrigerant which has passed through the room unit 4 to be heated.
The refrigerant consecutively passes through the second branching section 8 and the room unit-side second connecting pipes 29, 30, and flows into the respective room units 2, 3. The refrigerant which has entered the room units 2, 3 is decompressed to a low pressure by the first flow-rate controllers 36 which is controlled by superheated amounts at the outlets of the room unit-side heat exchanger 21. The refrigerant then flows into the room unit-side heat exchanger 21, undergoes heat exchange with room air, and evaporates and gasifies, thereby cooling the interior of the rooms.
The refrigerant in this gaseous state forms a circulation cycle in which the room unit passes through the room unit-side first connecting pipes 24, 25, the first valves 33, the third valves 35, the first connecting pipe 22, the fourth check valve 23, the four-way changeover valve 18 of the heat source unit 1, and the accumulator 20, and is sucked in by the compressor 17, so as to effect the operation in which cooling is mainly performed.
In addition, at that time, the first valves 33 and the third valves 35 connected to the room units 2, 3 are open, while the second valves 34 connected thereto are closed. The second valve 34 connected to the room unit 4 is open, while the first valve 33 and the third valve 35 connected thereto are closed.
Since the first connecting pipe 22 is held under a low pressure and the second connecting pipe 27 under a high pressure at that time, the refrigerant naturally flows to the third check valve 28 and the fourth check valve 23.
During this cycle, part of the liquid refrigerant enters the bypass pipe 37 from the converging portion of the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8, and is decompressed to a low pressure by the third flow-rate controller 15. The decompressed refrigerant is then subjected to heat exchange with the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the third heat exchanger 11, 12, 13, and with the converging portion of the room unit-side second connecting pipes 29, 30, 31 in the second branching section 8 by the second heat-exchange portion 10, and further with the refrigerant flowing into the second flow-rate controller 7 by the first heat-exchange portion 14. The evaporated refrigerant passes through the first connecting pipe 22 and the fourth check valve 23, and further passes through the four-way changeover valve 18 of the heat source unit 1 and the accumulator 20, and is sucked in by the compressor 17.
Meanwhile, the refrigerant at the second branching section 8, which has been cooled after being subjected to heat exchange at the first, second and third heat-exchange portions 14, 10, 11, 12, 13 and provided sufficiently with subcooling, flows into the room units 2, 3 to be cooled.
Next, a description will be given of the control of the fourth valve 43, the fifth valve 44, the sixth valve 45, and the seventh valve 46 when the high-level pressure has risen above a first set pressure.
FIG. 5 shows a mechanism for controlling the fourth valve 43, the fifth valve 44, the sixth valve 45, and the seventh valve 46, and reference numeral 49 denotes a first control circuit for controlling the fourth to seventh valves by means of the pressure detected by the third pressure-detecting means 48.
FIG. 6 is a flowchart illustrating the details of control effected by the first control circuit 49.
In the air conditioner in accordance with this first embodiment, the high-level pressure becomes high in the case of totally cooling operation and mainly cooling operation when the heat-source water temperature is high. In addition, the high-level pressure becomes high also in the case of totally heating operation and mainly heating operation using a small-capacity room unit when the room air temperature is high. Accordingly, control is effected such that the sixth valve 45 and the seventh valve 46 are opened when the third pressure-detecting means 48 has detected that the high-level pressure is more than the first set pressure. Through the above-described control, the high-pressure liquid refrigerant condensed by the heat exchanger is bypassed to be set to a lower pressure via the capillary tube, so that the high-level pressure and the low-level pressure become low, thereby preventing the air conditioner from stopping due to an abnormality in the high-level pressure.
Next, a description will be given of the details of control effected by the first control circuit 49 in this first embodiment with reference to the flowchart shown in FIG. 6.
When the air conditioner performs totally cooling operation and mainly cooling operation, in Step S91, a comparison is made between a high-level pressure Pd detected by the third pressure-detecting means 48 and a first set pressure P1. Here, if a determination is made that the high-level pressure Pd is greater than the set pressure P1, the operation proceeds to Step S92 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed.
If it is determined in Step S92 that the sixth valve 45 and the seventh valve are closed, the operation proceeds to Step S93 to open the sixth valve 45 and the seventh valve. If it is determined in Step S92 that the sixth valve 45 and the seventh valve 46 are open, the operation returns to Step S91.
If it is determined in Step S91 that the high-level pressure Pd is not more than the first set pressure P1, the operation proceeds to Step S94 to determine whether the sixth valve 45 and the seventh valve are open or closed. If it is determined in Step S94 that the sixth valve 45 and the seventh valve 46 are open, the operation proceeds to Step S95 to close the sixth valve 45 and the seventh valve 46.
If it is determined in Step S94 that the sixth valve 45 and the seventh valve 46 are closed, the operation returns to Step S91.
When the air conditioner performs totally heating operation and mainly cooling operation, in Step S96, a comparison is made between the high-level pressure Pd detected by the third pressure-detecting means 48 and the first set pressure P1. Here, if a determination is made that the high-level pressure Pd is greater than the set pressure P1, the operation proceeds to Step S97 to determine whether the fourth valve 43 and the fifth valve 44 are open or closed.
If it is determined in Step S97 that the fourth valve 43 and the fifth valve 44 are closed, the operation proceeds to Step S98 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed. If it is determined in Step S98 that the sixth valve 45 and the seventh valve 46 are closed, the operation proceeds to Step S99 to open the sixth and seventh valves. If it is determined in Step S99 that the sixth valve 45 and the seventh valve 46 are open, the operation returns to Step S96.
If it is determined in Step S97 that the fourth valve 43 and the fifth valve 44 are open, the fourth valve 43 and the fifth valve 44 are closed in Step S100, and the operation proceeds to Step S101. In Step S101, a determination is made as to whether the sixth valve 45 and the seventh valve 46 are open or closed. If a determination is made that they are open, the operation proceeds to Step S102 to open the sixth valve 45 and the seventh valve 46, and the operation returns to Step S96. If it is determined in Step S101 that the sixth valve 45 and the seventh valve 46 are open, the operation returns to Step S96.
If it is determined in Step S96 that the high-level pressure Pd is not more than the first set pressure P1, the operation proceeds to Step S103 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed. If it is determined in Step S103 that the sixth valve 45 and the seventh valve 46 are open, the operation proceeds to Step S104 to open the sixth valve 45 and the seventh valve 46, and the operation returns to Step S96. If it is determined in Step S104 that the sixth valve 45 and the seventh valve 46 are closed, the operation returns to Step S96.
Second Embodiment
Next, a description will be given of the control of the fourth valve 43, the fifth valve 44, the sixth valve 45, and the seventh valve 46 when the discharge temperature has risen above a first set temperature.
FIG. 7 shows a mechanism for controlling the fourth valve 43, the fifth valve 44, the sixth valve 45, and the seventh valve 46, and reference numeral 50 denotes a second control circuit for controlling the fourth to seventh valves by means of the pressure detected by a first pressure-detecting means 51.
FIG. 8 is a flowchart illustrating the details of control effected by the second control circuit 50.
In the air conditioner in accordance with this second embodiment, in the case of totally cooling operation and mainly cooling operation when the heat-source water temperature is high, the discharge temperature becomes high as the high-level pressure becomes high. In addition, in the case of totally heating operation and mainly heating operation using a small-capacity room unit when the room air temperature is high, the discharge temperature also becomes high as the high-level pressure becomes high. Accordingly, control is effected such that the sixth valve 45 and the seventh valve 46 are opened when the first temperature-detecting means 50 has detected that the discharge temperature is more than the first set temperature. Through the above-described control, the high-pressure liquid refrigerant condensed by the heat exchanger is bypassed to be set to a lower pressure via the capillary tube, so that the high-level pressure and the low-level pressure become low, thereby making it possible to control a rise in the discharge temperature.
Next, a description will be given of the details of control effected by the second control circuit 50 in this second embodiment with reference to the flowchart shown in FIG. 8.
When the air conditioner performs totally cooling operation and mainly cooling operation, in Step S106, a comparison is made between a discharge temperature Td detected by the first temperature-detecting means 51 and a first set temperature T1. Here, if a determination is made that the discharge temperature Td is greater than the set temperature T1, the operation proceeds to Step S107 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed.
If it is determined in Step S107 that the sixth valve 45 and the seventh valve 46 are closed, the operation proceeds to Step S108 to open the sixth valve 45 and the seventh valve 46. If it is determined in Step S107 that the sixth valve 45 and the seventh valve 46 are open, the operation returns to Step S106.
If it is determined in Step S106 that the discharge temperature Td is not more than the first set temperature T1, the operation proceeds to Step S109 to determine whether the sixth valve and the seventh valve 46 are open or closed. If it is determined in Step S109 that the sixth valve 45 and the seventh valve 46 are open, the operation proceeds to Step S110 to close the sixth valve 45 and the seventh valve 46.
If it is determined in Step S109 that the sixth valve and the seventh valve 46 are closed, the operation returns to Step S106.
When the air conditioner performs totally heating operation and mainly cooling operation, in Step S111, a comparison is made between the discharge temperature Td detected by the first temperature-detecting means 51 and the first set temperature T1. Here, if a determination is made that the discharge temperature Td is greater than the set temperature T1, the operation proceeds to Step S112 to determine whether the fourth valve 43 and the fifth valve 44 are open or closed.
If it is determined in Step S112 that the fourth valve 43 and the fifth valve 44 are closed, the operation proceeds to Step S113 to determine whether the sixth valve 45 and the seventh valve 46 are closed. If it is determined in Step S113 that the sixth valve 45 and the seventh valve 46 are closed, the operation proceeds to Step S114 to open the sixth valve 45 and the seventh valve 46. If it is determined in Step S113 that the sixth valve 45 and the seventh valve 46 are open, the operation returns to Step S111.
If it is determined in Step S112 that the fourth valve 43 and the fifth valve 44 are open, the fourth valve 43 and the fifth valve 44 are closed in Step S115, and the operation proceeds to Step S116. In Step S116, a determination is made as to whether the sixth valve 45 and the seventh valve 46 are open or closed. If a determination is made that they are closed, the operation proceeds to Step S117 to open the sixth valve 45 and the seventh valve 46, and the operation returns to Step S111. If it is determined in Step S116 that the sixth valve 45 and the seventh valve 46 are closed, the operation returns to Step S111.
If it is determined in Step S111 that the discharge temperature Td is not more than the first set temperature T1, the operation proceeds to Step S118 to determine whether the sixth valve 45 and the seventh valve are open or closed. If it is determined in Step S118 that the sixth valve 45 and the seventh valve 46 are open, the operation proceeds to Step S119 to close the sixth valve 45 and the seventh valve 46, and the operation returns to Step S111. If it is determined in Step S118 that the sixth valve 45 and the seventh valve 46 are closed, the operation returns to Step S111.
Third Embodiment
Next, a description will be given of the control of the fourth valve 43, the fifth valve 44, the sixth valve 45, and the seventh valve 46 when the low-level pressure has risen above a second set pressure.
FIG. 9 shows a mechanism for controlling the fourth valve 43, the fifth valve 44, the sixth valve 45, and the seventh valve 46, and reference numeral 52 denotes a third control circuit for controlling the fourth to seventh valves by means of the pressure detected by a fourth pressure-detecting means 53.
FIG. 10 is a flowchart illustrating the details of control effected by the third control circuit 52.
In the air conditioner in accordance with this third embodiment, in the case of totally heating operation and mainly heating operation when the heat-source water temperature is high, the low-level pressure becomes high since the evaporation temperature is high. Accordingly, control is effected such that the sixth valve 45 and the seventh valve 46 are closed when the fourth pressure-detecting means 53 has detected that the low-level pressure is more than the second set pressure. Through the above-described control, the high-pressure liquid refrigerant condensed by the heat exchanger is bypassed to be set to a lower pressure via the capillary tube, thereby preventing adverse effect from being exerted on the reliability of the compressor.
Next, a description will be given of the details of control effected by the third control circuit 52 in this third embodiment with reference to the flowchart shown in FIG. 10.
When the air conditioner performs totally cooling operation and mainly cooling operation, in Step S121, a comparison is made between a low-level pressure Ps detected by the fourth pressure-detecting means 53 and a second set pressure P2. Here, if a determination is made that the low-level pressure Ps is greater than the set pressure P2, the operation proceeds to Step S122 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed.
If it is determined in Step S122 that the sixth valve 45 and the seventh valve 46 are closed, the operation proceeds to Step S123 to open the sixth valve 45 and the seventh valve 46. If it is determined in Step S122 that the sixth valve 45 and the seventh valve 46 are open, the operation returns to Step S121.
If it is determined in Step S121 that the low-level pressure Ps is not more than the second set pressure P2, the operation proceeds to Step S124 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed. If it is determined in Step S124 that the sixth valve 45 and the seventh valve 46 are open, the operation proceeds to Step S125 to close the sixth valve 45 and the seventh valve 46.
If it is determined in Step S124 that the sixth valve 45 and the seventh valve 46 are closed, the operation returns to Step S121.
When the air conditioner performs totally heating operation and mainly cooling operation, in Step S126, a comparison is made between the low-level pressure Ps detected by the fourth pressure-detecting means 53 and the second set pressure P2. Here, if a determination is made that the low-level pressure Ps is greater than the set pressure P2, the operation proceeds to Step S127 to determine whether the fourth valve 43 and the fifth valve 44 are open or closed.
If it is determined in Step S127 that the fourth valve 43 and the fifth valve 44 are closed, the operation proceeds to Step S128 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed. If it is determined in Step S128 that the sixth valve 45 and the seventh valve 46 are closed, the operation proceeds to Step S129 to open the sixth connecting pipe 45 and the seventh valve 46. If it is determined in Step S128 that the sixth valve 45 and the seventh valve 46 are open, the operation returns to Step S126.
If it is determined in Step S127 that the fourth valve 43 and the fifth valve 44 are open, the fourth valve 43 and the fifth valve 44 are closed in Step S130, and the operation proceeds to Step S131. In Step S131, a determination is made as to whether the sixth valve 45 and the seventh valve 46 are open or closed. If a determination is made that they are closed, the operation proceeds to Step S132 to open the sixth valve 45 and the seventh valve 46, and the operation returns to Step S126. If it is determined in Step S131 that the sixth valve 45 and the seventh valve 46 are open, the operation returns to Step S126.
If it is determined in Step S126 that the low-level pressure Ps is not more than the second set pressure P2, the operation proceeds to Step S133 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed. If it is determined in Step S133 that the sixth valve 45 and the seventh valve 46 are open, the operation proceeds to Step S134 to close the sixth valve 45 and the seventh valve 46, and the operation returns to Step S126. If it is determined in Step S133 that the sixth valve 45 and the seventh valve are closed, the operation returns to Step S126.
Fourth Embodiment
Next, a description will be given of the control of the fourth valve 43, the fifth valve 44, the sixth valve 45, and the seventh valve 46 when the evaporation temperature has risen above a second set temperature.
FIG. 11 shows a mechanism for controlling the fourth valve 43, the fifth valve 44, the sixth valve 45, and the seventh valve 46, and reference numeral 54 denotes a fourth control circuit for controlling the fourth to seventh valves by means of the temperature detected by a second temperature-detecting means 55. The second temperature-detecting means 55 detects the evaporation temperature at a evaporation-temperature detecting circuit 56 in which the accumulator 20 and the heat source unit-side heat exchanger 19 are connected by means of a capillary tube.
FIG. 12 is a flowchart illustrating the details of control effected by the fourth control circuit 54.
In the air conditioner in accordance with this fourth embodiment as well, the evaporation temperature becomes high in the case of totally heating operation and mainly heating operation when the heat-source water temperature is high. Accordingly, control is effected such that the sixth valve 45 and the seventh valve 46 are opened when the second temperature-detecting means 55 has detected that the evaporation temperature is more than the second set temperature. Through the above-described control, the high-pressure liquid refrigerant condensed by the heat exchanger is bypassed to be set to a lower pressure via the capillary tube, so that the evaporation temperature becomes low, thereby making it possible to secure a cooling capability in the mainly heating operation.
Finally, a description will be given of the details of control effected by the fourth control circuit 54 in this fourth embodiment with reference to the flowchart shown in FIG. 12.
When the air conditioner performs totally cooling operation and mainly cooling operation, in Step S136, a comparison is made between a evaporation temperature ET detected by the second temperature-detecting means 55 and a second set temperature T2. Here, if a determination is made that the evaporation temperature ET is greater than the set pressure T2, the operation proceeds to Step S137 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed.
If it is determined in Step S137 that the sixth valve 45 and the seventh valve are closed, the operation proceeds to Step S138 to open the sixth valve 45 and the seventh valve 46. If it is determined in Step S137 that the sixth valve 45 and the seventh valve 46 are open, the operation returns to Step S136.
If it is determined in Step S136 that the evaporation temperature ET is not more than the second set temperature T2, the operation proceeds to Step S139 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed. If it is determined in Step S139 that the sixth valve 45 and the seventh valve 46 are open, the operation proceeds to Step S135 to close the sixth valve 45 and the seventh valve 46.
If it is determined in Step S139 that the sixth valve 45 and the seventh valve 46 are closed, the operation returns to Step S136.
When the air conditioner performs totally heating operation and mainly cooling operation, in Step S141, a comparison is made between the evaporation temperature ET detected by the second temperature-detecting means 55 and the second set temperature T2. Here, if a determination is made that the evaporation temperature ET is greater than the set pressure T2, the operation proceeds to Step S142 to determine whether the fourth valve 43 and the fifth valve 44 are open or closed.
If it is determined in Step S142 that the fourth valve 43 and the fifth valve 44 are closed, the operation proceeds to Step S143 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed. If it is determined in Step S143 that the sixth valve 45 and the seventh valve 46 are closed, the operation proceeds to Step S144 to open the sixth 45 and the seventh valve 46. If it is determined in Step S143 that the sixth valve 45 and the seventh valve 46 are open, the operation returns to Step S146.
If it is determined in Step S142 that the fourth valve 43 and the fifth valve 44 are open, the fourth valve 43 and the fifth valve 44 are closed in Step S145, and the operation proceeds to Step S146. In Step S146, a determination is made as to whether the sixth valve 45 and the seventh valve 46 are open or closed. If a determination is made that they are closed, the operation proceeds to Step S147 to open the sixth valve 45 and the seventh valve 46, and the operation returns to Step S141. If it is determined in Step S146 that the sixth valve 45 and the seventh valve 46 are open, the operation returns to Step S141.
If it is determined in Step S141 that the evaporation temperature ET is not more than the second set temperature T2, the operation proceeds to Step S148 to determine whether the sixth valve 45 and the seventh valve 46 are open or closed. If it is determined in Step S148 that the sixth valve 45 and the seventh valve 46 are open, the operation proceeds to Step S149 to close the sixth valve 45 and the seventh valve 46, and the operation returns to Step S141. If it is determined in Step S148 that the sixth valve 45 and the seventh valve 46 are closed, the operation returns to Step S141.
As described above, in accordance with the present invention, it is possible to effect control in such a manner as to suppress an excessive rise in the high-level pressure by means of the pressure-detecting means for detecting the pressure within the discharge-side pipe of the compressor and by means of the control circuit for controlling the valves; it is possible to effect control in such a manner as to suppress an excessive rise in the discharge temperature by means of the temperature-detecting means for detecting the discharge-side temperature of the compressor and by means of the control circuit for controlling the valves; it is possible to effect control in such a manner as to suppress an excessive rise in the low-level pressure by means of the pressure-detecting means for detecting the pressure within the inlet-side pipe of the accumulator and by means of the control circuit for controlling the valves; and it is possible to effect control in such a manner as to suppress an excessive rise of the evaporation temperature by means of the temperature-detecting means for detecting the evaporation temperature of the evaporation-temperature detecting circuit which connects the liquid side of the heat source unit-side heat exchanger and the inlet of the accumulator and by means of the control circuit. Accordingly, an advantage is offered in that, in an air conditioner in which cooling and heating are effected selectively by a plurality of room units and cooling is effected by one room unit and heating by another, it is possible to perform operation while ensuring a suitable evaporation temperature in mainly heating operation, without stopping due to an abnormality in the high-level pressure and an abnormality in the discharge temperature and without impairing the reliability of the compressor.
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A multi-chamber heat-pump type air conditioner in which a plurality of room units (2, 3, 4) are connected to one heat source unit (1), cooling and heating can be effected selectively for each room unit (2, 3, 4), and cooling can be effected by one room unit and heating can be simultaneously effected by another, wherein the high-level pressure or low-level pressure is controlled from rising high as compared to the time of normal operation, and the reliability of the compressor (17) is improved. In which, a third pressure-detector (48) is provided for detecting a rise in pressure between a compressor (17) and a four-way changeover valve (18), and a control circuit (49) is provided for controlling such that, in the event that the pressure within the pipe is below a predetermined pressure, a sixth valve (45) and a seventh valve (46) are closed, while in the event that the pressure within the pipe exceeds the predetermined pressure, the sixth valve (45) and seventh valve (46) are opened.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for a riding mower having a wheel-born chassis supporting the operator, an engine for driving at least one of the wheels and at least one cutting means arranged in a front mounted cutting unit that is placed such that at least a part of the cutting unit is situated close beneath the front part of the chassis.
2. Description of the Related Art
Riding mowers of the type mentioned above are previously known, see for instance EP 213096. Such mowers comprise a front part and a rear part. The front part supports the operator, the cutting unit, which is placed in front of the two front wheels, and the engine. The rear part supports the two rear wheels. The two parts are pivotally arranged with respect to one another about a vertical axis and a horizontal axis oriented in the direction of movement. This design gives a neat and easily driven mower having a minimal turning radius. Also, the mower s cutting unit is positioned such that the operator has a good view of the area being cut.
In order to achieve a vehicle that is as compact as possible and to minimize the total length of the mower, the cutting unit is placed close to the two front wheels. However the necessary space for the legs of the operator and the foot control means demands that the chassis extends forward such that it is partly placed above the cutting unit. This means that the lower side of the cutting unit, without being heavily demounted, is difficult to reach for cleaning and maintenance.
It has, for other types of riding mowers with front mounted cutting units on the market, namely such mowers on which the cutting unit is placed completely in front of the chassis, see U.S. Pat. No. 5,079,907, been suggested to facilitate cleaning and maintenance by making the cutting unit foldable to a mainly vertical position. For this type of mower, a link arm mechanism is used that is fastened to the cutting unit at each side of the mower at the area of the front wheel axis. This means that the turning motion of the cutting unit, depending on the forwardly extending position of the cutting unit, can be made without the cutting unit being hindered by the chassis.
SUMMARY OF THE INVENTION
The present invention is directed toward an arrangement that removes the disadvantages mentioned above and makes it possible to move the cutting unit easily to such a position facilitating service and maintenance while maintaining a desirably compact structure.
In accordance with the present invention, cutting means are arranged at a front mounted cutting unit, and the cutting unit is placed such that at least a part of the cutting unit is situated beneath the front part of the chassis. Means are also provided for moving the cutting unit forward with respect to the chassis such that support means arranged on the rear part of the cutting unit engage the ground. The rear part of the cutting unit can then be moved forwards at the same time that the front part of the cutting unit is turned upwards about a first pivot to a maintenance position.
BRIEF DESCRIPTION OF THE DRAWINGS
These and further features of the invention will be apparent with reference to the following description and drawings, wherein:
FIG. 1 is a side view illustrating a riding mower incorporating the present invention;
FIG. 2 is a plan view of a part of the cutting unit for the mower with its support system;
FIG. 3 is a vertical section as seen along line III—III in FIG. 2;
FIG. 4 is the same section as FIG. 3, but with the cutting unit in a first position before it is folded up;
FIG. 5 shows the same section as FIGS. 3 and 4, but with the cutting unit in a partly folded up position; and,
FIG. 6 shows the same section as in FIGS. 3-5, but with the cutting unit in a completely folded up position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, a riding mower 10 includes a front chassis part 11 which, by means of a pivot (not shown), is turnably secured about a horizontal axis as well as a vertical axis to a rear chassis part 12 . The rear chassis part is supported by two rear wheels 13 . The mower is also provided with a drive unit 14 , such as an internal combustion engine.
The front chassis part 11 is supported by two front wheels 15 , and has a seat 16 for the operator and a cutting unit 17 which is partly covered by one or more protecting hoods 18 . The cutting unit 17 is, at its front end, supported by two supporting rollers 19 . The front chassis part 11 is also provided with necessary control means, such as a steering wheel 20 , control means (not shown) for lowering and raising the cutting unit 17 , and for adjustment of the cutting height, etc.
The cutting unit 17 is supported by a supporting frame 21 (FIGS. 2 - 6 ), which is turnably secured for vertical movement about a pivot point 22 arranged at the front chassis part 11 . The supporting frame 21 is under the influence of two springs 23 . The springs 23 are fastened to the front chassis part 11 and help lift the cutting unit 17 . The supporting frame 21 can be raised and lowered by means of a lifting mechanism (not shown) in order to move the cutting unit between a raised transport position and a lowered cutting position.
A front part of the supporting frame 21 is provided with two side plates 24 that are fastened to a link arm 25 by means of a first pivot or hinge 26 . The first hinge 26 permits a turning motion of the link arm 25 with respect to the supporting frame 21 about a horizontal axis arranged perpendicular to the driving direction. The link arm 25 , which is directed obliquely downwards in front of the front chassis part 11 , is provided with a through hole 27 arranged below and in front of the first hinge 26 . The hole 27 is arranged to be positioned in line with openings 28 in the side plates 24 in order to lock the link arm 25 with respect to the supporting frame 21 by means of a locking pin 29 .
The cutting unit 17 comprises an up-side-down trough-shaped hull 30 that, in a conventional manner, encloses several horizontal knives 31 arranged on several vertical shafts driven from the driving unit 14 by means of a drive belt 32 connected to a central drive belt 33 whose shaft by means of another drive belt (not shown) drives the other knives. The front part of the cutting unit 17 is, at its upper side, provided with a central upstanding lug 34 forming a second pivot 35 to which a lower end of the link arm 25 is turnably arranged.
The cutting unit 17 is, at its upper side, provided with a front transverse rod 36 and a rear transverse rod 37 that are turnably secured to the cutting unit at a front pivot point 38 and a rear pivot point 39 , respectively. The rods 36 , 37 are provided with bent end parts 40 , 41 that are turnably arranged to front and rear brackets 42 , 43 arranged on a support beam 44 extending about the cutting unit and supporting the support rollers 19 . The two rods 36 , 37 are connected to one another by a link arm system including first, second, and third link arms 45 , 46 , 47 . The first link arm 45 is secured to the rod 36 , the second link arm 46 is secured to the rod 37 , and the third link arm 47 connects the first and second link arms 45 , 46 to one another. Thus, the two transverse rods 36 , 37 achieve a synchronous turning motion, which means that the cutting unit 17 is moved vertically parallel to the surface beneath. The first link arm 45 also supports a front rod 48 that has one end pivotally secured to the link arm 45 . An opposite end of the front rod 48 is provided with a hook 49 that is removably connected to a loop 50 on a rear rod 51 that can be acted on to adjust the cutting unit 17 to a desired cutting height.
The support frame 21 is provided with a yoke 52 extending between two legs of the frame 21 . A lower side of the yoke 52 is provided with a support 53 on which a tongue 54 normally rests. The tongue 54 extends from, and is fixed to, the rear transverse rod 37 and pivots together with the rod 37 . Thus, the rear part of the cutting unit 17 is manually supported by the support 53 . The support beam 44 , which is placed on the cutting unit, also supports two support wheels 55 which might be removably arranged and which are placed at the rear part of the cutting unit and at each side thereof. The purpose of the supporting wheels will be described below.
The device operates in the following manner. Cutting takes place by lowering the cutting unit 17 toward the surface by means of the support beam 21 and manually controlled means (not shown) belonging to the beam which means that the supporting rollers 19 engage the surface. Since the tongue 54 rests on the support means 53 , which is connected to the yoke 52 of the support beam 21 , the rear part of the cutting unit 17 will be lifted up from the ground during the cutting operation. A suitable cutting height can be set by moving the rear rod 51 in its length direction by means of manually operated control means (not shown). Thus, moving the rod 51 means that the cutting unit is raised or lowered with respect to the supporting frame 21 , this movement taking place with the cutting unit parallel to the ground. During cutting, the cutting unit can, because of the central support at the tongue 54 and the support means 53 and at the comparatively loose, centrally placed, bearing 35 , turn somewhat about an axis which is parallel with the driving direction in order to take up slight variations in inclination of the ground. The ground inclination is also, in a conventional manner, taken up as a turning motion between the front and the rear chassis parts 11 , 12 .
In order to undertake maintenance or cleaning of the cutting unit, the cutting unit 17 is placed in its operating position and is adjusted for the lowermost cutting height according to FIG. 3 . Then the front rod 48 is removed from the rear rod 51 by removing the hook 49 from the loop 50 after which the drive belt 32 is released by moving a tensioning pulley cooperating with the drive belt to an inactive position. Then the locking pin 29 is withdrawn from the hole 27 and the opening 28 such that the two side plates 24 of the support beam 21 are released from the link arm 25 . This means that the side plates 24 and the link arm 25 can be turned with respect to one another about the first pivot 26 . Then the front part of the support frame 21 is pressed manually downwards towards the ground, thereby moving the rear part of the cutting unit toward the ground until the support wheels 55 engage the surface (FIG. 4 ). Continued depression of the support frame 21 moves the complete cutting unit forward under the influence of the link arm 25 , which is turned about the first and second pivot 26 , 35 . This causes the tongue 54 to disengage from the support means 53 .
Thereafter, the pin 29 is inserted into the openings 28 of the side plates 24 and the support frame 21 is released, which means that the support frame returns by spring action to the position shown in FIG. 4 by means of the springs 23 such that the link arm 25 will rest on the pin 29 . It is now possible to manually move the rear part of the cutting unit 17 in the forward direction with the support wheels 55 in engagement with the ground. This forces the cutting unit to turn about the second pivot 35 to the position shown in FIG. 6 such that the underside of the cutting unit becomes accessible for cleaning and maintenance. In a corresponding way the mower is returned to its original position by making the above steps in reverse order.
While the preferred embodiment of the present invention is shown and described herein, it is to be understood that the same is not so limited but shall cover and include any and all modifications thereof which fall within the purview of the invention.
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A device for a riding mower having a wheel born chassis ( 11,12 ) intended to support the operator, an engine ( 14 ) for driving at least one wheel ( 13 ) and cutting knives ( 31 ) arranged in a front mounted cutting unit ( 17 ). The cutting unit is placed such that at least a part of the cutting unit is situated close beneath the front part of the chassis. The mower is provided with a first pivot ( 26 ) arranged in front of the chassis and about which the cutting unit ( 17 ) is turnably arranged. The cutting unit is adapted to move forward whereby a support ( 55 ) arranged on the cutting unit engages the ground and the rear part of the cutting unit is then moved forwardly at the same time as the front part of the cutting unit is turned upwards about the first pivot ( 26 ) to a maintenance position.
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CROSS-RELATIONSHIP TO PENDING APPLICATION
[0001] This application claims priority to provisional application Ser. No. 60/941,209 filed May 31, 2007, and is incorporated herein by reference.
FIELD
[0002] This invention relates generally to syringe systems and methods for mixing and delivering a therapeutic agent formed by combining a diluent with a lyophilized drug or a concentrated drug. More specifically, this invention relates to syringe systems, including a passive needle guard, used for reconstitution of lyophilized or concentrated drugs and methods for using such systems.
BACKGROUND
[0003] Lyophilization is a process by which the volatile components of a drug are removed in order to extend the shelf-life of the medication. Lyophilization may involve the rapid freezing of a material at a very low temperature followed by rapid dehydration. Solvents such as water are removed from the drug yielding a substance that is more stable and can be stored. Lyophilized drugs are generally stored in a glass vial or cartridge and covered by a rubber stopper or septum.
[0004] In order to administer the lyophilized drugs, the drug must generally be reconstituted. Reconstitution is the process of hydrating drugs that are packaged and stored in a dry lyophilized state. A diluent, such as water, saline, 5% Aqueous Dextrose or the like, is added to the lyophilized drug and the combination is mixed until the drug is fully dissolved. A syringe is typically used to inject the diluent into the vial containing the lyophilized drug. The syringe may be pre-filled with the diluent or the user may first withdraw the diluent from a second vial or container into the syringe. After the diluent is added to the vial containing the lyophilized drugs, the contents are then mixed to form a therapeutic agent.
[0005] After complete mixing of the diluent and the lyophilized drug, the therapeutic agent may be aspirated back into the syringe. Once the therapeutic agent is in the syringe, the medication is administered to the patient. Usually the therapeutic agent is administered within a short time after reconstitution in order to ensure that the drug is not degraded by the solvent.
[0006] Most current systems for reconstitution expose the user to the risk of inadvertent needle sticks. In addition, current systems may not adequately prevent the possible reuse of the syringe. A number of needle guards for syringes have been developed that are intended to prevent accidental needle sticks and/or inadvertent reuse of a syringe. However, because syringe safety shield devices normally actuate when the plunger is fully advanced during the administration of the drug, these same devices will prematurely actuate the safety shield during the drug reconstitution phase as the diluent is added to the lyophilized drug. Therefore, a method for preventing the activation of the safety shield during drug reconstitution is highly desirable.
[0007] Accordingly, a syringe system that can be used for reconstitution and that would automatically activate a needle shield during or following administration of the therapeutic agent would be considered useful.
SUMMARY
[0008] The present invention is directed to a syringe system for reconstitution of lyophilized or concentrated drugs. The present invention is also directed to the combination of such a system with a passive needle guard that is automatically activated to extend a shield to cover a needle of the syringe and to methods of making and using such systems. Typically, a passive needle guard shield is activated when a radial portion or thumb pad of a plunger contacts a lateral catch or trigger finger of the passive needle guard. As the thumb pad of the plunger is moved distally, the trigger finger is forced laterally which results in a shield being forced distally to cover a needle of the syringe or in some designs, the syringe needle withdraws into the shield.
[0009] The present disclosure describes a needle guard device or system that can be used with drugs requiring reconstitution without activating the safety mechanism, yet provides needle safety shielding after the drug has been injected into the patient. In a preferred embodiment, the needle guard device would be assembled and sold with a syringe that is preferably pre-filled with the diluent.
DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows an unassembled version of an exemplary embodiment of the device depicting the drug vial, drug vial adaptor, back plate, plunger, and the needle guard with an installed syringe.
[0011] FIG. 2 shows an exemplary embodiment wherein the drug vial adaptor is removably coupled with the needle guard and syringe via luer fittings.
[0012] FIG. 3 shows an exemplary embodiment of the device wherein a drug vial is removably coupled with the drug vial adaptor.
[0013] FIG. 4 shows an exemplary embodiment of the device with the plunger pushed distally to expel the diluent in the syringe into the vial for the purpose of reconstituting the drug in the vial.
[0014] FIG. 5 shows exemplary embodiment of the device with the plunger pulled back proximally after the drug has been reconstituted in the step depicted in FIG. 4 .
[0015] FIG. 6 shows an exemplary embodiment of the device after the reconstituted drug has been pulled into the syringe as shown in FIG. 5 and the drug vial adaptor has been replaced with an injection needle.
[0016] FIG. 7 shows an exemplary embodiment of the device showing the latched position of the shield trigger fingers. The curved under surface of the thumb pad of the plunger is in approximate contact with the proximal end of the trigger fingers.
[0017] FIG. 8 shows a cut away view of the diagram in FIG. 7 . The shield trigger fingers are shown engaging the body in the latched position. The latched position is achieved by contact between the latch surfaces of the shield trigger fingers and the body.
[0018] FIG. 9 shows a profile sectional view of the diagram in FIG. 8 . The dotted outline of the shield trigger fingers are shown in the unlatched position. The unlatched position is created when the plunger advances distally to an extent that the curved undersurface of the thumb pad pushes against the trigger fingers and displaces them laterally such that the latch surfaces of the shield trigger fingers and body are no longer engaged and will allow the shield to move distally with respect to the body.
[0019] FIG. 10 shows an exemplary embodiment of the device with the shield in the extended position.
DETAILED DESCRIPTION
[0020] Turning to the figures, FIG. 1 depicts an exemplary embodiment of the present needle safety guard device 5 and related components in an unassembled arrangement. As will be discussed in greater detail herein, FIG. 1 shows a drug vial 200 , vial adaptor 150 , needle guard 40 housing a syringe 10 , back plate 90 , stopper 20 , and plunger 30 . In FIG. 1 , the plunger 30 , stopper 20 , and supporting back plate 90 are shown separated from the rest of the safety device to better illustrate the components, however, in a preferred embodiment they are connected to the main part of the safety device 5 as shown in FIG. 2 .
[0021] In accordance with one aspect of the present disclosure, a medicine cartridge, such as a syringe 10 is provided ( FIG. 1 ). Preferably, the syringe 10 has a substantially smooth-walled cylindrical barrel 12 , a hub or distal end 14 that is the administration end, and a proximal end 16 having a flange 18 . The cylindrical barrel 12 typically is manufactured from substantially clear glass. Alternatively, the barrel 12 may be manufactured from plastic, e.g., polypropylene, k-resin, or polycarbonate, and the like.
[0022] The barrel 12 of the syringe 10 may be pre-filled with a diluent, or may be filled with the diluent at a later step. Preferably the syringe 10 , if pre-filled, also comprises a label or markings that indicates the quantity and type of diluent. For example, a sticker or label may be attached to the barrel 12 of the syringe 10 which provides the name of the diluent and the volume of the diluent. The diluent may be of any type known in the art including, but not limited to, sterile water, saline, 5% Aqueous Dextrose or the like. Alternatively, the user may aspirate the diluent into the syringe from a vial or container.
[0023] The proximal end 16 of the barrel 12 is configured to receive a stopper 20 and a plunger 30 ( FIGS. 1 and 2 ). The stopper 20 is configured to be slidably coupled into the cylindrical barrel 12 and movable from a proximal position to a distal position ( FIG. 1 ). The stopper 20 is preferably made of pliable rubber, thermoplastic rubber, plastic or similar material. The plunger 30 comprises a stem 32 , a distal end 34 , and a radial portion or thumb pad 36 . The plunger 30 is generally made of plastic, e.g. polypropylene, k-resin, or polycarbonate, or the like.
[0024] The distal end 14 of the cylindrical barrel 12 comprises a needle port or luer fitting 17 ( FIG. 1 ). The luer fitting 17 may be configured to couple with several different sizes of needles with different diameters and lengths or with other components that include a luer fitting or other type of holder. The needles and components may be connected by a Luer connector, Luer slip, Luer, or other holder as is known in the art. The luer fitting can be either of the slip version (no threads) or include threads. The luer fitting 17 is configured to allow interchanging of the needle and/or components so a user may use the most appropriate needle or component during filling the syringe, reconstitution, and administration of the medication to a patient.
[0025] The syringe 10 is housed inside the needle guard 40 wherein the needle guard 40 is preferably a passive needle guard ( FIG. 1 ). Safety shield devices generally function, by covering the needle with a rigid cylindrical shield that surrounds the needle and projects far enough beyond the distal tip of the needle so as to prevent a user's finger from coming in contact with the needle tip. To prevent a user from forgetting to deploy the safety shield, preferred safety devices operate passively or automatically by providing a mechanism that initiates and physically executes the shielding of the needle after the injection has been completed. The passive needle guard 40 generally comprises a body 50 for receiving and holding the syringe 10 , a shield 60 slidably attached to the body 50 , and a spring mechanism 55 ( FIG. 10 ). Both the body 50 and the shield 60 are generally molded from plastic, such as, polypropylene, k-resin, or polycarbonate, or the like. In a preferred embodiment, the body 50 and the shield 60 are substantially clear to facilitate observation of the syringe 10 therein. Alternatively, the body 50 and the shield 60 may be translucent or opaque, and may be colored, such as a latex color, a flesh tone, or a primary color.
[0026] The body 50 may comprise opposing side rails defining two elongate openings or windows 51 extending at least partially between a proximal end 52 and a distal end 53 of the body 50 ( FIGS. 1 , 9 , and 10 ). A substantially rigid collar is molded on the distal end 53 of the body 50 . The collar preferably has a substantially annular shape. The collar defines an opening 56 for allowing a needle 15 on a syringe 10 received in the opening 56 to extend distally beyond the body 50 ( FIGS. 1 and 6 ).
[0027] The shield 60 is a tubular member adapted to slidably fit on the body 50 and has a proximal end 62 and a distal end 64 . In a preferred embodiment, one or more trigger fingers 66 extend proximally from the proximal end 62 of the shield 60 ( FIGS. 7-9 ). The trigger fingers 66 may include a first catch 68 that is configured to engage a second catch 58 on the proximal end 52 of the body 50 of the needle guard 40 ( FIGS. 8 and 9 ). Engagement between the first catch 68 and the second catch 58 retains the shield 60 in a first, retracted position. This latched configuration is further secured by an angled orientation of the latch surfaces, which when combined with the force of the spring 55 urging these surfaces against each other, places a component of force on the trigger fingers 66 directed toward the centerline. Preferably, the one or more trigger fingers 66 are elongate fingers having a proximal tip 67 that is engageable by the thumb pad 36 of the plunger 30 as it is depressed to axially compress and deflect the one or more trigger fingers 66 radially outwardly, as is discussed further below.
[0028] The passive needle guard 40 also preferably includes a spring mechanism 55 coupled to the body 50 and the shield 60 for biasing the shield 60 towards an extended position when the trigger fingers 66 are deflected radially ( FIG. 10 ).
[0029] The back plate 90 is removably coupled with the needle guard 40 . The back plate 90 creates a physical barrier to removal of the plunger from the needle guard safety device 5 . The back plate 90 includes an aperture 92 dimensioned to receive the stem 32 of the plunger 30 , wherein the aperture is of a smaller size than a distal end of the plunger. When the plunger is moved proximally, the back plate 90 prevents a user from accidentally removing the plunger 30 .
[0030] The syringe 10 can be used to administer a lyophilized or concentrated drug to a patient. The lyophilized drug or concentrated drug may be of any type known to those of skill in the art. Preferably, the lyophilized or concentrated drug is stored in a vial 200 or container such as a glass vial ( FIG. 1 ). The vial 200 may include a cover 210 such as a rubber stopper, septum, or cap that can be penetrated by a needle. In a preferred embodiment, the vial 200 is made of a substantially clear glass so that the user can ensure that the diluent and lyophilized drug have been properly and fully mixed.
[0031] The drug vial adaptor 150 connects onto the end of the vial 200 that has the septum (FIGS. 1 and 3 - 5 ). The vial adaptor 150 has a thin pointed distal end 152 and a luer fitting 154 on the proximal end 156 . An inner channel runs from the sharp distal end 152 to the proximal luer fitting 154 ( FIG. 2 ). The vial adaptor luer fitting 154 is attached to the luer fitting 17 on the syringe 10 and the vial adaptor 150 is then attached to the vial 200 ( FIGS. 2 and 3 ). The sharp distal end 152 of the vial adaptor 150 is sized to penetrate the vial septum as it connects to the vial 200 , thus creating a fluid channel between the syringe 10 and vial 200 .
[0032] The steps of reconstituting the drug and administering it into the patient would be to install the drug vial adaptor 150 onto the syringe 10 inside the needle guard 40 via their respective luer fittings 17 , 154 ( FIG. 2 ). The drug vial 200 is then attached to the drug vial adaptor 150 creating a fluid-communicating channel between the vial 200 and the syringe 10 ( FIG. 3 ). The plunger 30 is then advanced to expel the diluent from the syringe 10 into the drug vial 200 ( FIG. 4 ).
[0033] It is at this point that the problems with existing safety devices would arise, since advancing the plunger 30 to expel the diluent in the drug vial 200 would trigger the safety shield mechanism of exiting safety devices. With the shield now covering the distal end of the device, the rest of the reconstitution steps would be impossible to perform and, additionally, the injection needle would not be accessible in order to inject the patient.
[0034] To prevent the relative motion of the safety shield 60 during the steps of reconstitution, it has been discovered that a component (e.g., a vial adaptor 150 ) attached to the luer connection 17 of the syringe 10 will prevent the relative motion of the safety shield 60 if it is of a sufficient diameter and proximity to the safety shield 60 . As the vial adaptor 150 is installed and tightened onto the syringe luer fitting 17 , it will be advanced proximally relative to the safety shield 60 , and when appropriately sized, will come in proximity to the safety shield 60 in a manner preventing any distal motion of the safety shield 60 relative to the syringe 10 or the rest of the safety device 5 .
[0035] The plunger 30 can then travel the full stroke to empty the syringe contents during reconstitution. Even though the safety shield mechanism will have been triggered (i.e. the thumb pad 36 will contact the trigger fingers 66 ), the shield 60 will not advance to the shielded position because the interaction of the vial adaptor 150 (or other component), shield 60 , and luer fitting 17 prevents it from doing so. Because the trigger fingers 66 have an elastic force urging them back into the latched position, the latch mechanism is reversible if the shield 60 has not moved forward. When the plunger 30 is pulled proximally to draw the drug mixture from the vial 200 into the syringe 10 , the trigger fingers 66 will relatch themselves against the second catch 58 on the body 50 so that the needle guard 40 is able to trigger the next time the plunger 30 is advanced sufficiently distally.
[0036] After the drug has been dissolved in the diluent, the plunger 30 is withdrawn proximally, pulling the drug mixture into the syringe 10 ( FIG. 5 ). In a preferred embodiment, a circumferential rib 35 on the distal end 34 of the plunger 30 interferes with the plunger support back plate 90 preventing the full withdrawal of the plunger 30 , so that users will not inadvertently and surprisingly remove the stopper 20 from the syringe 10 and expose the drug to a non-sterile environment ( FIG. 1 ). The vial adaptor 150 (with the vial 200 ) is removed from the syringe luer fitting 17 and replaced with an injection needle 15 having a luer fitting ( FIG. 6 ). The medication is now ready for injection into the patient and the needle guard 40 should deploy in the normal manner after the medication has been injected into the patient.
[0037] As discussed above, the thumb pad 36 of the plunger 30 is sized and shaped to displace the trigger fingers 66 laterally away from the latched position that connects them to the body 50 to an unlatched position that substantially disconnects them from the body 50 when the plunger is advanced sufficiently far forward distally, preferably far enough forward that the contents of the syringe 10 has been expelled, but before the plunger 30 is arrested by the stopper 20 reaching the distal end of the syringe 10 ( FIG. 9 ). As the medication is being injected into the patient with the vial adaptor 150 removed, the plunger 30 will displace the trigger fingers 66 causing the force of the spring 55 to move the shield 60 forward preventing the trigger fingers 66 from relatching and initiating the deployment of the safety shield 60 . The dotted lines in FIG. 9 depict the movement of the trigger fingers 66 from the latched position to the unlatched position.
[0038] After the plunger 30 is fully advanced and the safety shield mechanism has been released, the shield 60 is either moved distally relative to the syringe 10 and needle 15 or the syringe 10 and needle 15 are moved proximally with respect to the shield 60 . Passive or automatic deployment of the safety shield 60 is accomplished by way of the compression spring 55 pushing the shield 60 distally and/or the syringe 10 and needle 15 proximally. The spring force is released to the shield 60 and body 50 when the trigger fingers 66 are displaced from the latch configuration. The spring 55 is of sufficient size to move the shield 60 far enough to sufficiently shield the needle 15 from the user ( FIG. 10 ). In a preferred embodiment, a locking mechanism holds the shield in the extended position. The locking mechanism may comprise, for example, a set of cooperating detents or catches on the shield 60 and body 50 that maintain the shield in the extended position. Regardless of the relative motion of the safety shield 60 , what is common to all devices is that the safety shield 60 is actuated after the plunger has been advanced to empty the syringe contents.
[0039] Examples of devices that could be used to attach to the syringe luer fitting and to prevent the forward advance of the shield are not limited to drug vial luer adaptors 150 . Others could include female-to-female and female-to-male luer adaptors, luer adaptor fittings on disposable sets, filters with luer fittings, etc. provided that they have the correct geometry to prevent the shield from deploying. In addition, luer connections are widely used in the medical device industry, but any similar releasable connection could also function to hold the drug vial or similar device in proximity to the shield to prevent it from being deployed.
[0040] Although preventing the shield from deploying or moving distally over the syringe has been described, it is understood that the present invention would also apply to devices that move the syringe and needle proximally. Furthermore, the trigger finger based latch mechanism has been described in detail, but it is understood that any mechanism that triggers the deployment of a safety shield could be used.
[0041] While the invention is susceptible to various modifications, and alternative forms, specific examples thereof have been shown in the drawings and herein described in detail. It should be understood, however, that the invention is not to be limited to the particular forms or methods disclosed, but to the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the appended claims.
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The present disclosure describes a needle guard device or system that can be used with drugs requiring reconstitution. The needle guard is preferably a passive needle guard that can be used during reconstitution without activating the safety mechanism. Following administration of the medication, the needle guard shields a user from inadvertent needle sticks by extending a protective shield over the needle.
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FIELD OF THE INVENTION
[0001] The present invention relates to apparatuses and methods for distributing gas which may be applicable in the field of polymer oxidation and melt curtain ozonation in particular. Aspects of the invention relate to ozone applicators as well as other features of ozonation apparatuses and associated methods.
BACKGROUND OF THE INVENTION
[0002] The extrusion of molten polymers and copolymers, with subsequent bonding of the extruded polymer film or “curtain” onto a substrate, is well known. The process normally involves melting the polymer in an extruder, extruding the molten polymer through a die to form the melt curtain, and passing the substrate (e.g., paper or aluminum foil) and the extruded film simultaneously between two pressure rolls to bond the hot polymer film and the substrate. In a typical operation, plastic resin pellets are melted and extruded through a narrow (e.g., 0.030 inch) linear die opening to form the melt curtain or molten plastic web. Various polymers suitable for extrusion coating include polyolefins (e.g., polyethylene), olefinic copolymers (e.g., ethylene-propylene or ethylene-acrylic acid copolymers), and olefinic polymer blends (e.g., a blend of polypropylene with either polyethylene or polystyrene).
[0003] Extrusion coating is described in detail, for example, in U.S. Pat. No. 4,183,845 and WO 2002/094556. The process may be used in a number of applications, for example in the preparation of labels and decals or packaging materials such as those used in food packaging.
[0004] The adhesion of the molten polymer to the extrudate can be significantly improved with ozone application to the side of polymer melt curtain that contacts the substrate, or otherwise contacts an intermediate layer that adheres to the substrate. In particular, a discharge of ozone in the vicinity of the molten polymer, shortly before it contacts the substrate, provides controlled oxidation on the bonding or “preferred” side of the extrudate. The process known as melt curtain ozonation therefore provides bonding sites on the molten polymer which promote oxidative type bonding.
[0005] Good polymer/substrate adhesion and consequently minimal delamination is critically dependent on the manner in which ozone is applied. Also, the close proximity between the equipment from which ozone is applied (i.e., the ozone applicator) and the molten polymer renders this equipment subject to plugging and/or to becoming caked or coated, both internally and externally, with the polymer or polymer byproducts. This results in uneven ozone distribution and consequently poor adhesion of the finished laminate. Frequent cleaning (e.g., at approximately six-week intervals) of the ozone applicator is therefore often mandatory to combat the deposition and condensation of polymer, both onto and into, the ozone applicator, due to its contact with molten polymer or polymer vapors.
[0006] Thus, there remains a need in the art for improved gas distributors such as ozone applicators, as well as ozonation apparatuses and methods, which can improve the application of ozone in melt curtain ozonation, thereby reducing polymer/substrate delamination as well as the detrimental effects, including decreased operating efficiency, associated with polymer deposition on the ozone applicator.
SUMMARY OF THE INVENTION
[0007] The present invention is associated with the discovery of improved apparatuses and methods of discharging gas, especially ozone-containing gas used in melt curtain ozonation, as discussed above. The apparatuses and methods advantageously improve ozone distribution across the width of the molten polymer film, resulting in enhanced bonding between the polymer and substrate and consequently reduced delamination in the end product laminate, even for relatively wide laminate sheets. Also associated with the apparatuses and methods of present invention is a reduction in the extent of polymer or polymer byproduct and vapor deposition onto or inside of the ozone applicator during melt curtain ozonation.
[0008] Aspects of the invention therefore relate to an ozone applicator that provides improved distribution of discharged gas, such as ozone-containing gas that is a mixture of ozone gas and a diluent (e.g., air). According to one embodiment, the applicator, or applicator bar, includes elongated, inner and outer shells with the inner shell disposed within the outer shell. The shells may therefore be, for example, nested cylinders with the inner diameter of the outer shell exceeding the outer diameter of the inner shell such that an intermediate (e.g., annular) space is formed between the shells. Other shell geometries are possible and could similarly result in the formation of an intermediate space.
[0009] An inlet stream of gas such as ozone-containing gas flows, or is received, into the interior or innermost space that is surrounded by the inner shell. The gas then flows into the intermediate space through at least one opening such as an elongated aperture (e.g., having an oval shape), or in some cases through a plurality of holes, on the inner shell that allow fluid communication between the interior and intermediate spaces. These one or more elongated apertures or holes (or openings having other shapes) may be distributed along at least a portion of the length of the inner shell. The gas in the intermediate space then exits, or is discharged from, the applicator through at least one outlet on the outer shell that allows fluid communication between the intermediate space and the exterior of the applicator. This outlet may be, for example, in the form of a plurality of holes, or otherwise an elongated slot that extends longitudinally (axially) along at least a portion of the length of the outer shell.
[0010] Advantageously, in the inner/outer shell arrangement described above, the opening or plurality of openings of the inner shell do not align with the outlet of the outer shell. That is, the gas flow through the inner shell opening(s) does/do not coincide with the gas flow through the outer shell outlet (e.g., in the form of a plurality of openings), and typically these flows are in different directions. In many cases, it may be desired to configure the applicator such that the flow through the inner shell opening(s) is/are opposite (at a 180 angle relative to) or substantially opposite (at a 160-200 degree angle relative to) the flow through the outer shell outlet or discharge opening(s). Therefore, the inner shell opening or openings may be aligned substantially opposite the outer shell outlet.
[0011] In this manner, the change in direction of the ozone-containing gas flow through the inner and outer shells can provide a more tortuous or complicated pathway through the ozone applicator and greatly improve distribution of the exiting or discharged gas along its length (e.g., through a plurality of holes or an elongated outlet slot). Variations in the ozone-containing gas flow exiting the applicator bar and contacting the melt curtain are minimized across the applicator bar length and consequently the melt curtain width, even at peripheral or outermost locations.
[0012] In another embodiment, the ozone applicator comprises only a single elongated shell that surrounds the interior space from which an inlet stream of ozone-containing gas is received. In this case, the shell as a plurality of openings that are disposed about a portion of the shell surface (e.g., a cylindrical surface portion) that extends longitudinally (or axially, i.e., parallel to the shell axis) but that is confined to an arcuate section within about 90° (π/2 radians), and often within about 45° (π/4 radians), based upon an arc of a cross-sectional shape (e.g., a circle) of the shell. The openings may be disposed, for example, over an arcuate section of a cylindrical surface, with the arc ranging from about 10° (π/18 radians) to about 60° (π/3 radians), or otherwise disposed over an arcuate section with an arc of about 40° (2π/9 radians). For example, the openings may be holes disposed in longitudinally extending, substantially parallel lines that are separated by an arc angle as described above. In a particular embodiment, two separate, spaced-apart lines of holes extend over a portion (e.g., from about 30% to about 80%) of the shell length, which may be centered over this length, in a staggered conformation such that the holes of one line are in different axial positions relative to holes in the other line.
[0013] Gas distributors and particularly ozone applicators as described above provide a uniformly distributed flow of gas across the length of the applicator bar (and consequently the width of the melt curtain). This improvement in flow distribution is especially significant for applicator bar lengths of at least about 61 centimeters (at least about 24 inches), where gas distribution difficulties become significantly more pronounced in the case of conventional ozone applicators.
[0014] Exposing a polymer surface (e.g., an essentially flat surface of a molten extrudate) to ozone discharged from any of the ozone applicator bars described above therefore results in more uniform or even oxidation of the polymer and consequently improved adhesion of the polymer to a substrate, relative to the performance obtained from conventional apparatuses and methods. This improves laminate product quality, especially in the production of wide laminates. Also, compared to conventional applicators, the applicator bar configuration described herein advantageously allows a higher overall gas flow rate to be discharged through the bar, without causing pressure to increase within the ozonation apparatus to a level that could damage key equipment (e.g., dielectric tubes inside the ozone generator) used to generate ozone. These higher gas flows that can be achieved using the applicator described above also beneficially improve ozone distribution and substrate bonding.
[0015] Other aspects of the invention relate to modifications of ozonation apparatuses and particularly those used in melt curtain ozonation, as well as the resulting ozonation processes that result from these modifications. The modifications are associated with ensuring a constant feed of diluent gas (e.g., a substantially non-ozone containing gas such as air) through the ozone applicator. In particular, the use of a continuous supply of diluent gas during the entire melt curtain ozonation process (including non-normal operating periods such as startup and upset conditions, when ozone gas is not flowing through the applicator), provides commercial advantages. Importantly, the rate of accumulation (or build-up) of unwanted polymer or polymer byproduct inside of or on top of the applicator bar, due to its proximity to molten polymer and polymer vapors, is dramatically reduced. Such solids can adhere both within the applicator as a condensate, as well as on external surfaces of the applicator, as a coating or caked material.
[0016] Apparatuses and methods for performing polymer oxidation such as melt curtain ozonation are therefore associated with the discovery of advantages resulting from maintaining an essentially continuous or constant gas flow (i.e., a source of positive pressure), exiting the ozone applicator to minimize or prevent its contact with polymer or polymer vapors. These advantages include improved operating efficiency resulting from increased run time (i.e., less operational downtime associated with cleaning the ozonation equipment). Moreover, reducing blockage of the ozone applicator interior spaces and outlet by vapor and liquid polymer, respectively, prevents loss of the desired, well-distributed gas flow from the applicator outlet, as required for good polymer/substrate adhesion.
[0017] Accordingly, modifications of the melt curtain ozonation apparatuses, relative to conventional equipment, include piping, tubing, or other conduit connections that allow air or other diluent gas to be constantly fed to the ozone applicator. Therefore, rather than combining or mixing diluent gas and ozone gas prior to a valve or other device that diverts the entire, combined ozone-containing gas stream away from the applicator inlet (i.e., interrupts the entire gas flow to the applicator), the diluent gas is added downstream of such a device. For example, diluent air may be added to the ozone applicator through a jet pump, with the outlet of this pump combining with ozone gas downstream of a diverter valve that redirects the ozone gas to a rooftop mounted ozone destruct unit prior to venting.
[0018] The minimization or prevention of “no-flow” situations (e.g., during startup or upset conditions) or the substantial loss of gas flow through the applicator, when in proximity to molten polymer, greatly improves melt curtain ozonation processes. In particular, modifications to maintain continuous gas flow through the ozone applicator have dramatically reduced the extent to which polymer vapors condense within the inside of, or polymer adheres to the outside of, the applicator. Blockage of even a portion of the flow through the applicator (e.g., a portion of an outlet slot) prevents effective, well-distributed ozonation of polymer in melt curtain ozonation processes and adversely impacts polymer adhesion to the substrate. Frequent cleaning of the applicator to remove deposited polymer greatly reduces operating efficiency.
[0019] A further advantage of such flow routing modifications to conventional melt curtain ozonation apparatuses is that the amount of added diluent gas such as air, used to distribute ozone-containing gas across the length of the applicator, can be increased with only a relatively small impact on the reactor pressure within the ozonator. The modifications thus improve the efficiencies of ozone gas production and flow, ozone gas deliverability to the applicator, product quality, and production quantity. The modifications additionally reduce waste and machine downtime for cleaning, without the negative aspects of increased reactor pressure and hardware contamination.
[0020] Aspects of the invention are therefore directed to a melt curtain ozonation apparatus comprising an ozone gas conduit (e.g., comprising piping and/or tubing) that flows ozone gas from an ozone generator to an ozone applicator. The apparatus further comprises a device that allows interruption or diversion of ozone gas flow to the ozone applicator, where the device acts on the ozone conduit (i.e., is in fluid communication with the ozone gas stream) between the ozone generator and the ozone applicator. A diluent gas conduit for flowing diluent gas to the ozone applicator intersects the ozone gas conduit (i.e., provides mixing between the ozone gas and diluent gas streams) downstream of the device. The apparatus may optionally include a pressure regulator, such as a back pressure regulator, downstream pressure regulator, a pressure relief valve, etc. in order to prevent the pressure in the ozone generator from exceeding a maximum value, such as a specified maximum operating pressure.
[0021] Other aspects of the invention relate to melt curtain ozonation methods that involve flowing a mixture of ozone gas and a diluent gas into an ozone applicator, with at least a portion of the diluent gas being mixed with ozone gas downstream of a device, as discussed above, which allows interruption or diversion of ozone gas flow to the applicator. The device used may be a manually or automatically actuated valve, such as a diverter valve or a block valve, which is typically used to redirect or stop ozone gas flow during the ozonation process under certain circumstances such as startup, upset, and emergency conditions (all of which may be considered non-normal operating periods). According to these methods, therefore, ozone gas is stopped, interrupted, or diverted from the ozone applicator, in such circumstances during ozonation, without stopping or interrupting diluent gas flow. Typically, the diluent gas flow is maintained constant during any of these conditions, but it may also be desired in some cases to increase diluent gas flow to maintain a total amount of gas flow through the applicator that is equivalent to the normal flow of combined ozone gas and diluent gas. Otherwise, the diluent gas flow may also be decreased during these non-normal operating periods to a minimum value that is sufficient to prevent deposition or condensation of polymer from the melt curtain, onto or into the ozone applicator.
[0022] The advantageous features relating to ozone applicators and ozonation apparatuses, as discussed above, may be used separately. Otherwise, the use of the applicator configuration with the flow routing improvements provides a combination of benefits that can be exploited in melt curtain ozonation processes wherein a polymer in the form of a molten extrudate is oxidized.
[0023] These and other aspects and features relating to the present invention are apparent from the following Detailed Description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 depicts an ozone applicator and also separately depicts inner and outer shells of the applicator.
[0025] FIG. 2 depicts a cross-sectional view of an ozone applicator comprising elongated inner and outer shells.
[0026] FIG. 3 depicts a flow configuration for gases to an ozone applicator.
[0027] FIG. 4 depicts inner and outer shells of another representative ozone applicator.
[0028] FIG. 5 depicts a single shell of a further representative ozone applicator.
[0029] FIG. 6 depicts a close-up view of the single shell depicted in FIG. 5 .
[0030] FIG. 7 depicts a cross-sectional view of the single shell depicted in FIG. 5 .
[0031] FIG. 8 depicts the use of a coupling or adapter for use with an ozone applicator having a relatively small outer diameter.
[0032] The features of the apparatuses referred to in FIGS. 1-8 are not necessarily drawn to scale and should be understood to present an illustration of the invention and/or principles involved. Some features depicted in the figures have been enlarged or distorted relative to others, in order to facilitate explanation and understanding. The same reference numbers are used in the figures for similar or identical components or features shown in the various embodiments. Gas distributors such as ozone applicators, as well as melt curtain ozonation apparatuses, as disclosed herein, will have configurations, components, and operating parameters determined, in part, by the intended application and also the environment in which they are used.
DETAILED DESCRIPTION OF THE INVENTION
[0033] As used herein, for convenience, “ozone” refers to the triatomic oxygen molecule O 3 , while “ozone gas” refers to gas generated in an ozone generator, having a substantially elevated ozone content relative to the ambient surroundings. Typically this ozone content is in the range from about 10 g/Nm 3 (grams per normal cubic meter) to about 1000 g/Nm 3 . “Ozone-containing gas” refers to a mixture that results when ozone gas is mixed with a diluent gas such as air. The ozone-containing gas therefore has a lower ozone content than the ozone gas prior to mixing, typically in the range from about 2 g/Nm 3 to about 500 g/Nm 3 . “Diluent gas” refers to gas that is essentially free of ozone, for example, containing less than about 5 ppm of ozone. Air is a diluent gas, as are inert gases such as nitrogen and argon. Other types of diluent gases include mixtures of air and inert gases (e.g., nitrogen-enriched air), oxygen, or oxygen-enriched air.
[0034] A representative ozone applicator 10 is depicted in FIG. 1 , as well as component parts, namely an elongated outer shell 12 and an elongated inner shell 14 . In the applicator or “applicator bar” 10 , inner shell 14 is not visible, as it is disposed within outer shell 12 . As shown, both shells 12 , 14 are cylindrical with a circular cross section, but it will be appreciated that other cross-sectional geometries are possible (e.g., oval, polygonal, etc.). Typically, both shells are of approximately the same length, with shell lengths generally from about 25 to about 356 centimeters (about 10 to about 140 inches), and often from about 61 to about 356 centimeters (about 24 to about 140 inches). Because of their ability to uniformly distribute gas flow over wide widths (e.g., over wide sheets of molten polymer), applicators having lengths of at least about 61 centimeters (about 24 inches) provide considerable advantages. A representative applicator bar length is about 140 centimeters (about 55 inches).
[0035] Inner and outer shells 14 , 12 may be aligned, for example using set screws 25 that are spaced apart around end cap 26 . FIG. 1 illustrates a representative end cap 26 having four set screws 25 spaced evenly at 90° angles about the circumference of the edge of end cap 26 that fits over outer shell 12 . The center of end cap 26 may have a receiving hole 27 allowing inner shell 14 to extend through end cap 26 and providing a fixed spatial relationship between inner shell 14 and end cap 26 . Set screws 25 extend through end cap 26 to the exterior surface of outer shell 12 and allow adjustment or movement of outer shell 12 in relationship to inner shell 14 and end cap 26 . Outer shell 12 may therefore be positioned around a common central axis shared with inner shell 14 (e.g., in a concentric manner) or possibly in an offset relationship (i.e., where central axes of inner shell 14 and outer shell 12 are not aligned) if desired.
[0036] A representative cross-section of applicator 10 is shown in FIG. 2 where outer shell 12 has an inner diameter (or other inner dimension) that exceeds the outer diameter (or other outer dimension) of inner shell 14 . This allows the shells to be spaced apart from each other, so than an intermediate space 18 is formed between the shells 12 , 14 . In a representative embodiment, the inner diameter (i.d.) and outer diameter (o.d.) of outer shell 12 may be about 19 mm and about 25 mm (about ¾ inches and about 1 inch), respectively. Other inner and outer diameters (e.g., from about 6 mm to about 95 mm (about ¼ to about 3¾ inches) i.d. or from about 12 mm to about 102 mm (about ½ to about 4 inches) o.d.) are possible, depending on the particular application. Likewise, representative i.d. and o.d. ranges for the inner shell are from about 3 mm to about 64 mm (about ⅛ inches to about 2½ inches) and from about 6 mm to about 57 mm (about ¼ inches to about 2¼ inches), respectively, with about 6 mm (¼ inch) i.d. and about 12 mm (½ inch) o.d. being representative.
[0037] As shown in the cross-sectional view of FIG. 2 , inner shell 14 surrounds an interior space 20 that receives, or is in fluid communication with, a gas stream such as an ozone-containing gas stream during normal operating conditions in a melt curtain ozonation process. After entering interior space 20 , the gas stream flows from interior space 20 to intermediate space 18 through at least one opening 22 of inner shell 14 . In one representative embodiment, inner shell 14 has a plurality of holes 22 (see FIG. 1 ) that are distributed, or extend longitudinally, along at least a portion of the length of inner shell 14 . Holes 22 may otherwise extend non-linearly, for example, they may be positioned randomly or at predetermined locations about the surface of inner shell 14 .
[0038] In a representative embodiment, holes 22 may extend substantially linearly and be spaced apart evenly (e.g., with centers of adjacent holes being spaced apart at an interval that can range from about 3 mm to about 6 mm (about ⅛ inches to about ¼ inches)) along a portion or section of inner shell 14 that is centered with respect to the overall length of inner shell 14 . The length of this portion or section may be, for example, from about 30% to about 80%, and often from about 50% to about 70%, of the length of the inner shell. According to an exemplary embodiment where the total length of the applicator (meaning the extended length if the applicator is extendible) is about 140 centimeters (about 55 inches), the length of the section having holes may be about 84 centimeters (about 33 inches). Representative hole diameters are from about 0.8 mm to about 6 mm (about 1/32 inches to about ¼ inches), with 1.5 mm to 3 mm ( 1/16 inch to ⅛ inch) diameter holes being typical.
[0039] FIG. 2 illustrates intermediate space 18 as an annular space that is formed between inner shell 14 and outer shell 12 . Other geometries for intermediate space 18 are readily contemplated, depending on the geometry of inner shell 14 and outer shell 12 and their relative positioning (e.g., whether they are concentrically positioned or otherwise offset). Gas such as ozone-containing gas flowing into intermediate space 18 may be discharged from applicator 10 through at least one outlet 24 on outer shell 12 . Outlet 24 , like opening 22 , may comprise a plurality of holes through outer shell 12 which may be configured (in terms of spacing, positioning, and length and direction of extension) as described above with respect to holes 22 on inner shell 14 . Another exemplary outlet 24 or outer shell 12 is in the form of an elongated slot 24 that extends along at least a portion of the length of outer shell 12 .
[0040] As with holes 22 , described above, slot 24 may extend substantially linearly along a portion or section, in this case of outer shell 12 , that is centered with respect to the overall length of outer shell 12 . The length of this portion or section may be, for example, from about 30% to about 80%, and often from about 50% to about 70%, of the length of outer shell 12 . According to an exemplary embodiment where the total length of the applicator (meaning the extended length if the applicator is extendible) is about 55 inches, the length of the slot is about 33 inches. Representative slot widths are from about 0.8 mm to about 6 mm ( 1/32 inches to about ¼ inches), with 1.5 mm ( 1/16 inches) being typical. Alternatively, slot 24 may extend non-linearly, such as in a helical or wave form on the surface of outer shell 12 . The slot width may be adjusted, for example, using one or more adjustment screws 16 positioned on outer shell 12 that regulate the amount of force acting to close slot 24 (e.g., by tensioning a clamshell type closure). Other suitable hardware may be used for adjusting the width of slot 24 , thereby providing an independent mechanism for controlling the linear velocity of gas exiting slot 24 of applicator 10 (i.e., with a smaller opening directionally increasing gas linear velocity for a given volumetric flow rate). In the case of melt curtain ozonation, fine adjustments to the flow rate of ozone-containing gas, by changing the width of slot 24 , may be employed to obtain uniform gas distribution without disruption of the nearby melt curtain (or even to optimize this tradeoff).
[0041] As discussed above, the distribution of gas such as ozone-containing gas from slot 24 of applicator 10 is highly uniform, even in the case of applicator lengths exceeding about 24 inches. Exceptional distribution characteristics have been found to result when any of the applicators described herein having inner and outer shells is configured so that gas pressurized from interior space 20 is forced in different directions through opening 22 and outlet 24 before being discharged. That is, the gas flow direction through opening 22 does not coincide with that through outlet 24 , and often these flows are in different directions. It may be desired to configure applicator 10 such that the flows through opening 22 and outlet 24 are in opposite directions. For example, as shown FIG. 2 , gas flow from interior space 20 to intermediate space 18 is to the left, through opening 22 (e.g., a hole), whereas gas flow from intermediate space 18 to the exterior of applicator 10 is to the right, through outlet 24 (e.g., a slot). In this manner, the alignment of opening 22 and outlet 24 in opposite or substantially opposite directions significantly benefits the overall flow distribution of gas exiting applicator 10 .
[0042] FIG. 4 illustrates the use of an outlet on outer shell 12 in the form of a plurality of holes 22 distributed along a portion of the total length of outer shell 12 . Holes 22 of outer shell in FIG. 4 may therefore be sized, spaced, and configured about the length of outer shell, in the same manner as discussed above with respect to inner shell 14 . In the particular embodiment shown in FIG. 4 , inner shell 14 has only one opening, namely a single elongated aperture 45 that can advantageously extend over the midpoint of the length of inner shell 14 . In other embodiments, an inner shell having two, three, or more elongated apertures (e.g., extending in an axial line) centered about the length of the inner shell may also be used. A typical aperture 45 , as an opening in inner shell 14 in the embodiment shown in FIG. 4 , is elongated in the longitudinal or axial direction. A representative elongated aperture will have a length ranging from about 6 mm to about 25 mm (about ¼ inches to about 1 inch) and a width ranging from about 1.5 mm to about 6 mm (about 1/16 inches to about ¼ inches).
[0043] The central location of elongated aperture(s) provides a good distribution of gas exiting into the intermediate space and then discharging through the outlet of outer shell 12 , for example the plurality of holes shown in FIG. 4 . As discussed herein with respect to FIG. 2 , the one or more openings (e.g., elongated aperture(s)) of inner shell 14 in the embodiment of FIG. 4 preferably do not align with openings such as holes 22 of outer shell 12 . This increases the complexity of the gas flow path (i.e., by preventing gas in the intermediate space between shells from flowing without any encumbrance through a discharge opening) and thereby improves flow distribution. Preferably, the one or more elongated aperture openings of the inner shell are aligned substantially opposite the holes or other openings in the outer shell.
[0044] FIG. 5 illustrates yet another embodiment of an ozone applicator with improved gas flow distribution. This embodiment lacks an inner shell, and instead utilizes a single elongated shell 12 that surrounds an interior space for receiving gas (e.g., containing ozone). The shell 12 has a plurality of openings for discharging this gas, with the openings being disposed about part of its surface. This part of the surface may be limited in its radial direction, axial direction, or both. For example, the axial or longitudinal dimension over which the holes 22 or other openings extend may be limited in the manner discussed above with respect to the plurality of holes extending along at least a portion (e.g., from about 30% to about 80%) of the length of inner shell 14 in the embodiment illustrated in FIG. 1 , or along at least a portion of the length of outer shell 12 in the embodiment of FIG. 4 . The plurality of openings or holes 22 in shell 12 can therefore be disposed along a portion of this length that is centered with respect to the total length of the shell. In terms of the radial or circumferential dimension of the surface over which the holes are disposed, this dimension preferably confines or limits the surface to an arcuate section within about 90° (π/2 radians), and often within about 45° (π/4 radians), based upon an arc of a cross-sectional shape (e.g., a circle) of the shell.
[0045] FIG. 6 provides a close-up view of the features of shell 12 of the ozone applicator bar of FIG. 5 . Holes 22 are disposed about a part 46 of the total surface area of shell 12 . This part 46 of the total surface is confined to acute arc A, as shown in FIGS. 6 and 7 , with this arc corresponding to a curved, circular section (or possibly a section of another cross-sectional shape of shell 12 ). The arc is normally that of an acute angle, and is often in the range from about 20° (π/9 radians) to about 45° (π/4 radians). As is detailed in FIG. 7 , the part 46 of the surface over which holes 22 are disposed may have a smaller thickness relative to that of the rest of shell 12 . FIG. 7 shows a particular embodiment in which the part 46 of the surface having holes, or having boundaries defined by rows of holes, is a concave or curved surface, with the curvature being opposite the curvature of the rest of the surface of shell 12 .
[0046] As is shown in the particular embodiment of FIG. 6 , one line of holes 22 is radially spaced apart, by being separated by arc A, from another line of holes 22 . Also, these separate, axially or longitudinally extending lines are disposed in a staggered conformation, such that the centers of holes 22 in each line are not at the same axial position about the length of shell 12 . Instead, the centers of holes 22 of one line fall between the centers of holes of the separate line. In a preferred embodiment, the centers of one line of holes may, in the longitudinal direction, fall half-way between the centers of the separate line of holes. The hole diameters and hole spacing, as described above with respect to the embodiment comprising both inner and outer shells in FIG. 1 , are appropriate with respect to the embodiment illustrated in FIG. 6 .
[0047] In the embodiment shown in FIG. 6 , using a single elongated shell 12 , the outer diameter of this shell may be reduced relative to the outer diameter of an outer shell used in the two-shell configuration, for example in the embodiment illustrated in FIG. 1 . In this case, a coupling 50 may be used, as shown in FIG. 8 , to adapt the smaller diameter shell 12 to a larger diameter receptacle or pocket 55 . Coupling 50 therefore allows shell 12 , having a diameter that is smaller than a conventional applicator, to be maintained in a fixed position in bracketing used for pocket 55 for mounting such a conventional applicator. A representative receptacle or pocket 55 may be designed to accommodate a conventional shell having an outer diameter from about 25 mm to about 32 mm (about 1 inch to about 1.25 inches), whereas a single exemplary shell, for example in the embodiment illustrated in FIGS. 6 and 7 , may have an outer diameter of only about 19 mm (about ¾ inches). Coupling 50 can therefore be used to occupy some of the excess space between pocket 55 and shell 12 and also maintain a fixed position of shell 12 relative to a polymer melt curtain during ozonation.
[0048] Applicator bars described herein are suitable in polymer oxidation methods to improve the adhesion of a polymer to a substrate. According to such methods, a surface of the polymer (e.g., an essentially flat molten polymer extrudate) may be exposed to an ozone-containing gas discharged from any of the various applicators described above.
[0049] According to the particular polymer oxidation method known as melt curtain ozonation, ozone-containing gas, formed as a mixture of ozone gas and a diluent gas such as air, is routed to an ozone applicator such as those described above. The ozone gas is first formed, at concentrations discussed above, in an ozone generator according to known methods. Aspects of the invention are directed to methods and associated equipment for ensuring that a gas such as a diluent gas flows through the applicator continually during the ozonation process, even when ozone gas flow is stopped or interrupted. For example, ozone gas flow may be diverted from applicator during startup, shutdown, and non-normal operating periods over the course of the ozonation process, such as those associated with operational upsets and/or unsafe conditions. Apparatuses and methods associated with these aspects therefore ensure that gas flows through applicator 10 during ozonation even in the absence of ozone gas flow.
[0050] Accordingly, a representative flow configuration used in equipment such as in an ozonation apparatus for flowing gases to an ozone applicator is depicted in FIG. 3 . An ozone conduit 30 is used to flow ozone gas from an ozone generator 35 to an ozone applicator, such as the representative applicator 10 depicted in FIG. 1 . A device 32 is positioned on ozone gas conduit 30 and acts on the ozone gas stream to interrupt or stop flow to the ozone applicator when necessary, such as under any of the non-normal operating periods discussed above. Device 32 may, for example, be a diverter valve to route ozone gas to a vent conduit 34 rather than allowing ozone gas to continue, in the case of normal operation, through ozone gas conduit 30 . Device 32 , which may be an automatically or manually actuated valve, is positioned and acts on flow through ozone gas conduit 30 between ozone generator and ozone applicator 10 .
[0051] In the flow configuration depicted in FIG. 3 , diluent gas conduit 36 flows diluent gas such as air to ozone applicator 10 . As shown, diluent gas conduit 36 and ozone gas conduit 30 intersect or fluidly communicate, resulting in mixing of ozone gas and diluent gas to form ozone-containing gas in an ozone-containing gas conduit 38 upstream of applicator 10 . This intersection or mixing occurs downstream of device 32 , allowing diluent gas to be continually routed through applicator 10 , independently of ozone gas. The diluent gas may be fed to ozone gas conduit 30 through a jet pump (not shown) or other type of gas moving equipment. As discussed above, the flow of diluent gas may be increased or decreased when ozone gas flow is interrupted, depending on the desired mode of operation and the need to maintain positive pressure on a molten polymer film in the vicinity of applicator 10 . Importantly, the flow configuration allows continuous input of diluent gas through applicator 10 .
[0052] Typical flow rates of ozone gas and diluent gas during normal operating periods range from 2.8 to 280 liters per minute (0.1 to 10 cubic feet per minute (CFM)), but vary significantly according to the particular application. Ratios of ozone gas: diluent gas flow rates often range from 1:10 to 10:1. Ozone applicators described above, which may have an inner shell disposed within an outer shell, or otherwise a single shell with a particular outlet opening configuration, improve gas distribution compared to conventional applicators, allowing for greater flexibility in processes involving gas distribution such as melt curtain ozonation.
[0053] For example, the use of these ozone applicators allows comparatively higher gas flows through the applicator, without resulting in detrimentally high back pressure in the ozone generator, which typically operates at slightly above atmospheric pressure (e.g., from about 0.2 barg to about 0.7 barg (about 3 to about 10 psig)). In one representative embodiment, a flow of 57 liters per minute (2 CFM) of ozone-containing gas through a conventional applicator may result in excessive ozone generator pressures, whereas a flow of 85-113 liters per minute (3-4 CFM) is possible through applicators described above, without exceeding the ozone generator pressure thresholds. According to various embodiments of the invention, a pressure regulator (e.g., a pressure relief valve) may be included in an ozonation apparatus to prevent excessive ozone generator pressures.
[0054] Additionally, ozone applicators described above provide improved gas distribution, for example across the width of a sheet of molten polymer, allowing for comparatively less air or other diluent to be charged to the applicator to achieve a desired degree of distribution (e.g., uniformity of oxidation of a molten polymer surface). Reduced diluent flow rates provide correspondingly increased ozone concentrations in ozone-containing gas discharged from the applicator and consequently improved oxidization of a polymer surface. Overall, therefore, a comparatively greater range of flow rates can be applied to applicators having (i) an inner and outer shell configuration with internal openings (e.g., elongated apertures or otherwise holes) and an outlet (e.g., in the form of a plurality of holes or otherwise an elongated slot), or otherwise (ii) a single shell configuration with a plurality of outlet openings as described above. Gas distribution is improved at low flow rates, while back pressure buildup is managed at high flow rates.
[0055] Ozone applicators as described herein thus provide a number of possible advantages, particularly in melt curtain ozonation processes, such as higher laminate production rates and improved product quality in terms of reduced delamination or greater force needed to separate the polymer from the substrate (e.g., paper) in the finished product. In view of the above, it will be seen that other advantages may be achieved and other advantageous results may be obtained. It will also be appreciated that the apparatuses and methods described above may be used with, or performed in conjunction with, conventional apparatuses and methods, such as those used for corona pre-treatment or flame pretreatment. As various changes could be made in the above apparatuses and methods without departing from the scope of the present disclosure, it is intended that all matter contained in this application shall be interpreted as illustrative only and not limiting in any way the scope of the appended claims.
[0056] The following examples are set forth as representative of the present invention. These examples are not to be construed as limiting the scope of the invention as these and other equivalent embodiments will be apparent in view of the present disclosure and appended claims.
EXAMPLES
[0057] Various melt curtain ozonation studies were undertaken to compare the performance of an ozone applicator as described above and a conventional applicator. Overall testing conditions are summarized in Table 1 and specific operating parameters that were varied in each test are summarized in Tables 2A-2H.
[0000]
TABLE 1
1 Roll
1 Roll
Ozone Applicator Bars (2)
32,000 ft
60,000 ft
4 -12
P
48 24CT PET
25 wide
Makeready
Materials Needed:
Mica A131X Primer, NA-204 or NA-214
XL LINE SET-UP
Die gap = .030″
Nip Impression-½
CAAAC Plug or other as only one XL needed
Temp- F
Die Temp at 500° F. and 610° F. on edges
as specified
indicates data missing or illegible when filed
[0000]
TABLE 2A
Phase 1-Ozone Value Displayed v/s Voltage and Added Air
Use Makeready Film (No Primer) for Phase 1
Part 1: Ozone Monitor in Normal (Current) Position
(after added air B4 Applicator Bar)
Use current Applicator Bar
LDPE at Minimum coating weight and minimum nespeed
Record Displayed Value
Variable
% Voltage
Added Air
Ozone (g/Nm3)
1
60
0
2
70
0
3
75
0
4
80
0
5
85
0
6
90
0
7
95
0
8
100
0
9
60
1
10
70
1
11
75
1
12
80
1
13
85
1
14
90
1
15
95
1
16
100
1
17
60
2
18
70
2
19
75
2
20
80
2
21
85
2
22
90
2
23
95
2
24
100
Record Ozone Value
Variable
% Voltage
Added Air
Displayed
25
60
3
26
70
3
27
75
3
28
80
3
29
85
3
30
90
3
31
95
3
32
100
3
indicates data missing or illegible when filed
[0000]
TABLE 2B
Part 2: Ozone Monitor Input at OP Side of Applicator Bar
LDPE at Minimum coating weight and minimum linespeed
Record Displayed Value
Variable
% Voltage
Added Air
Ozone (g/Nm3)
40
60
0
41
70
0
42
75
0
43
80
0
44
85
0
45
90
0
46
95
0
47
100
0
48
60
0
49
70
0
50
75
1
51
80
1
52
85
1
53
90
1
54
95
1
55
100
1
56
60
2
57
70
2
58
75
2
59
80
2
60
85
2
61
90
2
62
95
2
63
100
2
Record Ozone Value
Variable
% Voltage
Added Air
Displayed
64
60
3
65
70
3
66
75
3
67
80
3
68
85
3
69
90
3
70
95
3
71
100
3
[0000]
TABLE 2C
Part 3: Ozone Monitor Input at OP Side of Conventional Applicator Bar
LDPE at Minimum coating weight and minimum linespeed
Record Displayed Value
Variable
%Voltage
Added Air
Ozone (g )
80
60
0
81
70
0
82
75
0
83
80
0
84
85
0
85
90
0
86
95
0
87
100
0
88
60
1
89
70
1
90
75
1
91
80
1
92
85
1
93
90
1
94
95
1
95
100
1
96
60
2
97
70
2
98
75
2
99
80
2
100
85
2
101
90
2
102
95
2
103
100
2
Record Ozone Value
Variable
% Voltage
Added Air
Displayed
104
60
3
105
70
3
106
75
3
107
80
3
108
85
3
109
90
3
110
95
3
111
100
3
indicates data missing or illegible when filed
[0000]
TABLE 2D
Part 4: Ozone Monitor Input at OP Side of Applicator
Bar Design Slot Gap at .010″ edges, .007″ center
LDPE at Minimum coating weight and minimum linespeed
Record Displayed Value
Variable
%Voltage
Added Air
Ozone (g/Nm3)
120
60
0
121
70
0
122
75
0
123
80
0
124
85
0
125
90
0
126
95
0
127
100
0
128
60
1
129
70
1
130
75
1
131
80
1
132
85
1
133
90
1
134
95
1
135
100
1
136
60
2
137
70
2
138
75
2
139
80
2
140
85
2
141
90
2
142
95
2
143
100
2
Record Ozone Value
Variable
% Voltage
Adde dAir
Displayed
144
60
3
145
70
3
146
75
3
147
80
3
148
85
3
149
90
3
150
95
3
151
100
3
[0000]
TABLE 2E
Part 5: Ozone Monitor input at OP Feed with Applicator
Bar (Dual Feed) Slot Gap at .010″ edge, .007″ center
LDPE at Minimum coating weight and minimum linespeed
Record Displayed Value
Variable
% Voltage
Added Air
Ozone (g/Nm3)
160
60
0
161
70
0
162
75
0
163
80
0
164
85
0
165
90
0
166
95
0
167
100
0
169
60
1
169
70
1
170
75
1
171
80
1
172
85
1
173
90
1
174
95
1
175
100
1
176
60
2
177
70
2
178
75
2
179
80
2
180
85
2
181
90
2
182
95
2
183
100
2
Record Ozone Value
Variable
% Voltage
Added Air
Displayed
184
60
3
185
70
3
186
75
3
187
80
3
188
85
3
189
90
3
190
95
3
191
100
3
[0000]
TABLE 2F
Phase 2-Ozone/TIAG Adhesion
Phase 2
Structure-48 ga PET/PEI/15# LDPE (NA-214)
Insert Slip Sheet labeled with Variable Number.
NA214 Melt Temp-590 F.
Save Sample labeled with OP Side for Aged Adhesion Testing.
Die Temp at 590 F. and 595 F. on edges
Ozone at 35 psi, O2 = 80 , Added Air = 2 ,
Reactor Pressure = 4.5
Part 1: Ozone Monitor Input at OP Side of Conventional Applicator Bar
Record
Off-line
Aged
Variable
Linespeed
Airgap
Ozone Monitor (g/Nm3)
Voltage (%)
TIAG
Adhesion
Adhesion
200
400
9
0
100
201
400
8.2
0
90
202
400
7.4
0
80
203
435
7.1
0
70
204
510
7.1
0
60
205
605
7.1
0
50
206
760
7.1
0
40
207
400
9
70
100
208
400
8.2
70
90
209
400
7.4
70
80
210
435
7.1
70
70
211
510
7.1
70
60
212
605
7.1
70
50
213
760
7.1
70
40
214
400
9
80
100
215
400
8.2
80
90
216
400
7.4
80
80
217
435
7.1
80
70
218
510
7.1
80
60
219
605
7.1
80
50
220
760
7.1
80
40
221
400
9
90
100
222
400
8.2
90
90
223
400
7.4
90
80
224
435
7.1
90
70
225
510
7.1
90
60
226
605
7.1
90
50
227
760
7.1
90
40
228
1010
7.1
90
30
indicates data missing or illegible when filed
[0000]
TABLE 2G
Part 2: Ozone Monitor Input at OP Feed with Applicator Bar (Dual Feed)
Slot Gap at .010″ edge, .007″ center
Record
Ozone
Line-
Monitor
Voltage
Off-line
Aged
Variable
speed
Airgap
(g/Nm3)
(%)
TIAG
Adhesion
Adhesion
229
400
9
70
100
230
400
8.2
70
90
231
400
7.4
70
80
232
435
7.1
70
70
233
510
7.1
70
60
234
605
7.1
70
50
235
760
7.1
70
40
236
400
9
80
100
237
400
8.2
80
90
238
400
7.4
80
80
239
435
7.1
80
70
240
510
7.1
80
60
241
605
7.1
80
50
242
760
7.1
80
40
243
400
9
90
100
244
400
8.2
90
90
245
400
7.4
90
80
246
435
7.1
90
70
247
510
7.1
90
60
248
605
7.1
90
50
249
760
7.1
90
40
250
1010
7.1
90
30
[0000]
TABLE 2H
Part 3: Coating Weight/Minimum Ozone versus Adhesion
Ozone Monitor input at OP Feed with Applicator Bar (Dual Feed)
Slot Gap at .010″ edge, .007″ center
Record
Ozone
Monitor
Voltage
Coating
Off-line
Aged
Variable
Linespeed
Airgap
(g/Nm3)
(%)
Weight
TIAG
Adhesion
Adhesion
301
510
7.1
0
10
60
302
510
7.1
70
10
60
303
605
7.1
70
10
50
304
760
7.1
70
10
40
305
510
7.1
80
10
60
306
605
7.1
80
10
50
307
760
7.1
80
10
40
308
1010
7.1
80
10
30
309
1010
7.1
80
15
30
310
1010
7.1
80
10
30
|
Apparatuses and methods are described for distributing gas which may be applicable in the field of polymer oxidation and melt curtain ozonation in particular. Ozone applicators and other features of ozonation apparatuses, which may be used separately or in combination, are also described.
| 1
|
BACKGROUND OF THE INVENTION
Undulated shed looms with electromagnetic shuttle drive are already known. In previously known shuttle drives of this type there is the danger that the synchronism between the beating up of the filling threads and the transporting of the shuttles is lost. As a result, there can be relative displacements of the shuttles with respect to each other or shuttles may even drop out of the field of force. Disturbances of this kind, for instance, can occur in case of increased rubbing of the warp yarns against the shuttles, upon the catching of a filling yarn in the warp yarns, or in case of a sudden stopping of the loom.
Also in one known magnetic drive device for the shuttles of an undulated shed loom, the shuttles are made in disk shape and are transported through the sheds by means of a conveyor belt which is provided with electromagnets. Due to the use of electromagnets, the magnets and the shuttles become very warm, and special cooling elements may have to be installed which means an increase in expense. Furthermore, the fact that the feeding of the electric current must be effected to magnets which are constantly in motion means an additional expense.
The closest prior art known to the applicant in connection with this application is in the British Pat. No. 742,060 and the German Pat. No. 1,020,578.
SUMMARY OF THE INVENTION
One of the objects of the invention is to avoid the above-mentioned disadvantages of loss of synchronism, and the invention is characterized by coupling means acting between the shuttles and the stop means in order to maintain the synchronous operation between the transporting of the shuttles and the beating-up movement of the beating-up means.
The present invention furthermore relates to an arrangement for the transporting of shuttles filled with filling thread through the sheds of an undulated shed loom by means of magnetic fields acting on ferromagnetic parts contained in the shuttles, by which fields the shuttles can be driven along their path. Thus the invention avoids the further disadvantages set forth above and is characterized by permanent magnets arranged movably along the path of the shuttles at fixed distances apart which are less than the length of a shuttle (said permanent magnets being hereinafter referred to as "drive magnets") and by drive means associated with these drive magnets, by which means the drive magnets can be moved in such a manner that local magnetic fields of varying intensity having a resultant component of force lying in the direction of movement of the shuttles on their ferromagnetic parts are present over the entire weaving width.
By the use of permanent magnets as drive elements for these shuttles, the transport of the shuttles takes place by mutual attraction and repulsion of magnetic poles. No feeding of electric current to the magnets is necessary and no undesired heating of the magnets takes place. In the present state of technology of permanent magnet materials, permanent magnets can be used for practically an unlimited period of time without any decrease or loss of their magnetic properties occurring and they furthermore require no maintenance.
One preferred embodiment of the arrangement in accordance with the invention is characterized by the fact that the drive magnets are arranged along two opposite sides of the path of the shuttles and are movable synchronously with each other on both sides and that each of the shuttles is equipped with at least two permanent magnets, hereinafter referred to as shuttle magnets.
Due to the fact that the shuttles are exposed on two sides of the path of conveyance to the action of the drive magnets, not only is particularly good efficiency obtained but all unilateral action on the driving of the shuttles is avoided. The equipping of the shuttles with the shuttle magnets also increases the efficiency of the shuttle movement and provides assurance that there will be no heating of the shuttles caused by magnetic pole reversals.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects will become apparent from the following description of illustrative examples with reference to the drawings, in which:
FIG. 1 is a vertical view in cross-section through a shed of an undulated shed-type loom;
FIGS. 2a and 2b are sectional views, each taken along the line II--II of FIG. 1;
FIG. 3 is a vertical view in cross-section similar to that shown in FIG. 1, of another embodiment;
FIG. 4 is a sectional view taken along the line IV--IV of FIG. 3;
FIGS. 5a through 5d are each schematic views seen in the direction of the arrow V in FIG. 4;
FIG. 6 is a vertical view in cross-section of a second embodiment of a detail as compared with FIG. 1;
FIGS. 7a through 7d are each a sectional view taken along the line VII--VII of FIG. 6;
FIG. 8 is a vertical view in cross-section of a third embodiment of detail referring to FIG. 1;
FIG. 9 is a view in cross-section taken along the line IX--IX of FIG. 8; and
FIG. 10 is a schematic view seen in the direction of the arrow X in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a shuttle 1 with its corresponding drive and a rotary reed 2 for the beating up of the filling threads.
The warp threads 11 are tensioned between heddles 5 and the fell of the cloth 6. The shuttles 1 each introduces a filling thread into the shed formed by the warp threads 11, the filling thread being withdrawn from a bobbin 7 which is rotatably supported in the shuttle 1.
The rotary reed 2 consists essentialy of a plurality of reed disks 9 mounted fixed in position equal distances apart on a drive shaft 8 and in operation it rotates in the direction indicated by an arrow. All reed disks 9 which have the same shape (not shown in detail) are in known manner continuously spaced apart in direction of rotation by the same central angle over the entire width of the loom. Thus corresponding points on the periphery of the individual reed disks 9 lie along a helix which extends on the periphery of the rotary reed 2, said helix having a given pitch and the reed disks 9 in operation produce a helical movement which is propagated in the direction of transport of the shuttles 1. The movement of the heedles 5 takes place in such a manner that each shuttle 1 during its movement for the introduction of the filling thread passes continuously through an open shed and a change of shed takes place between every two shuttles. The undulated movement of the heddles 5 and thus of the sheds, the helical movement produced by the reed disks 9 and the movement of translation of the shuttles 1 are so synchronized to each other that associated components are in each case in phase. In other words, the speed of propagation of the undulating movement of the sheds, the speed of propagation of the helical movement produced by the reed disks 9 and thus of the beating up of the filling threads and the speed of translation of the shuttles 1 upon the introduction of the filling thread are the same.
The shuttles 1, as shown in the drawing, are of trapezoidal cross-section, the sides of the trapezoid extending parallel to the warp threads 11 when the shed is open. As already mentioned, each of the shuttles 1 bears or has a rotatably supported bobbin 7 from which would filling thread 14 is withdrawn upon the introduction of the filling thread into the shed of the loom. On the side of the shuttles 1 facing away from the rotary reed 2, the shuttles are provided with permanent shuttle magnets 3 which are oriented transversely to the direction of translation of the shuttles and transversely to the warp threads 11.
Both above and below the path of transport of the shuttles 1 there is arranged a group of jointly driven multi-pole round magnets 40, 40' over the entire weaving width. Each of the round magnets 40, 40' is fastened to one end of a rotatably supported shaft 12, 12' on the other end of which a gear 18, 18' is mounted. The gears 18 and the gears 18' are connected via gears or a drive chain with each other and can be driven by a common drive. The round magnets 40, 40' have the shape of a truncated cone the angle of inclination of which is so selected that the circumferential surface of each round magnet extends parallel to the adjacent outer surface of the shuttle magnets 3. The drive group above and below the path of conveyance of the shuttles 1 is installed in separate housings 13, 13', a wall 15, 15' of which adjacent the shuttles 1 consists of a thin magnetically permeable material. One of the two housings 13, 13' --the upper housing 13 as shown in the drawing--is supported swingable around a shaft 10 on the loom and can be swung in clockwise direction around said shaft so that the sheds are readily accessible from the outside (see FIG. 1).
The shuttles 1 are provided, towards the rotary reed 2, with a nose-shaped projection 16 which projection is guided in a helical groove on the circumference of the rotary reed 2, said groove being formed by corresponding recesses 17 on the circumference of the reed disks 9. The helical groove formed by the recesses 17 has the same pitch as the helix formed by corresponding circumferential points of the individual reed disks 9. This mechanical coupling between rotary reed 2 and shuttle 1 serves to assure synchronism between the movement of the rotary reed 2 and thus the beating-up of the filling threads 14 on the one hand and the movement of translation of the shuttles 1 on the other hand. This synchronism can be disturbed by mechanical resistances, for instance by increased friction between shuttles 1 and warp threads 11, or by filling threads 14 being caught in the shed or by inertial forces occurring for instance upon a sudden stopping or upon the starting of the loom. Of course, the said coupling between the shuttles 1 and the reed disks 9 which serve as stop means is advantageous not only with the shuttle drive by permanent magnets which is shown in the drawing but in connection with all slip-sensitive and thus all electromagnetic shuttle drives.
As shown in FIGS. 2a and 2b, the round magnets 40, 40' each has eight magnet poles and is so developed that in each case a north pole N follows a south pole S and vice versa. The shuttles 1 are provided over their length with a plurality of several--five shown in the drawing--shuttle magnets 3 1 to 3 5 which are the same distance from each other. The shuttle magnets are so oriented within the shuttle 1 that the first, third and fifth shuttle magnets 3 1 , 3 3 and 3 5 have their one pole--in the case shown in the drawing the north pole N--pointed upward and the second and fourth shuttle magnets 3 2 and 3 4 have their other pole--as shown in the drawing the south pole S--pointing upwards. The pitch of the shuttle magnets 3 corresponds to the pitch of the poles on the circumference of the round magnets 40, 40'.
The round magnets 40, 40' on the upper and lower sides of the path of conveyance of the shuttle 1 form, with respect to their movement of rotation, two groups which have a phase difference with respect to each other equal to 1/2 the pole pitch. The round magnets 40, 40' are so arranged that in each case one round magnet of the one phase position lies alongside one round magnet of the other phase position. The distances between centers of the round magnets 40, 40' are so selected that they correspond to 3.5 pitches of the shuttle magnets 3.
In each case two round magnets 40, 40' of the upper and lower drive groups are arranged along a vertical with respect to each other and have a phase difference of one pole pitch with respect to each other with regard to their rotary movement.
In the instantaneous condition of the shuttle transportation shown in FIG. 2a and with the direction of rotation of the round magnets 40, 40' in the direction indicated by arrows, each shuttle 1 is pushed primarily by the force acting between its rearmost shuttle magnet 3 5 and the upper and lower round magnets 40, 40' adjacent same to the right in the direction of transport indicated by an arrow. At the same time the next round magnets 40, 40', as seen in the direction of transport, exerts a force on the first and second shuttle magnets 3 1 and 3 2 and pulls the shuttle 1 in the direction of transport.
When the round magnets 40, 40' have rotated 1/2 pole spacing from the position shown in FIG. 2a, the instantaneous condition shown in FIG. 2a is obtained. The shuttle 1 has almost moved out of the range of the left-hand round magnets 40, 40' as seen in the drawing and is pulled primarily by the round magnets 40, 40' shown in the center of the drawing and transported towards the round magnets shown to the right in the figure. When the last shuttle magnet 3 5 passes through the middle round magnets 40, 40' there is again obtained the instantaneous condition shown in FIG. 2a, although to be sure with the difference that the shuttles 1 have in the meantime been transported towards the right by an amount equal to the length of the center to center distance between two adjacent round magnets 40, 40'.
In the embodiment shown in FIGS. 3, 4 and 5a through 5d, two groups of horseshoe-shaped permanent magents 41, 41' arranged above and below the shuttle conveyance path are used as drive elements for the shuttles 1. The horseshoe magnets 41, 41' are supported at the one end by rotary shafts 21, 21' oriented perpendicular to the direction of transport of the shuttles, the said rotation shafts each bearing a gear 22, 22' on their other end. The gears 22, 22' are connected with each other by intermediate gears which can be driven by a drive which is common to the upper and lower drive groups, or they are each driven by one drive chain per drive group.
The shuttles 1 are developed in a manner similar to that used in the embodiment of FIG. 1; the essential difference is that the shuttles are equipped with three permanent magnets 3 which are distributed uniformly over their length.
The horseshoe magnets 41, 41' are spaced uniformly apart and the axes of rotation of the horseshoe magnets of the upper and lower drive groups each lies along a straight line extending parallel to the path of transport of the shuttles. Furthermore, every horseshoe magnet 41 of the upper drive group is so associated with a horseshoe magnet 41' of the lower group that the axes of rotation of these two magnets are aligned with each other and that the magnetic fields of the two magnets extend in opposite directions to each other at each moment of their rotary movement. The horseshoe magnets 41, 41' are furthermore so oriented with respect to each other that each magnet of the upper and lower drive groups has a phase difference in its rotary movement of 90° with respect to the next following magnet in the direction of transport of the shuttles. In accordance with FIG. 3, the shuttle magnets 3 are so arranged that, in the rotated position of the horseshoe magnets 41, 41' transverse to the path of conveyance of the shuttles they are aligned with the one pole of the horseshoe magnets. As shown in FIG. 4, the pitch of the shuttle magnets 3, whose cross-section is the same size as that of the poles of the horseshoe magnets 41, 41', corresponds to the center-to-center distance of the horseshoe magnets less the normal distance between the axis of the horseshoe magnets and the axis of one of their legs (see FIGS. 4 and 5a through 5d).
In FIGS. 5a through 5d the manner of operation of the shuttle transport is shown schematically for four consecutive positions of rotation of the horseshoe magnets each rotated 90° in respect to each other. In the figures, the horseshoe magnets 41 of the upper drive group are shown in each case. These horseshoe magnets act, in accordance with FIGS. 3 and 4, in each case on the north pole of the shuttle magnets 3. The horsehoe magnets 41' of the lower drive group coincide with those of the upper drive group and act in each case on the south pole of the shuttle magnets 3.
In accordance with FIGS. 4 and 5a through 5d the transport of the shuttles during each transport phase takes place in each case by the action of the forces between in each case three successive horseshoe magnets 41, 41' of the upper and lower drive groups and the three shuttle magnets 3 1 to 3 3 . The front and middle shuttle magnets 3 1 and 3 2 , as seen in the direction of transport indicated by an arrow, are in each case under the action of opposite poles while the rear shuttle magnet 3 3 is under the action of like poles of the horseshoe magnets 41, 41'. The front and middle shuttle magnets 3 1 and 3 2 are thus transported by attracting magnetic forces while the rear shuttle magnet 3 3 is transported by repelling magnetic forces.
In the embodiment shown by way of example in FIGS. 6 and 7a through 7d, two groups of horseshoe-shaped permanent magnets 42, 42' arranged above and below the path of transport of the shuttles are used as drive elements for the shuttles 1. The horseshoe magnets 42, 42' are fastened to bearing arms 19 and 19' respectively. The bearing arms 19 and 19' are each rotatably supported on a cam 23 and 23' respectively firmly mounted on a drive shaft 20 and 20' respectively. The drive shafts 20 and 20' are arranged parallel to the path of transport of the shuttles. Upon rotation of the drive shafts the horseshoe magnets carry out a stroke. The drive shafts 20 and 20' of the upper and lower drive groups can be driven by a common drive. The horseshoe magnets 42, 42' are so oriented that the magnetic fields of all horseshoe magnets extend parallel to each other. In each case one horseshoe magnet 42, 42' of the upper and lower drive groups respectively are arranged aligned with each other along a vertical. The stroke of each such pair of horseshoe magnets takes place synchronously and with a phase difference of 180°, or in other words two magnets of a pair of magents move simultaneously away from the path of transport, simultaneously reach the point of their maximum deflection, move simultaneously towards the path of transport and simultaneously reach the point of their minimum deflection.
The shuttles 1 are developed in the same manner as in the case of the embodiment of FIG. 1, the essential difference residing in the arrangement of the shuttle magnets 3. Each shuttle 1 bears at its front and rear ends a separate shuttle magnet 3, the shuttle magnets being so oriented that their magnetic field extends horizontally and thus parallel to the outer magnetic field of the horseshoe magnets 42, 42' and opposite to it.
Thus in operating condition the north pole of one shuttle magnet lies in each case between the two south poles of a pair of horseshoe magnets and the south pole of the shuttle magnet lies between the two north poles of a pair of horseshoe magnets. The length of the shuttle magnets 3 corresponds to the outside dimension between the two legs of a horseshoe magnet 42, 42', and the width of the shuttle magnets 3 corresponds to the width of the horseshoe magnets 42, 42'. The center distance between the two shuttle magnets corresponds to 2.5 times the center distance between the horseshoe magnets.
In FIGS. 7a through 7d the manner of operation of the transport of the shuttles is shown schematically in four different phases. Each horseshoe magnet 42, 42' is provided with an arrow which indicates in what direction the magnet in question is moved directly after the instantaneous condition shown. Since the lower drive group represents, with respect to arrangement, orientation, and movement of the horseshoe magnets 42', an exact mirrow image of the upper drive group and thus of the horseshoe magnets 42, in each case only the horseshoe magnets 42 of the upper drive group have been shown in FIGs. 7b through 7d.
The drive of the shuttles in this embodiment is effected by the forces of attraction between opposite magnet poles. The horseshoe magnets 42, 42' experience such a stroke movement that they carry out an approximately sinusoidal oscillation, the same pair of magnets having the smallest distance from one of the two shuttle magnets always attracting said shuttle magnet and thus the shuttle in the direction of transport indicated by an arrow.
In the instantaneous condition shown in FIG. 7a the shuttle magnet 3 1 is under the action of the magnet pairs 42 2 , 42' 2 and 42 3 , 42' 3 and the shuttle magnet 3 2 is under the action of the pair of magnets 42 5 , 42' 5 . Upon further rotation of the drive shafts 20 and 20' (FIG. 6), the pairs of magnets 42 5 , 42' 5 and 42 3 , 42' 3 move away from the shuttle and the pair of magnets 42 2 , 42' 2 moves towards the shuttle. In this way the force of attraction of the last mentioned pair of magnets on the shuttle magnets 3 1 becomes greater than the sum of the forces of attraction of the pair of magnets 42 3 , 42' 3 on the shuttle magnet 3 1 and of the pair of magnets 42 5 , 42' 5 on the shuttle magnet 3 2 . In this way the shuttle is transported into the position shown in FIG. 7b. Thereupon the pairs of magnets 42 4 , 42' 4 and 42 2 , 42' 2 move towards the shuttle. In this way the shuttle is transported by the action of the said pairs of magnets on the shuttle magnets 3 2 and 3 1 into the position shown in FIG. 7c. Thereupon the pair of magnets 42 4 , 42' 4 is moved further towards the shuttle and transports the latter, by the force on the shuttle magnet 3 2 , into the position shown in FIG. 7d. The shuttle has thus been transported by a length corresponding to the pitch of the horseshoe magnets and the cycle described starts all over again.
In the case of the embodiment shown in FIGS. 8, 9 and 10, separate drive shafts 25, 25' arranged above and below the path of conveyance of the shuttles and parallel to it are used as drive for the shuttles 1, and the said drive shafts are provided with permanent bar magnets 43, 43' equally spaced apart and extending in radial direction through the central axis of the drive shafts. Successive bar magnets are in each case turned by the same angle so that the penetration surfaces of the magnets through the shell of their drive shaft lie in each case on a helix. The orientation of the bar magnets 43, 43' within their drive shaft 25 and 25' respectively is so selected that the individual magnet poles also form a continuous helix. The upper drive shaft 25 and the lower drive shaft 25' are entirely identical and are so mounted on the loom that the magnetic fields of every two bar magnets 43, 43' of the upper and lower drive shafts which correspond to each other extend at each moment parallel to each other. The two drive shafts 25, 25' are provided at their one or both ends with gears (not shown) which are coupled with a common drive.
The shuttles 1 are developed in a manner similar to the embodiment of FIG. 1, the essential difference consisting of the arrangement of the shuttle magnets 3. Each shuttle 1 bears at its front and rear ends a shuttle magnet 3, these magnets being so oriented that their magnetic field extends in vertical direction. The magnetic fields of the two shuttle magnets 3 1 , 3 2 extend in opposite directions to each other. The center to center distance between the two shuttle magnets is so selected that it corresponds to the center to center distance between two bar magnets 43 or 43' which are 180° apart.
In FIGS. 9 and 10 the same instantaneous position of the transport of the shuttle has been shown, in FIG. 9 in sectional view and in FIG. 10 in a view as seen from the heddles 5, the housing 13, 13' surrounding the upper and lower drive groups being omitted from this last mentioned view, except for the wall 15, 15'.
As can be noted from FIGS. 9 and 10, the transport of the shuttles 1 in the direction of transport indicated by an arrow is effected by the forces of attraction between opposite magnet poles. In the instantaneous condition shown in these figures, the two shuttle magnets 3 1 and 3 2 are within the range of force of the bar magnets 43 1 , 43' 1 and 43 2 , 43' 2 . Upon further rotation of the drive shafts 25 and 25' in the direction indicated by arrows in FIG. 8, the poles of the bar magnets 43 1 , 43' 1 and 43 2 , 43' 2 , move away from the shuttle magnets 3 1 and 3 2 . At the same time however one pole each of the bar magnets 43 3 , 43' 3 and 43 4 , 43' 4 is turned towards the path of transport of the shuttles. In this way the shuttle magnets come into the field of force of the bar magnets 43 3 , 43' 3 and 43 4 , 43'.sub. 4 and are conveyed further by the latter by a distance equal to one spacing of the bar magnets. All further transportation steps take place in analogous manner.
Instead of the drive shafts 25, 25' shown in FIGS. 8 amd 9 with the bar magnets 43, 43' fitted in them, individual multi-pole round magnets arranged one behind the other on two drive shafts extending parallel to the path of transport of the shuttles can also be used.
In all the illustrative embodiments described the shuttles are provided with magnets. Of course instead of the shuttle magnets, non-permanently magnetized structural parts of ferromagnetic material can also be used without thereby making any change in the shuttle drive device in accordance with the invention.
It will be appreciated that various changes and/or modifications may be made within the skill of the art without departing from the spirit and scope of the invention illustrated, described, and claimed herein.
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The present invention relates to an undulated shed-type loom for transporting shuttles filled with filling thread through sheds by means of electromagnetic fields acting on the shuttles and having means for beating up the filling threads introduced against the fell of the cloth, the beating-up of the filling threads taking place synchronously with the transportation of the shuttles over the width of the loom.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and apparatus for determining yarn number or thickness deviations in yarn connecting processes of automatic open-end spinning machines.
2. Description of the Related Art
As is known, yarn connections are always necessary in automatic open-end spinning machines when the thread breaks, has to be cut due to faulty formation, or if the sliver supply runs out and new sliver must be inserted.
Although as a rule the yarn splicing region itself is monitored, in order to make certain that no yarn connections of unacceptable dimensions, strength, or poor appearance are in the yarn, it must be assured that there is no possibility for other less conspicuous yarn number or thickness deviations to remain undetected.
It is also possible for a slight yet permanent change in the yarn number or the yarn thickness to occur and remain undetected due to its small magnitude, when introducing new sliver. The above-mentioned yarn number or thickness deviations dealt with in this case are not visible with the naked eye. They will only become visible, if at all, in the finished fabric subsequently made from this yarn.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a method and apparatus for determining yarn number or thickness deviations, which overcome the hereinafore-mentioned disadvantages of the heretoforeknown methods and devices of this general type, and to determine, detect, and indicate possible deviations of the yarn number or thickness which cannot be detected with the naked eye in yarn connection processes of automatic open-end spinning machines.
With the foregoing and other objects in view there is provided, in accordance with the invention, a method of determining yarn number or thickness deviations for yarn connecting processes in automatic open-end spinning machines, which comprises producing a yarn connection at a yarn connection point, subsequently automatically measuring one of the yarn numbers or gauge, yarn thickness or yarn mass or bulk per unit length in a yarn section of limited length upstream of the yarn connection point with the yarn running to produce a measured value, comparing the measured value with a comparison value, and inducing or generating a signal with an indication regarding the spinning unit or location in the case of a deviation between the measured and comparison values with a predetermined magnitude.
As an alternative, there is provided a method of determining yarn number or thickness deviations for yarn connecting processes in automatic open-end spinning machines, which comprises producing a yarn connection at a yarn connection point, subsequently automatically measuring one of the yarn number or gauge, yarn thickness or yarn mass or bulk per unit length in yarn sections of limited length upstream and downstream of the yarn connection point with the yarn running to produce measured values, comparing the measured values with each other, and inducing or generating a signal with an indication regarding the spinning unit or location in the case of a deviation between the measured and comparison values with a predetermined magnitude.
The magnitude of the number, yarn mass or yarn thickness deviation determines whether the spinning station is kept in operation or not. The continued operation of the spinning station also depends on whether the number, yarn mass or yarn thickness deviation is permanent or not. Due to the automatic measurement with the yarn running, there is no time loss and also no production loss. Since unacceptable yarn number or thickness deviations in connection with yarn joining processes are to be considered as exceptions, the invention is mainly intended as a provision for ensuring quality. Through the use of the invention, it becomes possible to guarantee that the spool of yarn produced in an open-end spinning machine contains no deviations of yarn number or yarn thickness generated in yarn connection processes, which went undetected heretofore.
Since the yarn number, yarn thickness, or yarn mass of the spun yarn fluctuate due to the very nature of the process, such fluctuations can influence, disturb and falsify the result of measurements. For this reason, in accordance with another mode of the invention the method comprises sequentially forming mean or average values from the individual measured values, determining one of the mean yarn number, yarn thickness and yarn mass per unit length for the yarn section downstream of the yarn connection point, and subsequently determining one of the mean yarn number, yarn thickness or yarn mass per unit length for the yarn section upstream of the yarn connection point.
The formation of the mean value eliminates the natural fluctuations of the yarn number, yarn cross section, or yarn thickness, and the successive measurement simplifies the automation, because the measurements can be made at one fixed measuring location through which the yarn is conducted.
In accordance with a further mode of the invention, there is provided a method which comprises measuring the yarn number, yarn thickness and yarn mass per unit length in the yarn sections at least 300 mm downstream and at most 4 m upstream of the yarn connection point. This is done because it has been established that the number or thickness deviations are more pronounced in vicinity of the yarn connection region than at other yarn sections. This ensures that yarn irregularities can be reliably detected in the shortest time. It is advantageous to use measurements which were made in other spinning regions as comparison values.
To make this possible, in accordance with an added mode of the invention there is provided a method which comprises measuring the yarn number, yarn thickness and yarn mass per unit length at a predetermined number of spinning units or locations to produce a mean or measured value or values, producing mean or average comparison values from the measured value or values, continuously correcting the comparison values by deleting the measured value of the first spinning unit when including the measured value of the last spinning unit or location in the average value production, so that the average value production always extends to a predetermined number of spinning units or locations measured last. In this way, the comparison values are automatically and continuously corrected.
In order to carry out the method, there is provided an apparatus for determining yarn number or thickness deviations for yarn connecting processes in automatic open-end spinning machines, comprising a measuring device or meter for measuring at least one of yarn number, yarn thickness or yarn mass or bulk and producing a measured value, the measuring device including at least one measuring point disposed downstream of a yarn connection point at which the measurements are taken, the measuring device including a measuring value comparator for comparing the measured value with a comparison value, and including a measuring value difference indicator for indicating differences between the measured value and the comparison value, and an operative connection connected between the measuring value comparator and the measuring value difference indicator.
In accordance with another feature of the invention, the measuring device performs measurements and produces measured values at yarn sections disposed upstream and downstream of the yarn connection point, and the measuring value comparator compares the measured values.
If only one measuring location is provided, the yarn section before the yarn connection point passes the measuring location first, then the yarn connection point follows, and finally the yarn section behind the yarn connection point passes. The yarn number or yarn thickness is determined sequentially in time. However, if two measuring places are provided, the yarn section disposed before the connection point passes one measuring location while the yarn section behind the connection point simultaneously passes the second measuring location. Thus, measurements can be made simultaneously at the two measuring locations. Each can be provided with its own yarn number or yarn thickness measuring device. The use of only a single yarn number or yarn thickness measuring device is more economical, because the measuring time with the yarn running is quite short. Two measuring positions permit the simultaneous acquisition of the measured values before and after the thread connection point, so that the result of the measurement and the difference between the measured values can be determined even faster.
In accordance with a further feature of the invention, the measuring device includes a measuring value storage device or memory. A storage device is advantageous at least in all cases where the measured values are obtained successively in time intervals.
In accordance with an added feature of the invention, the measuring device includes a mean value former for forming mean values of a plurality of individual, sequential measurements. The advantages of forming the mean values were already mentioned above.
In accordance with an additional feature of the invention, there is provided a device connected to the mean value former for selecting a limited number of individual measurements upstream and downstream of the thread connection point for forming mean values. For instance, if ten individual measurements are provided for forming the average, it is possible to begin to form the average value at an early point in time, when the yarn connection point has not yet passed the measuring location. During the eleventh individual measurement, the first individual measurement is deleted from the production of the average value, at the twelfth individual measurement the second measurement is deleted and so on, until the yarn connection point reaches the measuring location. The yarn connection point itself is not included in the formation of the average value. As soon as the yarn connection point has left the measuring location, the formation of average values from individual measurements is resumed, and a predetermined number of individual measurements can be used for producing the average value, which can now be many more than ten individual measurements.
In accordance with again another feature of the invention, there is provided a selection device connected to the mean value former for selecting the mean or measuring values of the yarn number, yarn thickness or yarn mass per unit length measured at a predetermined number of spinning units and for producing a mean comparison value, the selection device including means for deleting the measuring value of a first spinning unit when the measuring value of a last spinning unit is added, so that a mean value is produced which always extends to a predetermined number of spinning units or positions measured last.
Since the yarn number, mass or thickness of the yarn connection point is also of interest, the yarn connection point can be measured in the same location. For this purpose, in accordance with again a further feature of the invention, the measuring device includes a second evaluation channel for measuring the thickness of the yarn connection point.
As a rule, automatic open-end spinning machines are provided with servicing devices for automatically starting the spinning process, for cleaning the spinning apparatus and for changing bobbins. In order to add a new, additional use to such servicing devices, in accordance with again an added feature of the invention, there is provided a movable servicing device, at least the measuring point of the measuring device being disposed on the servicing device.
In accordance with a concomitant feature of the invention, the yarn runs in a given normal position, and including a guide element disposed in vicinity of the measuring point for guiding the yarn from the given normal position to the measuring point and back again.
For instance, if the measuring location is located on a servicing device which handles the starting of the spinning or thread joining, guide elements are already provided, which conduct the yarn from the normal running position to the servicing device. These pre-existing guide elements can be utilized for guiding the yarn through or past the measuring location.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a method and apparatus for determining yarn number or thickness deviations, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of euivalents of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the single figure of the drawing which is a diagrammatic, side-elevational view of the apparatus according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the single figure of the drawing in detail, there is seen an open-end spinning machine 1 which includes a great number of individual spinning devices 2, yarn or thread withdrawal devices 3, and spooling or winding devices 4. Each spinning device 2 has a spinning box 5 which can be swung open. Sliver 6 is introduced into the spinning box 5 and spun to form yarn 7. The yarn 7 is wound onto a spool 8, which lies on a rotating drive roller 9 and is held by a pivotable spool frame 10.
A servicing device 13 can travel along the open-end spinning machine on rails 11, and is provided with an automatic spinning-starting or thread-joining device 14. The device 14 can act on the spinning box 5 in the direction of an arrow 15 in a manner which is not further shown or described. This is done in order to produce a thread connection in the form of a spinning start or thread joint with evenness of the yarn, after a threadbreak or after the sliver supply runs out. A location 16 where the thread is joined or started lies in the interior of the spinning box 5 and is marked by an X. The splice 17 itself is indicated in a very exaggerated way.
It is assumed that the spinning-starting or thread-joining device 14 has just produced a thread connection. Downstream of the splice 17 is a yarn section 18 which is about 400 mm long. Upstream of the splice 17 is a yarn section 19, which will have a length of 4 m later.
The normal running position of the yarn 7 is designated with reference numeral 7'. The yarn therefore runs under a pressure roller 19' of the yarn withdrawal device 3, is deflected at a guide rod 20, passes through a reciprocating thread guide 21, and reaches the spool 8 from the bottom.
However, the path of the thread is changed after the yarn connection 17 has been made. Two pivotable guide elements 22, 23 provided at the servicing device 13, move the thread out of its normal position and conduct it to a measuring point 24 of a yarn thickness meter or measuring device 25. The measuring point 24 is connected with the yarn thickness meter 25 by an electric line 26. The thickness meter 25 and a measuring element 24' of the measuring point 24 are in continuous readiness to operate, and begin with a continuous series of individual measurements at the moment the yarn 7 runs over the measuring point 24. The thickness meter 25 is provided with a measured value storage device 27 for storing measuring results. Furthermore, the meter 25 has a mean value former 28 for forming the arithmetic average or mean value of several sequential individual measurements and for forming the average or mean value of the measured values obtained at a defined number of the spinning units or points measured last. In turn, the mean value former 28 is connected with a device 29 for the selection of a limited number of individual measurements positioned upstream or downstream of the splice or thread connection point 17, which are used for forming the average or mean value. The mean value former 28 is also connected with a device 41. The device 41 serves for selecting the measured values or average or mean values of the yarn thickness, which were measured at a defined number of spinning units, for measuring the mean or average values for comparison. The device 41 is constructed in such a way that as the last measured spinning unit or point is included among the selected values, the measured value of the respective spinning unit or point measured first drops out, so that the average value obtained always represents a defined number of spinning units or points measured last. Furthermore, the yarn thickness meter 25 has an adjustment device 30, which serves especially for setting the number of individual measurements from which the average or mean values or comparison values are to be formed. Additionally, the yarn thickness meter 25 has a second evaluation channel 31 for measuring the thickness of the splice or yarn connection point 17.
This evaluation channel 31 responds only to very sudden thickness changes, and therefore only measures a yarn connection point 17 if its thickness clearly noticeably deviates from nominal values. The yarn thickness meter 25 is provided with a measured value comparator 32, which selectively compares the average or mean values of the measured values with each other, or with comparison values, and has a functional or operative connection 33 to a measurement value difference indicator 34, which is equipped with an optical transmitter 35. The optical transmitter 35 sends a light beam 36 to the receiver 37 of an opto-electrical device 38 as soon as the average or mean values deviate a few percent from each other, or from comparison values. In this case, the opto-electrical device 38 causes an indicator lamp 39 to light up.
If no comparison values are available, or they are not to be used, the procedure is as follows:
Although the yarn thickness meter 25 starts its measurement quite early, only the yarn section 18 is of interest for forming the average or mean value. It is assumed that with the aid of the adjustment device 30, ten individual measurements are set for forming the average or mean value for the yarn section downstream of the splice or connection point 17. In this case, the device 29 ensures that upon the occurrence of the eleventh individual measurement, the first measurement is dropped from the value formed, after the twelfth individual measurement, the second measurement is dropped out and so on, until the splice or yarn connection point 17 reaches the measuring point 24. The last average value which is now determined is stored in the measured value storage device 27. After the splice or thread connection point 17 has left the measuring point 24, the individual measurements are resumed and stored in the measured value storage device 27, then the average value is formed from the predetermined number of measurements with the help of the mean value former 28, and thereafter the measuring value comparator 32 compares the two average or mean values with each other. If the average values deviate from each other by more than 1%, for example by 8%, the average value comparator 32 sends a signal through the functional connection 33 to the measured value difference indicator 34, which thereafter causes the opto-electrical device 38 to turn on the indicator lamp 39.
If the yarn connection point 17 has a thickness greater than its nominal or desired value, the moment this splice 17 runs past the measuring point 24, the second evaluation channel 31 responds over a functional or operative connection 40 causing the separation of the thread connection by the spinning-starting or thread-joining device 14, and initiates a renewed start of the spinning operation or joining of the thread.
Thus, in the illustrated embodiment, a yarn connection point of abnormal size leads to a repetition of the start of spinning or thread joining, while a deviation of the yarn number or a deviation of the yarn thickness of a normal size only causes an optical signal, but does not stop the spinning device. The reason for this is that the number deviation or thickness deviation relates to the short piece of thread at both sides of the thread connection or joint 17. However, after the error signal has been given, the thickness or yarn number can be measured again for control purposes and if the measured value difference continues, the spinning device 2 can be stopped. In any case, the lighting of the indicator lamp 39 gives notice that a thickness or yarn number deviation existed, if only for a short time.
It is therefore possible to investigate for the causes of such deviations in the spinning device or in the servicing apparatus, in order to eliminate these deviations. Obviously it is also possible upon the occurrence of value deviations, to either immediately repeat the starting of the spinning operation or thread joining, or to take the spinning station out of operation. For this reason, the functional connection 33 must lead to the spinning-starting or thread-joining device 14. The spinning-starting or thread-joining device 14 is able to take the spinning station out of operation after repeated unsuccessful attempts at starting the spinning or thread-joining operation.
Before the servicing device 13 can travel to another spinning station, the two guide elements 22 and 23 swing back to their starting positions, to bring the yarn 7 back to its normal running position 7'. Then the guide elements swing back to the rear, so that they do not obstruct the further travel of the servicing unit 13.
Comparison values for later measurements are obtained in the following way:
Mean or average values of the yarn thickness at the initially measured spinning point or unit are stored in the measuring value storage device or memory 27. Similarly, the mean or average values of the yarn thickness of the later measured spinning points or units are stored. The mean value former 28 forms a comparison value from these mean values, which is continuously corrected in the following way:
First, the amount of spinning points or units that will be used for forming the comparison values from the measurements, is set. The comparison values are taken at ten spinning points or units.
When including the last measured spinning point or unit in the average value calculation, the first measured value is taken out of the average value calculation, so that the average obtained always relates to a predetermined number of places which were measured last.
When the comparison values are given or were obtained as described above and are being used, the yarn thickness of the thread section 19 which is disposed upstream of the connection point, is compared with these comparison values or average comparison values, and in the case of thickness deviations of a certain magnitude, the indicator lamp 39 lights up.
The invention is not limited to the described and illustrated embodiment which was used as an example.
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A method for determining yarn number and thickness deviations for yarn connecting processes in automatic open-end spinning machines includes producing a yarn connection at a yarn connection point, subsequently automatically measuring one of the yarn number, yarn thickness and yarn mass per unit length in a yarn section of limited length upstream of the yarn connection point with the yarn running to produce a measured value, comparing the measured value with a comparison value, and inducing a signal with an indication regarding the spinning unit in the case of a deviation between the measured and comparison values with a predetermined magnitude, and an apparatus for carrying out the method.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a camera system which includes an image-taking apparatus, such as a television camera and a video camera, and a lens apparatus mounted on the image-taking apparatus.
2. Description of the Related Art
Camera systems for use in television broadcast or video recording include an auto-focus (hereinafter abbreviated as AF) type in which a video camera is integral with a lens and focusing is performed automatically, and a manual focus (hereinafter abbreviated as MF) type in which a lens is removably mounted on a camera and focusing control is performed in response to manual operation of a manipulation member.
Recently, the AF has also been used in camera systems which employ interchangeable lenses.
Conventionally, only AF-capable lenses can be used in AF camera systems and only MF-capable lenses can be used in MF camera systems. In recent years, however, there is an increasing need for camera systems in which both of MF-capable lenses and AF-capable interchangeable lenses can be used.
In the MF-capable lenses, however, a so-called front focus type is typically employed in which a focus lens is placed closer to an object side than a variable magnification lens. On the other hand, in the AF-capable lenses, a so-called rear focus type is usually employed in which a focus lens is placed closer to an image side than a variable magnification lens. This is because of the operability, controllability and portability of the lenses.
Japanese Patent Application Laid-Open No. H6 (1994)-62305 has disclosed an AF method in such a camera system, for example. In the AF method, a signal indicating the sharpness evaluation value of an object is extracted from a video signal taken by a camera to move a focus lens in a direction in which the strength of the signal is increased. The AF method is called a climbing method (a contrast detection method).
With a smaller size and a lighter weight of the entire camera system, zoom lenses of the rear focus type allowing reductions in size and weight are used in the AF-capable lenses. In the zoom lenses of the rear focus type, the position of an image plane changes with varied magnification even when the same distance to an object is maintained, so that the position of a focus lens needs to be adjusted in association with the varied magnification. Such a method of adjusting a focus lens has been disclosed, for example, in Japanese Patent Application Laid-Open No. H1 (1989)-280709, Japanese Patent Application Laid-Open No. H8 (1996)-220414 and the like.
Description is now made for the structure of a conventional zoom lens of the rear focus type. In FIG. 4 , the zoom lens is comprised of four lens units including, in order from an object side, a fixed front lens unit (a first lens unit) 131 , a variable magnification lens unit 132 which is movable on an optical axis (a second lens unit, hereinafter referred to as a zoom lens unit), a fixed lens unit (a third lens unit) 136 , and a focus lens unit (a fourth lens unit) 118 which is movable on the optical axis for correcting image plane variations in varying magnification and for focusing.
Reference numeral 111 shows a zoom ring. When the zoom ring 111 is rotated, the zoom lens unit 132 is moved in the optical axis direction by a cam (not shown) formed on a fixed barrel 137 to perform variable magnification.
Reference numeral 115 shows a zoom motor which drives the zoom ring 111 through interlocking gears 133 and 134 . Reference numerals 119 and 120 show guide bars which guide a moving frame 122 for holding the focus lens unit 118 in the optical axis direction.
Reference numeral 121 shows a focus motor which is realized by a step motor, for example. The moving frame 122 has a screw portion formed thereon which engages with a screw shaft 123 which is driven by the focus motor 121 . Thus, when the screw shaft 123 is rotated by the focus motor 121 , the moving frame 122 is moved in the optical axis direction together with the focus lens unit 118 . Reference numeral 135 shows a stop unit which adjusts an amount of light.
FIG. 6 shows trajectory data which represents the positional relationship between the zoom lens unit 132 and the focus lens unit 118 on the optical axis for various object distances. The trajectory data shows the moving trajectories of the focus lens unit 118 for maintaining an in-focus state of an object at distances from INF (infinity) to MOD (minimum object distance).
For the rear focus lens, the focus lens unit 118 exists closer to an image side than the zoom lens unit 132 , so that simply driving the zoom lens unit 132 in the structure shown in FIG. 4 causes the position of the image plane to be changed with varied magnification. To maintain the in-focus state, it is necessary to determine the position where the focus lens unit 118 should be placed from the position of the zoom lens unit 132 and the object distance in the trajectory data of FIG. 6 to drive the focus lens unit 118 in association with varied magnification.
Next, description is made for AF processing in the aforementioned camera system which employs the rear focus lens with reference to a block diagram of FIG. 5 . In FIG. 5 , reference numeral 102 shows an image-pickup element such as a CCD sensor and a CMOS sensor, and 103 a camera processing circuit which produces a video signal based on an output signal from the image-pickup element 102 . The video signal is output to an AF circuit 104 . The AF circuit 104 extracts a high-frequency component from the video signal and outputs it as an AF evaluation value signal to a CPU 140 .
In normal AF processing (AF processing without varying magnification), the CPU 140 causes the focus lens unit 118 to wobble through a lens control section 139 on the zoom lens side to determine a drive direction of the focus lens unit 118 in which the strength of the AF evaluation value signal is increased. The CPU 140 outputs a focus control signal for driving the focus lens unit 118 by a predetermined drive amount in the determined direction and drives the focus lens unit 118 until the AF evaluation value signal is at the maximum.
In the AF processing with varied magnification, the CPU 140 calculates the drive amount of the focus lens unit 118 by using the trajectory data in FIG. 6 stored in a trajectory data memory 145 and information about the current positions of the zoom lens unit 132 and the focus lens unit 118 detected as described later and outputs a focus control signal according to the calculation result.
On the zoom lens side, reference numeral 106 shows a zoom position detector which detects the position of the zoom lens unit 132 on the optical axis. Reference numeral 107 shows a zoom motor driver which drives the zoom motor 115 . Reference numeral 125 shows a focus motor driver which drives the focus motor 121 realized by the step motor. The number of drive pulses input to the focus motor 121 is counted by the CPU 140 . The count is used to detect the position of the focus lens unit 118 .
Reference numeral 138 shows a stop position detector which detects the position of blades (that is, a stop value) provided for the stop unit 135 .
The lens control section 139 produces a drive signal for the zoom lens unit 132 based on a zoom control signal produced in a zoom operation circuit 141 in response to manipulation of a zoom switch 142 such as a seesaw switch. The lens control section 139 also produces a drive signal for the focus lens unit 118 based on a focus control signal output from the CPU 140 .
The trajectory data shown in FIG. 6 depends on optical characteristics of a zoom lens. For example, the moving amount of a zoom lens unit varies according to the magnification of a lens. For this reason, if interchangeable lenses having various optical characteristics are used for one camera, the trajectory data of each interchangeable lens is transmitted to the camera for storage in the trajectory data memory 145 when each interchangeable lens is mounted on the camera.
The focus control signal produced in the camera system which has the AF-capable lens of the rear focus lens type includes a signal which represents the drive amount of the focus lens unit 118 calculated by using the current positions of the zoom lens unit 132 and the focus lens unit 118 and the trajectory data in order to correct the image plane variations in varying magnification.
In contrast, in the camera system which has the MF-capable lens of the front focus type, the focus lens is placed closer to the object side than the variable magnification lens and thus the position of the image plane is not changed with varied magnification. This eliminates the need to drive the focus lens unit in varying magnification.
Now, description is made for the structure of a conventional front focus type zoom lens and a manual focus control system. In FIG. 7 , on the side of a camera 201 , reference numeral 110 shows a zoom/focus operation circuit. Connected to the zoom/focus operation circuit 110 are a zoom operation member 112 which outputs an operation signal for servo-driving a zoom lens unit (not shown) and a focus operation member 113 which outputs an operation signal for servo-driving a focus lens unit (not shown). The zoom/focus operation circuit 110 produces and outputs control signals according to operation amounts of the respective operation members. Reference numeral 144 is a camera control section which is responsible for control of the camera.
On the other hand, on the zoom lens side, reference numeral 114 shows a focus motor which drives the focus lens unit through an interlocking gear (which has no reference numeral). Reference numeral 116 shows a focus motor driver which drives the focus motor 114 in response to a focus drive signal from a lens control section 143 .
Reference numeral 117 shows a focus position detector which detects the current position of the focus lens unit 118 and transmits it to the lens control section 143 . Reference numeral 124 shows a focus ring associated with the focus lens unit. The focus ring 124 is rotated by the focus motor 114 to move the focus lens unit, thereby performing manual focusing.
Reference numeral 143 shows the lens control section which controls the zoom motor 115 and the focus motor 114 .
When the focus operation member 113 is operated, an operation signal output from the focus operation member 113 is input to the lens control section 143 as a focus control signal through the zoom/focus operation circuit 110 . Similarly, when the zoom operation member 112 is operated, an operation signal output from the zoom operation member 112 is input to the lens control section 143 as a zoom control signal through the zoom/focus operation circuit 110 .
These control signals are converted by the lens control section 143 into a focus drive signal and a zoom drive signal for achieving drive of the motors and output to the drives 116 and 107 , respectively. In response to the drive signals, the drivers 116 and 107 drive the focus motor 114 and the zoom motor 115 to rotate the focus ring 124 and a zoom ring 111 , respectively. In this manner, the focus lens unit and the zoom lens unit are driven.
A controller 109 which can be used to perform zoom and focus operation is connected to the camera for use in such a system, besides the operation members 112 and 113 . The controller 109 outputs a control signal according to the amount of operation thereof, and the control signal is output to the lens control section 143 through the camera control section 144 .
As described above, when the rear focus lens is used to perform the AF control, the focus control signal output from the camera for correcting the image plane variations associated with varied magnification is a signal which represents the position to which the focus lens unit should be moved (the drive amount), determined from the trajectory data in FIG. 6 , the current position of the zoom lens unit, the current position of the focus lens, and the object distance.
On the other hand, when the front focus lens is used to perform the MF control, the focus control signal output from the camera is a signal produced according to the operation amount of the focus operation member 113 .
In other words, the AF camera system with the rear focus lens and the MF camera system with the front focus lens produce the focus control signals on the camera sides in different manners, so that only dedicated interchangeable lenses can be used in each of the systems.
Next, description is made for a conventional camera system in which both of an MF-capable lens and an AF-capable lens can be used for one camera with reference to a block diagram of FIG. 8 . In FIG. 8 , components identical to those in FIGS. 5 and 7 are designated with the same reference numerals as those in FIGS. 5 and 7 and description thereof is omitted.
In FIG. 8 , reference numeral 200 shows a lens control section which is responsible for control of a zoom lens. The zoom lens is an MF-capable interchangeable lens or an AF-capable interchangeable lens.
When the zoom lens is mounted on a camera 301 , a camera control section 305 provided in the camera 301 outputs a request for transmission of an identification signal for determining whether the zoom lens is an MF-capable lens or an AF-capable lens. In response to the request, the lens control section 200 transmits the identification signal back to the camera control section 305 . The camera control section 305 switches between methods of producing a focus control signal depending on the determination result. In this manner, the focus control signal appropriate for the mounted lens is produced and output to the lens.
It should be noted that some zoom lenses have no identification signals to be transmitted in response to the transmission request from the camera control section 305 , in which case an identification signal cannot be transmitted back. In this case, the camera control section 305 determines that no reply is made in a certain time period and considers the mounted lens as an MF-capable lens before it starts control.
The control of the MF-capable lens is performed as described above with reference to FIG. 7 . The control of the AF-capable lens is performed as described above with reference to FIG. 5 . When the AF-capable lens is mounted, the camera 101 takes the trajectory data shown in FIG. 6 from the lens side and stores it in the trajectory data memory 145 .
As described above, in the conventional camera system, various types of lenses are used with different arrangements such as the front focus lens and the rear focus lens and with different focus control methods such as the MF control method and the AF control method. In a camera which can accept only a particular type of lens, if another type of lens is mounted thereon, normal focus control cannot be performed.
Specifically, since the focus control signal to be provided for the MF-capable front focus lens by the camera is not consistent with the focus control signal to be provided for the AF-capable rear focus lens, both types of lenses cannot be used in each of the MF-capable camera and the AF-capable camera.
As described in FIG. 8 , it is possible that the type of the mounted lens is determined on the camera side to switch between the methods of producing the focus control signal. However, to produce the focus control signal appropriate for the AF-capable lens (the rear focus lens) on the camera side, the camera must take the large amount of trajectory data from the lens at power-up, and the camera needs to have a memory of large capacity for storing the trajectory data and a calculation function for producing the focus control signal suitable for the AF-capable lens.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a camera system which allows different types of lens apparatuses to be used in combination with a single image-taking apparatus (camera) without requiring changes of focus control signals on the side of the image-taking apparatus depending on the type of a lens apparatus mounted on the image-taking apparatus, a lens apparatus, and an interchangeable lens system.
According to an aspect, the present invention provides a camera system comprising an image-taking apparatus which outputs a focus control signal, and a lens apparatus which includes a focus lens and is mounted on the image-taking apparatus. The lens apparatus includes a controller which produces a drive signal according to a type of focus of the lens apparatus based on the focus control signal and controls drive of the focus lens based on the drive signal.
According to another aspect, the present invention provides a camera system comprising an image-taking apparatus which outputs a focus control signal, a first lens apparatus which includes a first focus lens and is mounted on the image-taking apparatus, and a second lens apparatus which includes a second focus lens and is mounted on the image-taking apparatus. The second lens apparatus employs a type of focus different from a type of focus of the first lens apparatus. The first lens apparatus includes a first controller which produces a first drive signal according to the type of the first lens apparatus based on the focus control signal and controls drive of the first focus lens based on the first drive signal. The second lens apparatus includes a second controller which produces a second drive signal according to the type of the second lens apparatus based on the focus control signal and controls drive of the second focus lens based on the second drive signal.
According to another aspect, the present invention provides a lens apparatus comprising a focus lens, and a controller which produces a drive signal according to a type of focus of the lens apparatus based on a focus control signal output from an image-taking apparatus and controls drive of the focus lens based on the drive signal.
According to yet another aspect, the present invention provides an interchangeable lens system comprising a first lens apparatus which includes a first focus lens and is mounted on the image-taking apparatus, a second lens apparatus which includes a second focus lens and is mounted on the image-taking apparatus. The second lens apparatus employs a type of focus different from a type of focus of the first lens apparatus. The first lens apparatus includes a first controller which produces a first drive signal according to the type of the first lens apparatus based on a focus control signal output from the image-taking apparatus and controls drive of the first focus lens based on the first drive signal. The second lens apparatus includes a second controller which produces a second drive signal according to the type of the second lens apparatus based on the focus control signal and controls drive of the second focus lens based on the second drive signal.
These and other characteristics of the camera system, the lens apparatus, and the interchangeable lens system of the present invention will be apparent from the following description of specific embodiments with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the structure of a camera system which includes a rear focus lens and a camera in an embodiment of the present invention;
FIG. 2 is a block diagram showing the structure of a camera system which includes a front focus lens and the camera in the embodiment of the present invention;
FIG. 3 is a flow chart showing a processing program performed in the rear focus lens and the front focus lens in the embodiment of the present invention;
FIG. 4 is a section view showing a conventional rear focus lens;
FIG. 5 is a block diagram showing the structure of a conventional camera system which includes the rear focus lens and a camera;
FIG. 6 is a graph showing trajectory data of a focus lens unit in connection with object distance and the position of a zoom lens unit;
FIG. 7 is a block diagram showing the structure of a conventional camera system which includes a front focus lens and a camera; and
FIG. 8 is a block diagram showing the structure of a conventional camera system which allows a manual focus support lens and an auto-focus support lens to be used.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention is hereinafter described with reference to the drawings.
The embodiment is described in connection with a camera system which is comprised of an image-taking apparatus such as a television camera and a video camera and a lens apparatus (an interchangeable lens) such as a television lens and a video lens. In the camera system, one camera can be used without changing focus control signals for any types of lenses including a rear focus type and a front focus type, and a manual focus (MF)-capable lens and an auto-focus (AF)-capable lens.
FIG. 1 shows the structure of the camera system in which a lens apparatus of the rear focus type (hereinafter referred to as a rear focus lens) is mounted on a camera. FIG. 2 shows the structure of a camera system in which a lens of the front focus type (hereinafter referred to as a front focus lens) is mounted on the camera. In FIGS. 1 and 2 , components identical to those described in the section “DESCRIPTION OF RELATED ART” are designated with the same reference numerals as those in FIGS. 4 to 8 .
In FIGS. 1 and 2 , reference numeral 101 shows the camera such as a video camera and a television camera (the image-taking apparatus). The camera can be used with both of an AF-capable lens and an MF-capable lens, similarly to that described in FIG. 8 . However, the camera does not have the trajectory data memory 145 shown in FIG. 8 . Reference numeral 401 shows a zoom lens which is realized by a rear focus lens.
On the side of the camera 101 , reference numeral 102 shows an image-pickup element such as a CCD sensor and a CMOS sensor, and 103 shows a camera processing circuit which produces a video signal based on an output signal from the image-pickup element 102 . The video signal is input to an AF circuit 104 . The AF circuit 104 extracts a high-frequency component from the video signal and outputs it as an AF evaluation value signal to a camera control section 105 serving as a controller.
Reference numeral 105 shows the camera control section which produces and outputs a focus control signal for performing AF control based on the AF evaluation value signal from the AF circuit 104 . The camera control section 105 also outputs toward the lens side a zoom control signal and a focus control signal based on operation signals for zoom and focus input from a zoom/focus controller 109 connected to the camera 101 .
The lens 401 shown in FIG. 1 is the rear focus lens which has a focus lens unit 118 placed closer to an image side than a zoom lens unit 132 . The lens 401 has the same optical system structure as that of the optical system of the rear focus lens shown in FIG. 4 .
On the side of the lens 401 , reference numeral 106 shows a zoom position detector which is coupled to a gear 115 a engaging with a zoom ring 111 to detect the position of the zoom lens unit 132 . When the zoom ring 111 is rotated, the zoom lens unit 132 is driven by a cam formed on a fixed barrel (see 137 in FIG. 4 ) in an optical axis direction to provide variable magnification.
Reference numeral 107 shows a zoom motor driver which drives a zoom motor 115 in response to a zoom drive signal from a lens control section 408 .
The lens control section 408 is responsible for control of the entire lens 401 . The lens control section 408 uses an AF control signal from the camera control section 105 and a zoom control signal and a focus control signal from a zoom/focus operation circuit 110 or the zoom/controller 109 to produce drive signals (a zoom drive signal and a focus drive signal) for the zoom lens unit 132 and the focus lens 118 .
The lens control section 408 relies on the focus control signal to produce the focus drive signal for driving the focus lens 118 depending on the type of focus based on lens arrangements such as the front focus type and the rear focus type or based on focus control methods such as manual focus and auto-focus.
The lens control section 408 has a memory, not shown, in which zoom tracking data matching the optical characteristics of the lens 401 is stored therein, corresponding to the trajectory data shown in FIG. 6 .
A zoom operation member 112 and a focus operation member 113 are connected to the zoom/focus operation circuit 110 . The zoom operation member 112 produces and outputs the zoom control signal for servo-driving the zoom lens unit 132 according to an operation amount by a user. The focus operation member 113 produces and outputs the focus control signal for servo-driving the focus lens unit 118 according to an operation amount by a user.
Reference numeral 121 shows a focus motor which is realized by a step motor for driving the focus lens unit 118 . By the focus motor 121 is rotated a screw shaft 123 , to drive a moving frame 122 engaging therewith to the optical axis direction. The moving frame 122 holds the focus lens unit 118 . Reference numerals 119 and 120 show guide bars which guide the moving frame 122 in the optical axis direction.
Reference numeral 125 shows a focus motor driver which drives the focus motor 121 in response to the focus drive signal from the lens control section 408 .
Reference numeral 106 shows the zoom position detector which detects the position of the zoom lens unit on the optical axis. The number of drive pulses input to the focus motor 121 is counted by the lens control section 408 . The count is used to detect the position of the focus lens unit 118 .
On the other hand, a lens 501 shown in FIG. 2 shows a front focus lens in which a focus lens unit 118 is placed closer to an object side than a zoom lens unit 132 . In FIG. 2 , components identical to those in FIG. 1 are designated with the same reference numerals as those in FIG. 1 . A camera 101 is the same as the camera shown in FIG. 1 .
In the lens 501 , reference numeral 114 shows a focus motor which drives the focus lens unit through interlocking gears 114 a and 114 b . Reference numeral 116 shows focus motor driver which drives the focus motor 114 in response to a focus drive signal from a lens control section 508 .
Reference numeral 117 shows a focus position detector which detects the current position of the focus lens unit 118 and transmits it to the lens control section 508 . Reference numeral 124 shows a focus ring which engages with the focus lens unit 118 . The focus ring 124 is rotated by the focus motor 114 to move the focus lens unit 118 to perform manual focusing.
The lens control section 508 is responsible for control of the entire lens 501 , and produces and outputs a zoom drive signal and a focus drive signal for controlling a zoom motor 115 and the focus motor 114 , respectively.
When a focus operation member 113 is operated, an operation signal output from the focus operation member 113 is input to the lens control section 508 as a focus control signal through a zoom/focus operation circuit 110 . Similarly, when a zoom operation member 112 is operated, an operation signal output from the zoom operation member 112 is input to the lens control section 508 as a zoom control signal through the zoom/focus operation circuit 110 . The lens control section 508 produces a focus drive signal and a zoom drive signal based on the focus control signal and the zoom control signal and drives the focus motor 114 and the zoom motor 115 through the drivers 116 and 107 , respectively, to rotate the focus ring 124 and a zoom ring 111 . In this manner, the focus lens unit 118 and the zoom lens unit 132 are driven.
Next, description is made for a processing program used in common to the lens control section 401 of the rear focus lens 401 and the lens control section 508 of the front focus lens 501 in the camera system of the embodiment in which both of the rear focus lens 401 and the front focus lens 501 can be used for the one camera 101 , with reference to a flow chart of FIG. 3 .
In the embodiment, the focus control signal output from the camera control section 105 of the camera 101 is a position signal which represents a drive position (a drive amount) of the focus lens unit 118 or a speed signal which represents a drive direction and a drive speed of the focus lens unit 118 .
The flow of the processing on the side of the AF-capable rear focus lens 401 is first described in the combination of the rear focus lens 401 and the camera 101 shown in FIG. 1 .
At step 101 , the lens control section 408 takes a focus control signal from the camera control section 105 . Then, at step 102 , it determines whether the lens itself is a rear focus lens or a front focus lens.
Since the rear focus lens is used in this case, the flow proceeds to step 103 to determine the current focus mode is an AF mode or an MF mode. In the case of the AF mode, the flow proceeds to step 105 where the lens control section 408 monitors an output from the zoom position detector 106 to determine whether or not the zoom lens unit 132 is being driven (whether or not zooming is being driven).
When it is determined that zooming is not being driven at step 105 , the flow proceeds to step 106 to perform AF processing. The AF processing is later described. When the current focus mode is not the AF mode (that is, it is the MF mode) at step 103 , the flow proceeds to step 111 . At step 111 , it is determined whether or not zooming is being driven similarly to step 105 .
In the AF processing at step 106 , the following control is performed in the camera 101 and the rear focus lens 401 . When a luminous flux from an object passes through the rear focus lens 401 and arrives on a light-receiving surface of the image-pickup element 102 , the luminous flux is photoelectrically converted by the image-pickup element 102 and the resultant electric signal is output therefrom. The camera processing circuit 103 performs various types of processing on the output signal input thereto from the image-pickup element 102 to produce a video signal.
The AF circuit 104 extracts a high-frequency component from a portion of the video signal corresponding to a focus detection area set to the center of the image screen or the like to produce an AF evaluation value signal according to the sharpness (contrast) of the object image. For example, when the focus detection area is set to the center of the image screen, the camera system is always focused on an object present at the center of the image screen.
In normal AF processing without varying magnification (without zoom drive), the camera control section 105 outputs a command signal to the lens control section 408 for causing the focus lens unit 118 to wobble in order to determine the drive direction of the focus lens unit 118 in which the strength of the AF evaluation value signal output from the AF circuit 104 is increased. The camera control section 105 then outputs a focus control signal to the lens control section 408 such that the focus motor 121 is driven in the determined direction by a predetermined number of drive steps. The processing is repeated until the AF evaluation value signal is at the maximum, that is, until an in-focus state is achieved for the object.
When it is determined that zooming is being driven at step 105 or when it is determined that the current focus mode is not the AF mode (it is the MF mode) at step 103 and that zooming is being driven at step 111 , the flow proceeds to step 107 .
At steps 107 to 110 , the following AF processing (zoom tracking processing) is performed in order to correct image plane variations associated with zoom drive to maintain an in-focus state. In this case, the zoom tracking processing has higher priority, and focus control by the camera 101 is not performed.
First, at step 107 , the lens control section 408 takes the current position of the zoom lens unit 132 by the zoom position detector 106 . Next, at step 108 , it calculates the position of the focus lens unit 118 from the count of drive steps for the focus motor 121 . Specifically, the focus lens unit 118 is reset to a predetermined original position (a reference position) at power-up, and the drive steps from the reference position is counted to obtain the relative position of the focus lens unit 118 with respect to the reference position based on the count.
When the focus motor 121 is realized by a DC motor, the position of the focus lens unit 118 can be taken by using a focus position detector similar to the zoom position detector 106 . The detected positions of the zoom lens unit 132 and the focus lens unit 118 are stored in a memory, not shown, in the lens control section 408 .
Next, at step 109 , to perform focus control of moving the focus lens unit 118 on zoom tracking data in association with the zoom drive, the lens control section 408 first calculates a point (an in-focus position) on the zoom tracking data which matches the current position of the zoom lens unit 132 and the current position of the focus lens unit 118 . Next, the lens control section 408 calculates a drive amount of the focus lens unit 118 for moving the focus lens unit 118 corresponding to the movement amount of the zoom lens unit 132 on the zoom tracking data.
The lens control section 408 outputs a focus drive signal necessary for the drive of the calculated drive amount at step 110 , and drives the focus motor 121 through the focus motor driver 125 at step 120 .
When it is determined that zooming is not being driven at step 111 , the flow proceeds to step 112 where it is checked whether the focus control signal from the camera control section 105 is a position signal or a speed signal. In the case of the position signal, the position of the focus lens unit 118 is calculated from the count of drive steps for the focus motor 121 (step 113 ). Then, the lens control section 408 produces a focus drive signal based on the focus control signal and the calculated position of the focus lens unit 118 (step 114 ).
Since position servo is used in this case, the focus motor 121 is stopped when it is determined that the drive position indicated by the focus control signal is equal to the position of the focus lens unit 118 calculated from the count of the drive steps for the focus motor 121 .
On the other hand, when it is determined that the focus control signal is the speed signal (speed servo) at step 112 , the lens control section 408 considers the focus control signal as the speed signal and produces a focus drive signal (step 115 ). Then, it drives the focus motor 121 through the focus motor driver 125 (step 120 ).
Next, description is made for the flow of processing on the side of the front focus lens 501 in the combination of the MF-capable rear focus lens 501 and the camera 101 shown in FIG. 2 .
When the lens control section 501 takes a focus control signal at step 101 , it determines whether the lens itself is a rear focus lens or a front focus lens. Since the front focus lens is used in this case, the flow proceeds to step 104 to check whether the focus control signal is a position signal or a speed signal. In the case of the position signal, the focus position detector 117 takes the position of the focus lens unit 118 (step 116 ).
The lens control section 508 produces a focus drive signal from the focus control signal and the taken position of the focus lens unit 118 (step 118 ). Since position servo is used in this case, the focus motor 114 is stopped when it is determined that the position indicated by the focus control signal is equal to the position of the focus lens unit 118 detected by the focus position detector 117 .
When it is determined that the focus control signal is the speed signal at step 104 , the lens control section 501 considers the focus control signal as the speed signal and produces a focus drive signal (step 117 ).
Then, it drives the focus motor 114 through the focus motor drive 116 (step 120 ).
In this manner, according to the embodiment, it is possible for the lens to determine the type of focus in the lens, that is, the type of the lens arrangement such as the front focus type and the rear focus type, and the type of the focus control method such as the manual focus support and the auto-focus support to produce the focus drive signal according to the determined type based on the focus control signal from the camera side. This eliminates the need to change the focus control signal output from the camera side depending on the type of the lens mounted on the camera. Consequently, a plurality of types of lenses can be used for one camera.
In addition, the focus control calculations are made by using the trajectory data (the zoom tracking data) in the AF-capable lens, so that it is not necessary to transmit the large amount of trajectory data from the lens to the camera. Moreover, it is not necessary for the camera to have a memory for storing the trajectory data or have the function of focus control calculations with the trajectory data.
While a preferred embodiment has been described, it is to be understood that modification and variation of the present invention may be made without departing from the scope of the following claims.
This application claims priority from Japanese Patent Application No. 2003-343923 filed on Oct. 2, 2003, which is hereby incorporated by reference herein.
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A camera system is disclosed which allows different types of lens apparatuses to be used in combination with a single image-taking apparatus without requiring changes of focus control signals on the side of the image-taking apparatus depending on the type of a lens apparatus mounted on the image-taking apparatus. The camera system includes an image-taking apparatus which outputs a focus control signal and a lens apparatus which includes a focus lens and is mounted on the image-taking apparatus. The lens apparatus includes a controller which produces a drive signal according to a type of focus of the lens apparatus based on the focus control signal and controls drive of the focus lens based on the drive signal.
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BACKGROUND OF THE INVENTION
The present invention relates to venetian blinds and more specifically to holders or clips for supporting a valance in front of or around the head of a venetian blind.
A valance for a venetian blind head is desirable in order to eliminate an objectional but unavoidable light gap at the top of the blind. Most blinds have a clearance at the top so that if the installation brackets are fastened overhead, the brackets will provide space above the head for thickness of the bracket and screw heads. If the window jamb is not deeply recessed or if there is a small frame or sash, (such as for instance in metal casement windows) a visible light gap exists. Such gap can be covered with the valance according to the present invention.
It is very difficult to finish the heads of venetian blinds with various colors, designs, and trims since this would involve a costly process and it might be difficult to match the color and design of the head channel and the slats of the venetian blind since they are coated and formed by different processes.
Still further, a window covering would look more attractive aesthetically by having the horizontal slats begin from the very top of the window opening to the bottom rather than starting below the venetian blind head.
In tilting a venetian blind to closed position, the slats have a percentage of overlap which provides better light exclusion and control. However, the top slat cannot overlap the bottom of the head. Therefore, an objectionable light gap may be produced if the blind is not closed fully or in some cases due to mechanical or assembly discrepancies, the gap will even appear when the blind is completely closed.
Finally, a valance gives the interior decorator the option of using a different color scheme for the valance than for the slats, that is to either use contrasting or matching colors or designs in a room.
Basically, the valance consists of two slats, one arranged above the other. The lower slat slightly overlaps the bottom edge of the upper slat in order to disguise any irregularities, ripples, dents or non-parallelness in the slats, especially since the valance is above eye level. Although the thickness of the clip will create a light gap, such gap will not be visible because of the overlap and sight angle.
It is an object of the present invention to provide a variety of holders for supporting a valance at various locations at a venetian blind head channel.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated by way of example in the attached drawings, in which:
FIG. 1 is a top view of a venetian blind head with the valance according to the present invention attached;
FIG. 2 is a front elevation of the venetian blind head and valance of FIG. 1;
FIG. 3 is a side elevation of FIG. 2;
FIG. 4 is a cross section through a venetian blind head with two valances and one embodiment of a holder or clip for attaching the valance to the blind head;
FIGS. 5 and 6 illustrate the holder or clip in front and rear elevation, respectively;
FIG. 7 is a perspective view of a second embodiment of a holder or clip for the valance;
FIG. 8 illustrates a third embodiment of a holder for attaching a portion of the valance to the side of the head of a venetian blind;
FIG. 9 is a side view of the holder of FIG. 8;
FIGS. 10, 11 and 12 are front, side and top views, respectively, of a further embodiment of a holder or clip for attaching a valance to the side of a venetian blind head;
FIGS. 13 and 14 are top views of two embodiments of a venetian blind in which the slats are not directly attached to the sides of the venetian blind head, but instead are somewhat spaced therefrom and attached to a wall or window frame;
FIG. 15 shows a bracket for connection to a wall and to which a holder of FIGS. 11 and 12 can be attached.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawing in detail, and FIGS. 1 to 3 in particular, a venetian blind head generally designated with the reference numeral 10 comprises a head channel 12 with end brackets 14. The head channel contains the usual components for operating a venetian blind, such as a tilter 16 to be operated by a wand 18 (see FIG. 4) or a cord and supports 20 for the ladders 22. All of these elements described so far are conventional and do not form part of the present invention.
A valance 24 consisting for instance of two slats is attached to the head channel by clips or holders 26 (three being shown in FIG. 1). Various valance designs are contemplated and such valances are disclosed in assignee's copending U.S. Design patent application Ser. No. 747,861, filed Dec. 6, 1976. Thus, for instance, FIG. 2 indicates that each valance 24 comprises a central section 28 overlapping two end sections 30, 32, respectively. The end sections 30, 32 are held to the brackets 14 by clips or holders 60 described in detail further below.
A clip or holder 26 for connecting the front valance 24 to the head channel 12 is shown in FIGS. 4 to 6. It comprises a sheet metal body 34 or substantially rectangular shape with a substantially triangular end portion 36. However, end section 36 could likewise be rectangular.
Clip 26 is also provided with three hook-like elements 38, lateral wings 40 and a rear extension 42 including a downwardly sloping portion 44, a substantially horizontal portion 46, a substantially vertical portion 48, and an indented portion 50. These portions are clearly shown in FIG. 4, which figure also illustrates how the clip 26 is attached to a head channel 12 with a downwardly and inwardly folded portion 13. The lateral wings 40 rest against the substantially vertical wall 15 of head channel 12 while section 46 rests on portion 13 and portions 48 and 50 are firmly pressed against portion 13 so that clip 26 assumes a stable position with respect to the head channel 12. Two or more of clips 26 can be arranged along the length of the head channel and valances 28 or 30 may be inserted between the hook-like elements, 38, as likewise shown in FIG. 4.
While clip 26 is shown in FIGS. 4 to 6 as being made from one integral piece of sheet metal, it is to be understood that the clip could also be made from two or more sheet metal pieces if such were desired for manufacturing or other reasons. Thus, for instance, portions 34, 36 and 38 could form one piece, and portions 40 to 50 another piece, which would be connected to the piece forming portions 34, 38, for instance by welding, by connecting elements, such as screws, and in any other convenient manner.
A further embodiment of a clip is illustrated in FIG. 7. Clip 52 shown therein has a main body portion 34 which could essentially be the same as portion 34 of clip 26 with hook-like elements 38. Clip 52 also comprises a downwardly bent portion 54 and an upwardly bent portion 56 substantially parallel to portion 34, and a curved portion 58 which would be substantially the equivalent of portions 46, 48 and 50 of clip 26 (See FIG. 4) in that it fits over portion 13 of channel 12 and could be forced thereover to snap clip 52 in place onto head channel 12 with portion 56 firmly placed against side wall 15.
According to the present invention, a different type of clip or holder is provided for attaching valances to an end bracket, such as bracket 14 shown in FIG. 1. A first embodiment of such a clip is shown at 60 in FIGS. 8 and 9. It comprises a sheet metal body similar to that illustrated in FIG. 6 and designated with reference numerals 34 and 36. It also comprises three hook-like elements 38 and prongs 62 which are adapted to pass through bores 64 customarily provided in such end brackets. In this manner, the prongs 62 can be passed through the bores 64 and the entire clip 60 is slipped downwardly so that the clip comes to a firm rest position by the prongs 62 engaging the inside of bracket 14. A slat 30 is shown in dot dash lines as being attached to clip 60, in FIG. 8.
A very advantageous embodiment of a clip for attaching a valance to the end bracket of a venetian blind head is illustrated in FIGS. 10 to 12. This clip designated with the reference numeral 66 again comprises a sheet metal body 34 with an end section 36 and three hook-like elements 38. It also comprises four tabs 68 struck from the body 34 and extending rearwardly therefrom. Each tab 68 is provided with a slot 70, enabling it to be compressed as it is pushed into an opening such as bore 64 shown in FIG. 8. Since the tabs are resilient they hold securely in brackets and because they are tapered and undercut at 72 they can be used with brackets of different thicknesses. The tabs have sufficient holding power to resist the tension of a valance which has been curved around the brackets. Each after having been removed several times, the tabs continue to hold well. However, if they should lose their grip they can very easily be made effective again by spreading the prongs with a screwdriver or knife blade.
The design of FIG. 13 differs from that of FIG. 1 in that the valance 74 is curved rather than bent at right angles, as is the valance 30 illustrated in FIGS. 1 to 3. Moreover, the bent valance 74 is connected to a window jamb 76 by means of a clip such as clip 66 previously described, which is screwed directly to the jamb 76 by passing screws through holes 67 of clip 66, the hooks or prongs having been flatened by hammerblows or eliminated.
The arrangement accroding to FIG. 14 is similar to that of FIG. 13. However, the curved valance 74 is connected to a bracket 78 attached to a wall. A bracket, such as bracket 66, is interposed between the valance 74 and bracket 78, by passing the tabs 68 through holes 80 of bracket 78.
It is to be understood that the invention is not limited to the embodiments shown and described herein, but only by the scope of the appended claims.
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A holder or clip for supporting a valance in front or around a venetian blind head, with a flat sheet metal body having prongs for holding the valance and having tabs or an especially shaped body portion for connection to the blind head.
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RELATED APPLICATIONS
This application is a continuation-in-part (CIP) of U.S. patent application for “Cell culture apparatus and a fabricating method of the same”, U.S. application Ser. No. 11/446,207, filed Jun. 5, 2006, now U.S. Pat. No. 7,749,761.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cell culture apparatus and the fabricating method of the same, especially to a cell culture apparatus and its fabricating method for cell culturing.
2. Description of Related Art
Conventional cell culture apparatus for in vitro cell culture or bioreactors in laboratories has certain limits in culturing cells for medical uses. Those apparatus, cell culture dish, for example, are not ideal for preserving physiological function of primary mammalian cells which may attribute to deficient of proper physiological conditions on dish, 3D microenvironment and mass transfer system, for example. For most apparatus for cell culture in 3D, said conventional bioreactors, are mostly developed for batch mass production of biologics, recombinant proteins, for examples which demand large volume and complicated operating process.
A couple of technologies have been developed to provide 3D environment of cell in vitro. Preconfigured scaffold made from biomaterials and collagen sponge, for example, provide not only mechanical strength but nutrients deposition which facilitate cell growth and metobolites in 3D form in vitro. Those scaffold, or term “frame”, for cell culture, however, mostly fabricated by sol-gel method which has some limitations on practical application of biomedical uses, which could be summarized as follows: (1) Larger pore size of scaffold lead to cell cluster formation. The pore size of the frame made of the sol-gel method is in the range of 50-100 μm. However, the size of a normal cell is in the range of 5-20 μm. In contrast to smaller size of cells, larger pore size of frame will lead to cluster formation of cells inside scaffold. (2) Limitation of physical scale of pore size fabricated by conventional method: the pore size of a cell culture frame produced by conventional methods is limited to 100 μm, and the precise shape of the frame is not easy to be re-produced due to poor mechanical strength of biomaterials. (3) Poor mass transformation of nutrients in scaffold. Scaffold in bulk form could lead to insufficient nutrients exchange from cell culture medium through inner scaffold which may result in cell apoptosis in inner part of scaffold.
Therefore, it is desirable to provide an improved method to mitigate the aforementioned problems.
SUMMARY OF THE INVENTION
A hydrogel composition, comprising: 50-100 wt % of 2-hydroxyethyl mathacrylate (HEMA); 5-30 wt % of triethylene glycol dimethacrylate (TEGDMA); 5-30 wt % of r-methacryloxypropyl trimethoxysilane (MAPT MS); and 5-15 wt % of α,α-diethoxyacetophenone (DEAP).
The hydrogel composition of the present invention further comprising 5-50 wt % of bisphenol A and glycidyl methacrylate (Bis-GMA).
Another aspect of the present invention is related to a cell culture apparatus comprising: a substrate; and at least one layer of bio-compatible material forming on said substrate, wherein the material is hydrogel composition or photo-sensitive silica gel composition, and a pattern with at least one recess is formed on said layer of bio-compatible material.
Further, a method for fabricating the cell culture apparatus of the present invention is also disclosed. The method comprises the steps of: (a) providing a substrate; (b) forming a layer of bio-compatible hydrogel composition, or photo-sensitive silica gel composition; and (c) forming a pattern of at least one recess on said layer of bio-compatible material by photolithography.
The method for fabricating the cell culture apparatus of the present invention, further comprising the steps of: (d) filling said recess with a sacrificial layer; (e) exposing said recess and rinsing; (f) forming a layer of bio-compatible hydrogel composition, or photo-sensitive silica gel composition; (g) forming a pattern of at least one recess on said layer of bio-compatible material by photolithography; and (h) removing said sacrificial layer.
According to the method of the present invention, a step (b-1) is further comprised between steps (b) and (c). A second substrate is provided on the layer of bio-compatible hydrogel composition or photo-sensitive silica gel composition in step (b-1). Furthermore, a step (a-1) is further comprised between steps (a) and (b). A spacer is provided on the substrate.
Moreover, wherein the steps (d), (e), (f) and (g) can be repeated one to five times as desired.
The material used for the cell culture apparatus have good biocompatible feature. Besides, it is also suitable for manufacturing process of photolithography. Therefore, cell culture apparatus with microfluidic channel can be produced through photolithography in batch through the method of the present invention. Also, the micro-sized (μm) dimension of the cell culture apparatus can be easily controlled. Hence, the cell culture can be re-produced precisely.
Besides, the biocompatible material of the cell culture apparatus has porous structure. Cultured cells can communicate each other by released signals through the porous water gel between different cell culture platforms. The interactions or signal regulations between cells stabilize physical activities of target cells, therefore their lifespan and biological functions can be prolonged.
The present invention also provides a cell culture apparatus, comprising a substrate; and a layer of bio-compatible material forming on said substrate, wherein the material is hydrogel composition or photo-sensitive silica gel composition, and a pattern with at least one recess on said layer of bio-compatible material.
The cell culture apparatus of the present invention is composed with hydrogel composition, which is optionally comprises: bisphenol A and glycidyl methacrylate (Bis-GMA) (viscous material), triethylene glycol dimethacrylate (TEGDMA) (cross linker), r-methacryloxypropyl trimethoxysilane (MAPT MS) (adhesion improving reagent), α,α-diethoxyacetophenone (DEAP) (photo-sensitive agent) or the combinations thereof.
The hydrogel composition preferably comprises: 50-100 weight percentage of 2-hydroxyethyl mathacrylate (HEMA), 0-50 weight percentage, preferably 5-50 weight percentage of bisphenol A and glycidyl methacrylate (Bis-GMA), 5-30 weight percentage of triethylene glycol dimethacrylate (TEGDMA), 5-30 weight percentage of r-methacryloxypropyl trimethoxysilane (MAPT MS), and 5-15 weight percentage of α,α-diethoxyacetophenone (DEAP).
In the method of the present invention, the photolithography of step (c) can comprise any step of conventional photolithography. Preferably, the photolithography of step (c) comprises exposure and development. The light source for photolithography can be any conventional light used for curing bio-compatible materials. Preferably, the bio-compatible material is exposed to UV light.
In the method of the present invention, the substrate can be any conventional substrates. More preferably, the substrate is made from transparent or semi-transparent materials. The substrate material is preferably selected from the group consisting of glass, silicon, plastic, rubber, ceramic and the combination thereof.
In the present invention method, the step of development can be performed through any conventional process. Preferably, the bio-compatible material is developed by any developers. And the developer used in the present method can be any solvent used to dissolve bio-compatible materials, e.g., HEMA. Preferably, the solvent is ethanol, acetone or the mixture thereof. The recess formed on the bio-compatible material can be of any pattern. Preferably, the recess is at least one microfluidic channel.
The width of the microfluidic channel is preferably in a range from 1 μm to 1000 μm, and more preferably is between 1 μm to 100 μm. The material of the sacrificial layer used in the present method is 2-acrylamido-2-methyl-propanesulfonic acid (AMPS), N-isopropyl-acrylamide (NiPAAm) or methacrylic acid (MAA). Preferably, the material of the sacrificial layer is AMPS.
The step (h) in the method of the present invention is preferably achieved by water rinsing. The step (a) is performed by any known process. Preferably, the step (a) is performed by spin coating. The bio-compatible material exposed to UV light undergoes a photo-curing reaction. Preferably, the photo-curing reaction is polymerization.
The bio-compatible material is photo-cured to obtain a micro structure through a photolithography process, such as UV exposure. The micro structure operates in coordination with the pattern of microfluidic channels is so-called a cell micro patterning. The main feature of the cell culture apparatus of the present invention is optionally of a porous or non-porous configuration. The main material of the cell culture apparatus depends on the purposes of cell interaction or cell isolation.
A three dimensional scaffold of the cell culture apparatus is obtained through repeated steps of exposure and development. Different cell lines can have different distributions by simply controlling the flow of microfluid, The cell micro patterning in the cell culture apparatus thus can be obtained. Therefore, the cell culture environment or physical tissue structure in the present cell culture apparatus is more imitative to those in vivo by controlling the distribution or combination of different cells.
Moreover, the water gel composition and the photosensitive silicon composition are transparent or semi-transparent materials. Therefore, it is suitable for embedding the culture plate and proceeding tissue section other than monitoring the lysed bio-molecules.
Furthermore, the cell culture apparatus of the present invention can be connected or equipped with existing microscope systems directly for monitoring in real time.
Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1( a )-( c ) illustrates the flowchart of the fabricating method of the cell culture apparatus in example 1;
FIG. 2 is a diagram illustrating the structure of the cell culture apparatus in example 1 of the present invention;
FIG. 3 is a flow chart of another embodiment in example 2 of the present invention method;
FIG. 4 is the photo of cultured cells in example 1;
FIG. 5 is the photo of cultured cells in example 2.
FIGS. 6( a )-( c ) illustrate the flowchart of the fabricating method of the cell culture apparatus in example 3;
FIG. 7 is a diagram illustrating the structure of the cell culture apparatus in example 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Example 1
The material of the cell culture apparatus of the present invention is a high biocompatible material such as 2-hydroxyethyl mathacrylate (HEMA). The material is optionally combined with viscous material, cross-linker, adhesion improving reagent and photo-sensitive agent. The biocompatible material is photo-cured after exposing to UV light, and the cured material can be adhered well to the substrate of the cell culture substrate.
The biocompatible material of water gel composition of the present invention comprises: 50-100 weight percentage of 2-hydroxyethyl mathacrylate (HEMA), 0-50 weight percentage, preferably 5-50 weight percentage of phenol A and glycidyl methacrylate (Bis-GMA), 5-30 weight percentage of triethylene glycol dimethacrylate (TEGDMA), 5-30 weight percentage of r-methacryloxypropyl trimethoxysilane (MAPT MS), and 5-15 weight percentage of α,α-diethoxyacetophenone (DEAP).
The main material of the cell culture apparatus is HEMA. The Bis-GMA is used as viscous material. TEGDMA acts as the cross-linker, MAPTMS is the adhesion improving reagent, and DEAP is the photosensitive agent. The photosensitive agent in the HEMA can be cured by polymerization through UV light exposure. FIGS. 1( a )-( c ) illustrate the flowchart of the fabricating method of the cell culture apparatus of the present embodiment. First, a substrate 1 is provided, and the substrate material is selected from the group consisting of glass, silicon, plastic, rubber, ceramic and the combination thereof. The biocompatible adhesion-improving reagent of the correlative substrate material is alkoxysilanes, halosilanes, alkylthiols, or alkylphosphonates. In the present embodiment, the substrate material is glass, and the adhesion-improving reagent is MAPTMS.
Second, a layer of biocompatible material is formed on the substrate 1 . In the present embodiment, a first material layer 2 is formed on the substrate 1 by spin coating. The biocompatible material used in the present embodiment comprises: 5 wt % of HEMA, 4 wt % of Bis-GMA, 2.7 wt % of TEGDMA, 2.7 wt % of MAPTMS, and 1.35 wt % of DEAP.
Then, a pattern is formed on the first material layer 2 through photolithography. As shown in FIG. 1( b ), a photomask 3 is aligned over the first material layer 2 to perform exposure. The first material layer 2 exposed to UV light undergoes polymerization and becomes insoluble in the developer. On the contrary, non-exposed portion of the first material layer 2 is not polymerized, meanwhile, the HEMA exists in the form of monomer and it remains soluble in the developer.
Finally, non-exposed portion is removed by the developer, and the molded microfluidic channels defined by the photomask is obtained on the first material layer 2 . The light for exposure in the present invention can be any conventional light used for curing the biocompatible material in the present invention. The developer can be any conventional solvent to remove uncured biocompatible material in the present invention. In the present embodiment, the first material layer 2 is exposed to UV light (365 nm, 100 W/cm 2 ) for 60 seconds with the photomask 3 . A developer containing acetone and ethanol in a ratio of 50:50 is used to remove uncured biocompatible material. A layer of micropattern is formed, and it is used as the platform for cell culturing, as shown in FIG. 1( c ).
The micropattern of the cell culture apparatus of the present invention have at least one recess 21 . The forming process of the recess 21 is different with various patterns of photomasks and the process of photolithography. The size of micropattern is various by different photomasks. In the present embodiment, the micropattern is a microfluidic channel with a width of 5 μm.
Cells with the same or different phenotypes can be cultured in the same cell culture apparatus of the present invention. As it is shown in FIG. 2 , an upper cover 4 is formed with a soft material, such as silicon. There forms an inlet hole 41 and an outlet hole 411 on the upper cover 4 for cells flowing. Then, the upper cover 4 is contact with the first material layer 2 tightly, and the inlet hole 41 of the upper cover 4 is connected to the recess 21 of the first material layer 2 . Cells are applied into to the recess 21 of the first material layer 2 through the inlet hole 41 . The cells are retained in the bottom of the recess 21 (the surface of the substrate 1 ). Circulating culture media is then applied after the cells attached completely. Similarly, the other recess 22 is used for cell culturing by applying cells and culture media through inlet 42 and outlet 422 . The cells culture in the recess 21 and recess 22 can be different or the same.
FIG. 4 shows the photo of cultured cells. The condition for cell culturing is: (1) rinsing the culture plate with micropattern with PBS solution twice; (2) suspending 5×10 5 cells/ml of CA 3 cells in MEM culture medium containing 10% FBS, then seeding the cells into the culture plate for one-day culturing; (3) removing the culture medium and rinsing the plate with PBS for twice, for removing un-attached cells or non-clustered cells. Then, keep monitoring the condition of cell growing.
The cell culture apparatus can be used to monitor the lysed bio-molecules. Moreover, it is suitable for embedding the culture plate and proceeding tissue section, because the HEMA composition and the photosensitive silicon composition are transparent. The biocompatible material used in the present invention is a porous water gel (HEMA). The biological signals (e.g. proteins) released from a cell can be transmitted to another surrounding cell through the porous microstructure. Therefore, the purpose of co-culturing cells achieves. The problem of low growth rate in culturing isolated liver cells in vitro can also be solved. Furthermore, the cell culture apparatus of the present invention performs various combinations of cell lines. It imitates more closely to a real human tissue since the real tissue is composed with multiple cell lines.
Another embodiment is shown in FIG. 3 . The multiple culture layers can be prepared following the method described above. A three-dimensional cell scaffold is formed via spin coating and photolithography. The recesses 21 , 22 on the single layer of cell culture platform, as shown in FIG. 1( c ), are filled with a sacrificial layer 7 . Steps of spin coating and photolithography are repeated to form the second material layer 5 . Then, another photomask 6 is aligned to the second material layer 5 , and the second material layer 5 is exposed to UV light. Polymerization is introduced in the exposed portion of the second material layer 5 . The portion of non-exposed second material layer 5 is then removed by a developer. Thus, a micropattern is formed. In the present embodiment, the micropattern is a microfluidic channel, which has at least one groove with width of 5 μm. Finally, the sacrificial layer 7 is removed. And a three dimensional scaffold of multiple cell culture platforms with network pattern is created. In the present embodiment, the material of the sacrificial layer is AMPS, and it is removed by water rinsing.
Example 2
The material of the cell culture apparatus of the present invention can be a photosensitive silicon composition in place of HEMA composition.
The process is the same as described in example 1. A glass substrate 1 is provided as shown in FIG. 1( a ). About 3 ml of patternable silicon rubber (Corning, WL-5350) is applied onto the glass substrate 1 . The glass substrate 1 is spun on a spin coater in 500 rpm for 30 seconds, and a first material layer 2 with 50 μm thickness is formed. Then, the glass substrate is placed on the hot plate for soft baking under 110° C.-120° C.
Refer to FIG. 1( b ). The silicon rubber (the first material layer 2 ) is exposed to UV light (600-1000 mJ/cm 2 ) in an exposure. The post exposure baking is performed on the glass substrate on the hot plate under 150° C. Subsequently, the cell culture platform is created after developing for one hour by a negative develop reagent, as shown in FIG. 1( c ).
FIG. 5 shows the photo of cultured cell of the present embodiment, and the condition is the same as described in example 1.
Example 3
The example illustrates the method for manufacturing the cell culture apparatus. The microfluidic channel can be formed as well as to bond the upper substrate and the lower substrate together. Therefore, the manufacturing steps and time consuming are saved. The material used in the present example is a biocompatible material, for example, HEMA. Optionally, the viscous material, cross-linker, adhesion improving reagent, and the photosensitive agent are further included. The bio-compatible material is cured after exposed to UV light, moreover, the cured material is adhered well to the substrate of the cell culture apparatus.
The biocompatible material of water gel composition of the present invention comprises the same material as described in example 1: 50-100 weight percentage of 2-hydroxyethyl mathacrylate (HEMA), 0-50 weight percentage, preferably 5-50 weight percentage of phenol A and glycidyl methacrylate (Bis-GMA), 5-30 weight percentage of triethylene glycol dimethacrylate (TEGDMA), 5-30 weight percentage of r-methacryloxypropyl trimethoxysilane (MAPT MS), and 5-15 weight percentage of α,α-diethoxyacetophenone (DEAP).
The main material of the cell culture apparatus is HEMA. The Bis-GMA is used as a viscous material. TEGDMA acts as the cross-linker, MAPTMS is the adhesion improving reagent, and DEAP is the photosensitive agent. The photosensitive agent in the HEMA can be cured by polymerization through UV light exposure. FIG. 6( a )-( c ) illustrates the flowchart of the fabricating method of the cell culture apparatus of the present embodiment. First, a substrate 1 is provided, and the substrate material is selected from the group consisting of glass, silicon, plastic, rubber, ceramic and the combination thereof. And the biocompatible adhesion-improving reagent of the correlative substrate material is alkoxysilanes, halosilanes, alkylthiols, or alkylphosphsnates. In the present embodiment, the substrate material is glass, and the adhesion-improving reagent is MAPTMS.
A first material layer 2 is formed over the substrate 1 by spin coating in the present example. The first material layer 2 is a photoresist, and a structure with predetermined height is formed at the edge of the substrate after photolithography. The height of the next layer of biocompatible material can thus be controlled. As shown in FIG. 6( b ), a layer of biocompatible material 8 is formed on the first material layer 2 and the substrate 1 by spin coating. The biocompatible material used in the present embodiment comprises: 5 wt % of HEMA, 4 wt % of Bis-GMA, 2.7 wt % of TEGDMA, 2.7 wt % of MAPTMS, and 1.35 wt % of DEAP.
Then, an upper cover 9 with patterns (pores 91 ) is stacked on the first material layer 2 . Press the layer of biocompatible material 8 to regulate the thickness of the structure between the upper and the lower layers. A photomask 31 having a pattern 35 is aligned to the pores 91 on the upper cover 9 , and the beginning of the fluid path on the pattern 35 is aligned to the pores 41 to perform exposure. During the photolithography with UV light, polymerization is introduced in the exposed portion of the layer of biocompatible material 8 , where the region would not be removed by the developer. On the contrary, the HEMA material on the portion of non-exposed biocompatible material layer 8 is then removed by a developer because HEMA still remains in monomer.
Finally, non-exposed portion is removed by the developer, and the pattern of molded microfluidic channels 35 defined by the photomask 31 is obtained on the surface of substrate 1 and that of the upper cover 9 . The light source for exposure in the present invention can be any conventional light source used for curing the biocompatible material in the present invention. The developer can be any conventional solvent to remove uncured biocompatible material in the present invention. In the present embodiment, the biocompatible material layer 3 is exposed to UV light (365 nm, 100 W/cm 2 ) for 70 seconds through the photomask 5 . A developer containing acetone and ethanol in a ratio of 50:50 is used to remove uncured biocompatible material. A cell culture apparatus with micropattern is formed between the substrate 1 and the upper cover 9 .
It spends less time in fabricating the cell culture apparatus of the present invention. The structure dimension with micro-size can be controlled precisely, and can be batch re-produced, because the micropattern is formed via photolithography. Besides, since the biocompatible material HEMA forms a porous water gel, cells can communicate each other by released signals through the porous water gel between different cell culture platforms.
In the conventional techniques, the materials used for preparing micropattern via photolithography are PDMS, PEG or other materials without biocompatible feature.
The present invention provides a method for fabricating a multiple-used cell culture apparatus, and it can be produced in large quantity. The apparatus also provides a microenvironment, which closely imitates a native cell environment for a better monitoring of cell metabolism in vitro. In addition, the cell culture apparatus can combine with automatic systems for high throughput and high content drug candidate screening.
Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.
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A cell culture apparatus and a method for fabricating the cell culture apparatus are disclosed, the method comprises forming at least one fillister on a biomaterial composite layer by photolithography, wherein the biomaterial composite layer contains two gel materials. One is a bio-compatible hydrogel composition having various weight ratio of: 2-hydroxyethylmathacrylate (HEMA), bisphenol A and glycidyl methacrylate (bis-GMA), triethylene glycol dimethacrylate (TEGDMA), r-methacryloxypropyl trimethoxysilane (MAPTMS), α,α-diethoxyacetophenone (DEAP), and the other one is a photo-sensitive silica gel composition.
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CROSS-REFERENCE TO RELATED APPLICATION
Cross Reference
This application is a United States national phase application of co-pending international patent application number PCT/US2007/079352, filed Sep. 25, 2007, which claims priority to U.S. Provisional Patent Application No. 60/826,805, filed Sep. 25, 2006, the disclosures of which are incorporated herein by reference.
BACKGROUND
The present invention relates to connection members for components of pressure containing machinery and, more particularly, a coupling guard system for protecting and sealing an interior region of a coupling between components of the pressure containing machinery.
In existing close-coupled pressure containing machinery, the pressure containing device and structural support are combined into one unit. Historically, access to a coupling and its components has been limited due to generally small access ports in an outer casing of the coupling, which are provided for maintenance access. Combining the pressure sealing and structural support components leads to difficulty creating and maintaining a sealing surface between the co-joined equipment when sealing to contain low mole weight gasses.
SUMMARY
In one embodiment, the invention provides a guard system for a coupling that connects a first component to a second component in a pressurized machinery system. The guard system includes a coupling guard moveable between an open position, which allows access to an internal region of the coupling, and a closed position, which forms a seal surrounding the coupling from the first component to the second component. The guard system also includes a guide for directing movement of the coupling guard.
In another embodiment, the invention provides a guard system including a coupling guard moveable between an open position, which allows access to an internal region of the coupling, and a closed position, which forms a seal surrounding the coupling from the first component to the second component. A guide for directing movement of the coupling guard extends between the first component and the second component wherein the coupling guard is moveably coupled to the guide. An adjuster is coupled to the coupling guard for adjusting a position of the coupling guard relative to the guide.
In yet another embodiment, the invention provides a pressure containing coupling guard system for connecting a compressor casing to a drive casing in an industrial compression system. The coupling guard system includes a coupling guard moveable between an open position, which allows access to an internal region between the casings, and a closed position, which forms a seal surrounding the internal region. The coupling guard includes sealing surfaces comprising at least one radial sealing surface at one axial end of the coupling guard and at least one circumferential sealing surface at one axial end of the coupling. The system also includes a guide for directing axial movement of the coupling guard, wherein the guide has a slide bar extending between the compressor casing and the drive casing for aligning the coupling guard to at least one of the casings, and an adjuster for adjusting positioning of the coupling guard on the slide bar.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a close-coupled pressure containing machinery.
FIG. 2 is a perspective view of the machinery shown in FIG. 1 , including a coupling guard system according to one embodiment of the invention and in a closed position.
FIG. 3 is a perspective view of the machinery shown in FIG. 1 , including the coupling guard system shown in FIG. 2 in an open position.
FIG. 4A is an end view of a coupling guard that is part of the coupling guard system shown in FIG. 2 .
FIG. 4B is a sectional view of the coupling guard taken along line 4 B- 4 B of FIG. 4A .
FIG. 5 is a perspective view of a slide adjuster that is part of the coupling guard system shown in FIG. 2 .
FIG. 6 is a perspective view of a slide guide that is part of the coupling guard system shown in FIG. 2 .
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
For example, terms like “central”, “upper”, “lower”, “front”, “rear”, and the like are only used to simplify the description of the present invention and do not alone indicate or imply that the device or element referred to must have a particular orientation. The elements of the retractable pressure containing coupling guard system referred to in the present invention can be installed and operated in any orientation desired. In addition, terms such as, “first”, “second”, and “third” are used herein for the purpose of description and are not intended to indicate or imply relative importance or significance.
DETAILED DESCRIPTION
FIG. 1 illustrates a close-coupled pressure containing machinery system of a type that is suitable for use with the present invention. In FIG. 1 there is specifically shown an industrial compression system 10 , which is used in industry to compress gasses or fluids for industrial purposes. The system 10 might, for example, be used on an oil drilling platform or an oil production platform. The industrial compression system 10 includes two compressors 14 close-coupled to a double-ended electric motor drive 18 . This arrangement allows for a compact design with significant benefits over more traditional base-plate mounted compressor trains. Each compressor 14 is surrounded by a cylindrical compressor casing 22 and the motor 18 is surrounded by a cylindrical motor casing 26 . The compressor casing 22 and the motor casing 26 are separate bodies that are positioned to facilitate installation and removal of components. The compressor casing 22 and the motor casing 26 are connected together with a coupling 30 ( FIG. 3 ), which separates pressure containing components and provides a mechanical support structure for connecting the casings 22 , 26 .
Referring to FIG. 3 , the coupling 30 includes access ports 34 . The ports 34 provide openings to facilitate removal of bearings, seals, gears, electrical connections and other components within an interior region 38 of the coupling 30 while the electrical drive 18 and the compressor 14 remain connected together. The coupling 30 is attached to the compressor casing 22 and the motor casing 26 with an attachment structure that resists various forces thereon. In the illustrated embodiment, a main case attachment structure 42 , or casing, includes threaded studs and nuts for coupling 30 the coupling to the motor casing 26 , and the like may be used for coupling the coupling 30 to the compressor casing 22 . Other means of mechanical attachment may be employed such as shear rings or other commonly used attachment structures. The attachment structure 42 should be sufficiently sound structurally to prevent separation, vibration, disattachment, torquing or other problems in the integrity of the attachment of the compressor casing 22 to the motor casing 26 .
In the illustrated embodiment, a coupling guard system 46 covers the coupling 30 to allow increased maintenance access to the coupling 30 and the associated components while maintaining a high degree of sealed joint integrity. The coupling guard system 46 is a retractable, pressure containing guard system. The coupling guard system 46 separates pressure containing components of the machinery system 10 from structural support components, and maintains a pressure seal over the access ports 34 in the coupling 30 . It is desirable that the pressure containing structure 46 is independent of the main structural mechanical connection 30 ; therefore, a pressure containing sealing surface is not subject to mechanical loads associated with support and operation of the equipment. As an independent structure, the pressure containing sealing surface provides ease of maintenance and sealing integrity.
FIG. 2 illustrates the coupling guard system 46 in a closed position to protect the coupling 30 , and FIG. 3 illustrates the coupling guard system 46 in an open position to allow access to the coupling 30 . In the open position, access to the interior region 38 of the coupling 30 is gained through the ports 34 . In the closed position, the ports 34 are covered by a coupling guard 50 , or cover, in order to seal the coupling 30 and components contained within the coupling 30 . The coupling guard 50 is mounted to the machinery system 10 for axial movement, and may be locked into position to form a sealing surface over the coupling 30 .
The coupling guard system 46 includes the coupling guard 50 ( FIGS. 4A and 4B ), two pairs of slide blocks 54 ( FIG. 5 ), or adjusters, and two slide guides 58 ( FIG. 6 ), or bars. The coupling guard 50 is generally cylindrical and includes an exterior surface 62 and an interior surface 66 . In the illustrated embodiment, the coupling guard 50 is constructed as a single ring having no bolted joints. The guard 50 includes two slots 70 defined on the exterior surface 62 with the slots 70 spaced approximately 180° apart. For example, one slot 70 is provided at a nine o'clock position and the other slot 70 is at a three o'clock position to control alignment and axial movement of the guard 50 . Each slot 70 is defined by a pair of radially extending projections 74 , and receives a slide guide 58 for sliding movement thereon. A radially extending flange 78 extends between the first and second slots 70 . Structural ribs, lifting lugs, vents, drains and injection connections in the coupling guard 50 may be varied as appropriate and necessary. Any connecting hardware, pattern of openings, construction of casing and direction that the coupling guard retracts may be varied as appropriate or necessary.
At each axial end 82 of the coupling guard 50 , sealing members 86 , 90 are positioned such that when the coupling guard system 46 is in the closed position, the sealing members 86 , 90 operate to prevent pressurized gases from escaping from the interior region 38 of the coupling 30 . The sealing members 86 , 90 provide a high integrity seal when the coupling guard system 46 is in the closed position. Various locations for the sealing members 86 , 90 may be used as long as seal integrity is maintained. In the illustrated embodiment, the coupling guard 50 includes the sealing members 86 , 90 or elements to facilitate sealing between the coupling guard system 46 , the coupling 30 and the casings 22 , 26 . Sealing member 86 is positioned on a radial surface at each axial end 82 of the coupling guard 50 . Sealing members 90 are positioned on the interior surface 66 of the coupling guard 50 at each axial end 82 . In one embodiment, the sealing members 86 , 90 each include a groove formed in the surface of the coupling guard 50 and an O-ring 94 received and retained in the groove. The diameter on which each groove is placed is minimally different so as to minimize axial forces exerted on the coupling guard 50 from the pressurized contents. In one embodiment, the sealing members 86 , 90 have similar construction in order to minimize axial forces.
As shown in FIGS. 2 and 3 , one pair of slide blocks 54 is attached to the projections 74 defining each slot 70 . Each slide block 54 ( FIG. 5 ) includes first and second end surfaces 98 and first and second side surfaces 102 . An aperture 106 extends through the first and second end surfaces 98 for slidingly receiving a slide bar 110 extending from the motor casing 26 towards the compressor casing 22 . The slide bar 110 provides directional guidance to the coupling guard system 46 . At least one side surface 102 of the slide block 54 includes a pair of apertures 114 for coupling the block 54 to the coupling guard 50 . In the illustrated embodiment, a roller 118 is positioned between the coupling apertures 114 for facilitating sliding movement of the coupling guard 50 along the slide guides 58 . The roller 118 is directed toward the slot 70 such the respective slide guide 58 is sandwiched between the coupling guard slot 70 and the slide block 54 . The slide blocks 54 are used as a manual slide adjuster to axially move the coupling guard 50 relative to the casings 22 , 26 . It should be readily apparent to those of skill in the art that other types of friction reducing components, such as low-friction inserts, may be used in the slide blocks 54 .
The coupling guard system 46 includes the two slide guides 58 for providing directional guidance and support to the coupling guard 50 in axial movement between the closed position and the open position. Each slide guide 58 extends between the compressor casing 22 and the motor casing 26 , as is coupled thereto. In one embodiment, the slide guides 58 may operate as an assembly tool. In still another embodiment, rollers may be provided in the slide guides 58 for facilitating sliding movement of the coupling guard 50 . Referring to FIG. 2 , a lock block 122 is positioned between the coupling guard 50 and a motor casing end of the slide guide 58 to prevent axial movement of the coupling guard 50 when in the closed position. It should be readily apparent to those of skill in the art that other known locking mechanisms may be used. Further, fewer or more slide guides 58 may be used. Also, other means for positioning and directing movement of the coupling guard 50 , such as a linear tab engaging a slot or other type of similar positioning member, may be used.
In FIGS. 2 and 3 , only one side of the coupling guard system 46 is shown; therefore, only one pair of slide blocks 54 and one slide guide 58 is shown. The second pair of slide blocks 54 and second slide guide 58 is located on the opposite side of the coupling guard system 46 . That is, the slide blocks 54 and slide guides 58 are positioned approximately 180° degrees apart on each side of the coupling guard 50 .
Referring to FIG. 2 , the retractable pressure containing coupling guard system 46 is shown in a closed position. In the closed position, the sealing members 86 , 90 engage mating surfaces on the compressor casing 22 and motor casing 26 to form a sealed enclosure around the coupling 30 . A lock block 122 is positioned between the coupling guard 50 and a motor casing end of the slide guide 58 to prevent axial movement of the coupling guard 50 . The lock block 122 provides a positive axial stop, while allowing the coupling guard 50 to float on the sealing surfaces 86 , 90 as necessary during equipment operation. The lock block 122 is removed or moved to a non-blocking position in order to move the coupling guard system 46 to the open position.
To move the coupling guard system 46 to the open position, a user utilizes the slide blocks 54 , or manual slide adjusters, to physically slide the coupling guard 50 along the slide guides 58 . Rollers 118 on the slide blocks 54 facilitate sliding movement of the coupling guard 50 . In a further embodiment, electric, hydraulic or pneumatic mechanisms may also be employed as a means to slide the coupling guard 50 between the closed position and the open position.
The coupling guard system 46 enables opening and closing of the coupling guard 50 with a simple, convenient process, and provides for ease of maintenance and sealing integrity.
The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention.
Since other modifications, changes and substitutions are intended in the foregoing disclosure, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
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A guard system for a coupling that connects a first component to a second component in a pressurized machinery system includes a coupling guard moveable between an open position, which allows access to an internal region of the coupling, and a closed position, which forms a seal surrounding the coupling from the first component to the second component. The system also includes a guide for directing movement of the coupling guard.
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FIELD OF THE INVENTION
The present invention relates to systems for controlling electric motors and, more particularly, to a system for deriving an accurate stator resistance estimate for use by electric motor controllers.
DESCRIPTION OF THE ART
Induction Motors
Induction motors have broad application in industry, particularly when large horsepower is needed. A three phase induction motor receives three phases of electrical voltage to produce a rotating magnetic stator field. A rotor contained within the stator field experiences an induced current (hence the term induction) which generates a rotor field. The interaction of the rotor field and the stator field causes rotation of the rotor.
A common rotor design is a "squirrel cage winding" in which axial conductive bars are connected at either end by shorting rings to form a generally cylindrical structure. The flux of the stator field cutting across the conductive bars induces cyclic current flows through the bars and across the shorting rings. The cyclic current flows in turn produce the rotor field.
The use of this induced current to generate the rotor field eliminates the need for slip rings or brushes to provide power to the rotor, making the design relatively maintenance free.
Field Oriented Control Of Induction Machines
To a first approximation, the torque and speed of an induction motor may be controlled by changing the frequency of the driving voltage and thus the angular rate of the rotating stator field. Generally, for a given torque, increasing the stator field rate will increase the speed of the rotor (which follows the stator field). Alternatively, for a given rotor speed, increasing the frequency of the stator field will increase the torque by increasing the slip, that is the difference in speed between the rotor and the stator field. An increase in slip increases the rate at which flux lines are cut by the rotor, increasing the rotor generated field and thus the force or torque between the rotor and stator fields.
Referring to FIG. 9, the rotating phasor 1 of the stator magneto motive force ("mmf") will generally have some angle α with respect to the phasor of rotor flux 2. The torque generated by the motor will be proportional to the magnitudes of these phasors 1 and 2 but also will be a function of their angle α. The maximum torque is produced when phasors 1 and 2 are at right angles to each other (e.g., α32 90°) whereas zero torque is produced if these phasors are aligned (e.g., α=0°). The phasor 1 may therefore be usefully decomposed into a torque producing component 3 perpendicular to the phasor 2 and a flux component 4 parallel to rotor flux phasor 2.
These two components 3 and 4 of the stator mmf are proportional, respectively, to two stator currents i qe , a torque producing current, and i de , a flux producing current, which may be represented by orthogonal vectors in the rotating frame of reference (synchronous frame of reference) of the stator flux having slowly varying magnitudes.
Accordingly, in controlling an induction motor, it is generally desired to control not only the frequency of the applied voltage (hence the speed of the rotation of the stator flux phasor 1) but also the phase of the applied voltage relative to the current flow and hence the division of the currents through the stator windings into the i qe and i de components. Control strategies that attempt to independently control the currents i qe and i de are generally termed field oriented control strategies ("FOC").
Ideally, the torque is established by the applied voltage and slip of the invertor. In reality, however, various other operating parameters that change during motor operation alter the torque-slip relationship. Therefore, where precise motor operation is required, various feedback loops are used to monitor stator winding currents and voltages and/or motor speed.
The controller uses feedback information to determine how the invertor supplied voltage must be altered to compensate for system disturbances due to changing operating parameters, and then adjusts control signals to ensure the correct invertor voltage is supplied. Unfortunately, the machine parameter values that establish the invertor supplied voltage change over time. The changing motor parameter values make controller adjustments ineffective when variations in operating parameter values are not accounted for.
For example, the production of any given set of currents i qe and i de requires that the stator be excited with voltages V qe and V de as follows:
V.sub.qe =r.sub.s i.sub.qe +ω.sub.e λ.sub.de ( 1)
V.sub.de =r.sub.s i.sub.de -ω.sub.e λ.sub.qe ( 2)
where:
V qe , V de =terminal voltages;
r s =stator resistance;
i qe , i de =terminal current components;
ω e =electrical field frequency;
λ de , λ qe =flux linkage components;
and where:
r s i de , r s i qe =invertor supplied voltages; and
ω e λ de , ω e λ qe =counter electromotive forces (EMFs).
Stator resistance r s changes with temperature and stator winding temperature increases as the average current through the winding increases. Thus, in a variable speed motor, when invertor supplied voltage and current is increased or decreased, stator resistance r s is subject to change which in turn results in an unexpected demand in stator voltage.
Similarly, the counter EMFs are affected by stator winding current adjustments. The rotor field, which is indirectly induced by the stator winding current, itself induces a current in the stator windings resulting in the counter EMFs. Thus, any change in stator winding current indirectly changes counter EMF values.
Complicating matters further, the stator resistance r s and counter EMFs change by varying degrees when the stator winding current is adjusted. Thus, in order to achieve precise motor control, precise determination of both stator resistance r s and counter EMFs would be helpful.
U.S. Pat. No. 5,298,847, issued Mar. 29, 1994, describes one way to accurately determine a counter EMF in an electric motor by determining the phase angle of the stator current within the dq frame of reference and transforming feedback voltages into a new d'q' frame of reference defined by a phase angle. In the new d'q' frame of reference, stator current i s is in quadrature with the d'-axis voltage component V' de and thus, there is no r s i component on the d'-axis. The d'-axis voltage is the counter EMF ω e λ' qe and thus, the counter EMF ω e λ' qe can be found.
Unfortunately, no simple and precise method to determine stator resistance r s has been developed. Some methods to estimate stator resistance r s that are presently used in the industry require massive amounts of CPU time in order to determine and update stator resistance values and the resulting values often are not sufficiently accurate. Others link the estimator to a control loop that incorporates a pure integrator. These too are normally insufficiently accurate.
The industry has also developed ways to measure stator resistance r s directly by injecting test signals into the stator windings and observing alterations in motor parameters. However, such signal injections inevitably result in motor system disturbances which are unacceptable where precise motor operation is required.
Thus, it would be advantageous to have a non-invasive, non-disturbing method and/or apparatus that could dynamically and accurately determine stator resistance during motor operation without requiring a huge amount of processor time.
SUMMARY OF THE INVENTION
The present invention comprises a non-invasive system for accurately determining stator resistance values in an electric motor during motor operation. The system of the present invention includes a mechanism for determining the phase angle of the stator current within a dq frame of reference and a mechanism for transforming feedback voltages within the dq frame of reference into a new d'q' frame of reference wherein the q'-axis is in phase with the stator current and the d'-axis is in quadrature therewith. Because the stator current is in quadrature with the d'-axis, there is no r s i component in the d'-axis. Thus, the d'-axis feedback voltage component V' deF is equal to the counter EMF ω e λ' qe . By comparing the counter EMF ω e λ' qe to the commanded counter EMF ω e λ qe '*, a counter EMF error is derived. The error can be eliminated by forcing the counter EMF ω e λ qe ' to be identical to a commanded counter EMF ω e λ qe '*. When this is done, both the q' and d'-axis counter EMFs are controlled and equal the commanded counter EMFs ω e λ de '*, ω e λ qe '* respectively.
Once the counter EMFs ω e λ' de , ω e λ' qe are forced to conform to the commanded counter EMFs ω e λ de '*, ω e λ qe '*, the q'-axis invertor supplied current i' qe is equal to a q'-axis command current i qe '* because there is no d'-axis command current component i de '*. Thus, Equation 1 can be rewritten as:
V'.sub.qeF =r.sub.s i.sub.qe '*+ω.sub.e λ.sub.de '* (3)
Solving Equation 3 for the stator resistance r s : ##EQU1## Deriving a stator resistance estimate r s is then simply a matter of subtracting the q'-axis command counter EMF (ω e λ de '*) from the q'-axis feedback voltage V' qeF and dividing by the q'-axis command current (i qe '*).
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1(a)-1(c) provide three graphs in the dq frame of reference showing a number of important electrical quantities characteristic of the operation of an AC induction motor;
FIG. 2 provides a block diagram of a converter system which utilizes the present invention in generating both a voltage error signal and a stator resistance estimate;
FIG. 3 provides an overall block diagram of a control system for use in controlling an AC induction motor according to the present invention;
FIG. 4 provides a detailed block diagram of a processing unit of FIG. 3;
FIG. 5 provides a block diagram of the major process program routines within the software for the digital controller shown in FIG. 4;
FIG. 6 is a detailed block diagram of the low speed slip control shown in FIG. 5;
FIG. 7 is a detailed block diagram of the high speed slip control shown in FIG. 5;
FIG. 8 is a detailed block diagram of the flux control mechanism shown in FIG. 5; and
FIG. 9 schematic view in cross-section of an induction motor showing instantaneous locations of the rotor flux, the stator mmf, and the torque and flux components of the stator mmf.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the description that follows, an "*" denotes a "command" signal, an "e" subscript denotes that a signal is referred to the synchronous reference frame, an "s" subscript denotes that a signal is referred to the stationary frame of reference and an "F" subscript denotes that a signal is a feedback signal.
In addition, for the purposes of the following description, due to the phase shift between current and voltage and cross coupling of the speed voltages, d-axis voltage parameters relate to torque/slip and q-axis voltage parameters relate to flux while d-axis current parameters relate to flux and q-axis current parameters relate to torque/slip. In order to simplify this explanation, however, parameters will simply be referred to their respective d, q, d' and q'-axis.
As well known, a voltage phasor is a function of various operating characteristics such that in steady state d and q-axis voltage components in a rotating frame of reference can be expressed according to Equations 1 and 2 above.
Thus, each voltage component V qe , V de in steady state is the sum of two voltages, an invertor supplied voltage represented by an r s i term and a counter EMF represented by an ω e λ term. The invertor supplied voltages r s i result from the stator current flowing through stator windings wherein the windings have a combined resistance r s .
The counter EMFs result from rotation of the dq reference frame at an angular velocity ω e . In the synchronous frame, the stator flux linkages produce the counter EMFs, thus affecting stator winding voltages.
Referring to FIG. 1(a), the graph 10 depicts the vectorial relationships between the invertor supplied and counter EMF voltages and the voltage and current phasors within a rotating d-q frame of reference. Included in FIG. 1(a) are a stator voltage phasor 18 (V s ) and a stator current phasor 19 (i s ) related to and lagging behind the voltage phasor 18. Also included on FIG. 1(a) are the invertor supplied voltages 20, 21 (r s i de , r s i qe ), counter EMFs 12, 14 (ω e λ de , ω e λ qe ), d and q-axis current components 11, 13 (i qe , i de ), and d and q-axis voltage components 15, 16 (V de , V qe ).
The stator current phasor 19 (i s ) can be expressed as:
i.sub.s =i.sub.qe +ji.sub.de (5)
and the stator voltage phasor 18 can be expressed as:
V.sub.s =V.sub.qe +jV.sub.de (6)
where the real components of Equations 5 and 6 are functions of stator resistivity and the imaginary components are functions of inductance and thus are frequency dependant.
Clearly, referring also to Equations 1 and 2, in order to ascertain either of the counter EMF voltages ω e λ de , ω e λ qe from the d and q axis voltages 15, 16 (V qe or V de ), it is necessary to determine the value of an associated invertor supplied voltage r s i qe or r s i de . Similarly, any attempt to determine stator resistance based on the d and q-axis voltages V qeF , V deF leads to inherent contamination by one or the other counter EMFs 12, 13 (ω e λ de , or ω e λ qe ).
Importantly, for purposes of the present invention, by performing a coordinate transformation on the d and q-axis voltages 15, 16 (V de , V qe ), the stator voltage 18 (V s ) can be observed in a new frame of reference which simplifies its expression and facilitates control of the counter EMF components and determination of the stator resistance r s .
Referring to FIG. 1(b) the current phasor 19 (i s ) lags the q-axis by a conversion angle Φ. A new coordinate system can be chosen by shifting the q-axis by the conversion angle Φ such that a new q-axis (i.e. a q'-axis) is in phase with the current phasor 19 (i s ) and a new d'-axis is in quadrature therewith. Then, by performing a coordinate transformation on the d and q-axis voltages 15, 16 (V de , V qe ) both d' and q'-axis voltages 17, 29 (V' deF , V' qeF , see FIG. 1(c)) can be derived.
Referring still to FIG. 1(b) the d'-axis voltage V' deF is in quadrature with the current phasor 19 (i s ). The d'-axis invertor supplied voltage (r s i' de ) is therefore zero because the d'-axis current component i' de is zero. In the d'q' frame of reference, Equation 2 simplifies to:
V'.sub.deF =-ω.sub.e λ'.sub.qe (7)
By comparing the d'-axis counter EMF ω e λ' qe to a d'-axis command counter EMF ω e λ qe '*, a d'-axis voltage error V' derr can be derived. The controller can then compensate for the d'-axis voltage error V' derr to drive the motor at the d'-axis commanded counter EMF ω e λ qe '*.
As well known in the art, because the counter EMFs ω e λ' qe , ω e λ' de are interrelated (i.e. to change one, both must be altered), when one counter EMF is corrected the other counter EMF is automatically corrected. In the present case, when the d'-axis counter EMF ω e λ' qe is corrected and forced to equal the d'-axis con, hand counter EMF ω e λ qe '*, the q'-axis counter EMF ω e λ' de is corrected and forced to equal the q'-axis command counter EMF ω e λ de '*.
Referring again to Equation 4, after sensing the q-axis voltage V qe , transforming the q-axis voltage V qe to the d'q'frame of reference to produce the q'-axis voltage V' qeF , and deriving the q'-axis command counter EMF ω e λ de '* and current i qe '* values, an accurate stator resistance estimate r s can be derived.
Referring now to FIG. 2, a stator resistance identifier 56 may be implemented using hardware but more often will be implemented using software run on a standard motor controlling microprocessor such as a model 8096 microelectronic processor as supplied by Intel Corporation of Santa Clara, Calif. The stator resistance identifier 56 includes seven operational blocks 62, 64, 66, 68, 70, 72, and 74 for receiving six inputs V qeF , V deF , i* de , i* qe , ω e λ* qe , and ω e λ* de representing synchronous digital d and q-axis voltage feedback signals, current command signals, and counter EMF command signals respectively. The identifier 56 generates both a d'-axis counter EMF error signal V' derr and a stator resistance estimate r s for use in motor control.
In block 62 a ratio i* de /i* qe of command currents is formed and the arc tangent of this ratio is taken to generate the conversion angle Φ representing the angular displacement between the q-axis and the q'-axis shown in FIG. 1(b). In the block 64, the voltage feedback signals V qeF and V deF undergo a coordinate transformation as a function of the conversion angle Φ to yield d' and q'-axis voltage signals V' qeF and V' deF . Referring also to FIG. 1(b), the d'-axis voltage signal V' deF is derived according to Equation 6 below:
V'.sub.deF =V.sub.deF cos Φ-V.sub.qeF sin Φ (8)
Similarly, referring to FIG. 1(c), the q'-axis voltage signal V' qeF can be derived according to Equation 7 below:
V'.sub.qeF =V.sub.qeF cos Φ+V.sub.deF sin Φ (9)
In the block 66 the command counter EMF signals ω e λ* qe and ω e λ de * also undergo a coordinate transformation as a function of the conversion angle Φ to produce d' and q'-axis command voltage signals V de '* and V qe * (i.e. d'-axis and q'-axis command counter EMF signals ω e λ qe '* and ω e λ de '*) according to the following equations:
V.sub.de '*=-(ω.sub.e λ*.sub.de) (sin Φ)-(ω.sub.e λ*.sub.qe) (cos Φ) (10)
V.sub.qe '*=(ω.sub.e λ*.sub.de) (cos Φ)-(ω.sub.e λ*.sub.qe)(sin Φ) (11)
The d'-axis voltage signal V' deF and the d'-axis command voltage signal V de '* are both in quadrature with the stator current and therefore, both of these values are free from contamination due to stator resistance effects (i.e. there is no i' de or i* de component and therefore there can be no r s i' de or r s i de '* voltage drop). According to Equation 7, the d'-axis feedback voltage signal is equal to the actual d'-axis counter EMF ω e λ' qe .
By subtracting the d'-axis command counter EMF ω e λ qe '* (or V de '*) from the d'-axis counter EMF ω e λ' qe (or V' d ) an error signal can be derived. To this end, the d'-axis voltage signal V' deF (or ω e λ' qe ) and the d'-axis command voltage signal V de '* (or ω e λ qe '*) are fed to summer 70 where they are differenced to generate the voltage error signal V' derr . A controller uses the voltage error signal V' derr to alter the invertor frequency through the slip gain so that the d'-axis voltage V' deF (or ω e λ' qe ) is identical to the d'-axis command voltage V de '* (or ω e λ qe '*). The details of the circuitry for a suitable controller to conform the d'-axis voltage V' deF to the d'-axis command voltage V de '* have been previously shown and described in Kerkman, et al., U.S. Pat. No. 5,298,847 issued Mar. 29, 1994 which is incorporated herein by reference.
The q'-axis voltage signal V' qeF and q'-axis command voltage signal V qe '*, unlike their d'-axis counterparts, are highly dependent on stator resistance r s and thus include stator resistance information. The q'-axis voltage V' qeF and command voltage V qe '* signals are differenced at summer 72 to generate a q'-axis voltage error signal V' qerr .
The d and q-axis command currents i* de , i* qe are also provided to block 68 which produced a q'-axis command current signal i q '* according to Equation 12 below: ##EQU2##
Because the q'-axis is in phase with the stator current i s , the q'-axis current is equal to the q'-axis commanded current i qe '* (i.e. is equal to the stator current i s ).
The q'-axis voltage error signal V' qerr is divided by the q'-axis command current signal i q '* at block 74 to produce the stator resistance estimate r s .
Referring now to FIG. 3, the present invention will be described in the context of a current regulated pulse width modulated (PWM) motor control 23 that receives a command velocity signal ω* r and produces voltage pulse trains V as , V bs and V cs to drive a motor 22 at the command velocity ω* r . A processing unit 37 determines a stator resistance estimate r s that can be used with adaptive controllers to adjust the slip gain and field current command to maintain field orientation and flux control as described in more detail in Kerkman et al., U.S. Pat. No. 5,032,771 issued Jul. 16, 1991.
The motor control 23 (also called a "drive") includes a power section that receives power at a line frequency of 60 Hz from a three phase AC power source 24. The three phases of the power source are connected to an AC/DC power converter 26 and the power section of the drive. The AC/DC power converter 26 rectifies the alternating current signals from the AC source 24, to produce a DC voltage (VDC) on a DC bus 27 that connects to power inputs on a pulse width modulating (PWM) invertor 28, which completes the power section of the drive. The AC source 24, the AC/DC power converter 26, and DC bus 27 provide a DC source for generating a DC voltage of constant magnitude. The PWM invertor 28 includes a group of switching elements which are turned on and off to convert this DC voltage to pulses of constant magnitude.
The pulse train pattern from a PWM invertor is characterized by a first set of positive going pulses of constant magnitude but of varying pulse width followed by a second set of negative going pulses of constant magnitude and of varying pulse width. The RMS value of this pulse train pattern approximates one cycle of a sinusoidal AC waveform. The pattern is repeated to generate additional cycles of the AC waveform. To control the frequency and magnitude of the resultant AC power signals to the motor, AC invertor control signals are applied to the PWM invertor.
The processing unit 37 produces d and q-axis digital synchronous command current signals i* qe , i* de and a digital electrical velocity signal ω* e to drive the PWM invertor 28. Because the invertor 28 responds to stationary, analog, three phase voltage signals, the command current signals i* qe and i* de and velocity signal ω* e must be converted accordingly. To this end, the command current signals i* qe , i* de are provided to a synchronous-to-stationary converter 53 that transforms the signals into the stationary reference frame according to the following matrix equation: ##EQU3##
Next, the stationary command current signals i* qs , i* ds and angular velocity signal ω* e are provided to a digital-to-analog converter 54. At the converter 54, the command current signals i* qs , i* ds and angular velocity signal ω* e are multiplied by V REF to arrive at the proper signal level for input to the current regulator 32. The details of the current regulator 32 have been previously shown and described in Kerkman, et al., U.S. Pat. No. 4,680,695 issued Jul. 14, 1987, and that patent is incorporated herein by reference.
The current regulator 32 produces d and q-axis voltage command signals V* ds , V* qs which are provided to a 2-3 phase converter 30 as well known in the art. The q-axis leads the d-axis by 90° in phase difference. The 2-3 phase converter 30 converts the d and q-axis voltage command signals V* ds , V* qs into three phase balanced voltage command signals V as *, V bs *, and V cs * to drive the PWM invertor 28. The balanced voltage signals vary in phase by 120°.
The PWM voltage invertor 28 receives the three balanced voltage command signals. The magnitude and the frequency of these signals determines the pulse widths and the number of the pulses in pulse trains V as , V bs , and V cs which are applied to the terminals of the motor. The voltages V as , V bs , and V cs are phase voltage signals incorporated in the line-to-line voltage observed across the stator terminals.
Two main control loops are provided that include various converters and sensors that supply information to the processing unit 37 for use in determining how the command currents i* qe , i* de must be altered to drive the motor 22 at the command velocity ω* r . The first is a feedback loop that supplies winding voltage information. The second is either a feedback or observer loop that provides position information.
In the first loop, stator voltages V as , V bs , V cs across the stator windings are sensed using voltage sensing devices (not shown) of a type known in the art. The signals V as , V bs , V cs are fed back through a 3 to 2 phase converter 31 that produces d and q-axis feedback voltage signals V qsF and V dsF . The feedback signals V qsF and V dsF are received by a stationary-to-synchronous transformer 35 which transforms the voltages from the stationary reference frame to a synchronous reference frame producing feedback voltage signals V qeF and V deF according to the following matrix equation: ##EQU4## The synchronous signals are passed through an analog-to-digital converter 46 producing digital feedback voltage signals. The voltage feedback quantities V qeF and V deF become inputs to routines run by the processing unit 37.
The second control loop may includes a position detector or a position observer. The position detector may be a resolver 44 that is coupled to the motor 22. The position observer estimates the position through techniques known in the art and generates a rotor position signal θ r . As the rotor rotates, the position is determined either through the sensor or the observer. The rotor position signal θ r is provided to an A to D converter 40 which produces a digital rotor position signal. The velocity is then estimated by any of the techniques known in the art by the processing unit 37.
Referring now to FIG. 4, the processing unit 37 includes a controller 36 and various other components which will be described in more detail below. The rotor position signal θ r is operated on by a differential operator 80 to form a rotor velocity estimate ω r . The rotor velocity signal ω r is subtracted from the command velocity ω* r at summer 45 to produce a velocity error signal e.sub.ω. The error signal e.sub.ω is provided to a proportional-integral (PI) controller 43 that produces a torque-related q-axis command current signal i* qe . The q-axis command current signal i* qe is provided to a multiplier 42 and the controller 36.
Referring now to FIG. 5, the controller 36 consists of a plurality of different control mechanisms including a stator resistance identifier 56, a slip control for both low and high frequencies 58, and a flux control 60. As explained above in reference to FIG. 2, the stator resistance identifier 56 receives the voltage feedback signals V qeF , V deF and command current and counter EMF signals i* de , i* qe , ω e λ* de , ω e λ* qe produces a d'-axis voltage error signal V' derr and a stator resistance estimate r s . Once the d'-axis voltage signal V' derr and the stator resistance estimate r s are determined, these values can be used in the dq frame of reference to control the motor.
Referring also to FIGS. 6 and 7, the slip control 58 includes different control mechanisms for high and low speed control. Referring to FIG. 6, when motor speed is less than a predetermined value, say 30 Hz, the d'-axis voltage error V' derr is multiplied by the sign of the d'-axis voltage command V*' d at multiplier block 47 and the resulting signal is provided to a proportional-integral (PI) controller 48 to produce a slip constant K s .
Referring to FIG. 7, when the motor speed is greater than 30 Hz, the stator resistance estimate r s is multiplied by the d-axis command current i de * at multiplier block 49 to produce a d-axis voltage estimate signal V rde . The d-axis voltage estimate signal V rde is subtracted from the d-axis feedback voltage V deF at summer 50 to produce an estimated d-axis counter EMF ω e λ qeF . The d-axis command counter EMF ω e λ* qe is subtracted from the d-axis estimated counter EMF ω e λ qeF at summer 54 and the resulting signal is multiplied by the sign of the d-axis voltage command V* d at multiplier block 7. The resulting signal is provided to a PI controller 55 which provides the slip constant K s .
Referring again to FIG. 4, the slip constant value K s is multiplied by the q-axis command current signal i* qe at multiplier 42. The product is the slip angular velocity ω s . The slip angular velocity ω s is summed with the rotor angular velocity at summer 39 to produce the electrical frequency ω* e . Integrating the electrical frequency ω* e at integrator 8 provides the electrical angular position θ e which is used by the stationary to synchronous and synchronous to stationary converters 35, 53.
Referring now to FIG. 8, the flux control 60 is similar to the high speed slip control shown in FIG. 7. The flux control 60 receives the stator resistance estimate r s and the q-axis command current signal i* qe and multiplies the two values at multiplier 100 to produce a q-axis voltage estimate V rqe . The q-axis estimate V rqe is subtracted from the q-axis feedback voltage signal V qeF at summer 102 to produce an estimated q-axis counter EMF ω e λ deF . The estimated counter EMF ω e λ de is subtracted from the command counter EMF ω e λ* de at summer 104 and the resulting signal is provided to a proportional-integral controller 106 to produce the d-axis command current signal i* de .
The stator resistance estimate could be used for a plurality of different motor control purposes. In the present application, the stator resistance estimate is described as being used to determine both the angular electrical velocity ω* e and d-axis current command signal i* de .
Thus, a simple and non-intrusive method of determining stator winding resistance has been disclosed. While a technique for controlling rotor velocity using the resistance estimate has been disclosed, the inventive part of the disclosure is limited to a method and apparatus for determining a stator resistance estimate by shifting to the d'q' frame of reference and calculating the stator resistance in that frame after correcting the counter EMF values.
While this description has been by way of example of how the present invention can be carried out, those with experience in the art will recognize that various details may be modified to design other detailed embodiments, and that many of these embodiments will come within the scope of the invention.
For example, the invention could be used with many different feedback loop configurations or motor controllers that operate in the dq frame of reference. In addition, the resistance estimate can be used for many different motor control operations including, but not limited to, temperature monitoring using a look-up table or other scale means. Moreover, while an apparatus has been described, the invention is not so limited and should include a method wherein feedback voltages are converted into d and q-axis components in a synchronous dq frame of reference, the phase angle of the current command vector in the dq frame of reference is determined, the V de and V qe voltage components are operated on to generate new voltage components V' de , V' qe in a new coordinate frame of reference where the q'-axis is defined by the phase angle and the d'-axis in quadrature with the q'-axis, and the voltage component V de ', does not include a voltage drop component. The method also includes determining the value of the current command vector, operating on a command counter EMF components to generate new q' and d'-axis command counter EMF components, forcing the d'-axis voltage component V' de to conform to the d'-axis command counter EMF component, whereby such conforming also conforms a q'-axis counter EMF component to a q'-axis command counter EMF component, mathematically combining the q'-axis voltage component V' qe and the q'-axis command counter EMF to produce a voltage error signal, and mathematically combining the voltage error signal and the current command vector to produce a stator resistant estimate.
Therefore, to apprise the public of the scope of the invention and the embodiments covered by the invention the following claims are made:
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A non-invasive system for accurately determining the stator resistance in an electric motor during motor operation. The system includes a mechanism for determining the phase angle of the stator current within the dq frame of reference and a mechanism for transforming feedback voltages into a new frame of reference defined by this phase angle. Counter EMFs are detected which are free of stator resistance and used to force the counter EMF components of the stator winding voltages to conform to desired values. The stator resistance is then derived using simple mathematical relationships between the resistance, stator current, feedback voltage and known counter EMF values.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent Application No. 10-2011-0060457, filed on Jun. 22, 2011 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure in one or more embodiments relates to an emergency evacuation installation against fire. More particularly, the present disclosure relates to an emergency evacuation installation for providing evacuees with a backup shelter when isolated from a vulnerable emergency exit or other means of evacuation until the arrival of rescue workers against firing or burning poisonous gas, while the evacuation installation is normally self-concealed resisting damages from rain and weather elements, swiftly attached, possessing an elegant external appearance, and is selectively movable between the floors of a building.
BACKGROUND
[0003] As the majority of the population is concentrated in cities, ever increasing number of high-rise buildings are erected for more and more people to live and work in a limited space.
[0004] For concern of human fatality in the high-rise buildings in case of fire, it has been stipulated to install emergency exits and fire doors, or a rappelling type descender or various other means have been provided as an alternative emergency escape, although a very small number of the prospective users might be familiar with the use of such contraption, setting aside how well they could actually follow the emergency maneuvering of the descender with fear.
[0005] Besides, the emergency exit, for example is where the most people converge and is thus occasionally incapacitated. In addition, a fire door is typically installed at the emergency exit for preventing a flow of smoke and flames but it is often made to work only with the manual operation of a volunteer, which may happen rarely. In this case, the emergency exit tends to function as the smoke chimney, rather resulting in the spread of a fire. There have been reports of a substantial number of casualties occurred due to the adverse effect of the fire door which exposes the victims unprotected to the flame and even more deadly poisonous gas.
[0006] The present applicant proposed a safe escape technology in Korean Patent Registration No. 10-099824-00000 Nov. 29, 2010 entitled “The installation to evacuating from a fire” with a box-type collapsible fixture placed on veranda or balcony to allow isolated persons from an emergency exit to safely escape from flames and noxious fumes until rescuers arrive for help. However, such facilities may not be aesthetically pleasing as they are publically visible between occasional services, and they are susceptible to oxidation corrosions at various metallic panels and hinges in wet weather hampering the full durability.
[0007] In addition, there may be a difficulty for the general public to maneuver those facilities in the collapsing and expanding operations, and the suggested configurations could be regarded as structurally unstable.
DISCLOSURE
Technical Problem
[0008] Therefore, present disclosure in one or more embodiments provides a self-concealed emergency evacuation installation which is adapted to visually blend in with the exterior of a building to improve aesthetic appearance thereof, prevent elements such as rainwater from seeping inside, provide a transit rescue pod for occupants when isolated from an emergency exit or other means of evacuation to escape from flames and noxious fumes until rescuers arrive for help, give the occupants a sense of structural stability, while the evacuation installation is swiftly installed movably between the floors of the building.
SUMMARY
[0009] The present emergency evacuation installation includes a frame, a rear panel, a couple of side panels, a bottom panel, a top panel and an emergency ladder.
[0010] The frame is fixed to the railing of the veranda having double entrance doors respectively hinged on both sides of the frame and each having a knob projecting forward and a pair of first ladder docking holes extending vertically through the frame and opening towards the upper surface of the frame. The rear panel of a rectangular shape is disposed rearward of the frame and provided with a flange formed by forward right-angled bending of the periphery of the rear panel with an exit door formed centrally of the rear panel. The side panels each includes a first and a second panel which are interconnected in an inwardly folding arrangement by a number of corresponding first hinges and each side panel is also connected at its front and rear ends by a number of second and third hinges foldably with the rear portion of the inside of the frame and one lateral end of the rear panel, respectably. The bottom panel has a lateral end attached to a number of fourth hinges formed inside of a lower end portion of the frame, at least one air inlet hole with a closing and opening plate adjustably disposed thereover, a lower sliding door configured to be pushed sideways to slide open a predetermined portion of the bottom panel, and a pair of second ladder fixture holes extending through the bottom panel and located between the lower sliding door and the double entrance doors so that the bottom panel is expanded until it is stopped by a lower section of the flange of the rear panel to complete the floor surface as the emergency evacuation installation is deployed. The top panel has a lateral end attached to a number of fifth hinges formed inside of an upper end portion of the frame and an upper sliding door configured to be pushed sideways to slide open a predetermined portion of the top panel, and engages, when deployed, a downward surface of an upper section of the flange. And the emergency ladder is installed inside of one of the double entrance doors and has upper hooks each bent into a forward curve terminated by a distal end which can be inserted in each of the second ladder fixture holes and foots which can be inserted in another pair of first ladder docking holes of a down stair emergency evacuation installation once the emergency evacuation installation is repeated in a column over the building.
Advantageous Effects
[0011] According to the present disclosure as described above, various components of the present emergency evacuation installation attached to the balcony are not exposed to the outside as the installation is neatly enclosed to blend in the exterior of a building while in constant readiness for deployment in case of emergency and thereby allows unhindered use thereof with a contribution to aesthetics of the building. Further, the emergency evacuation installation is configured to prevent damages and corrosions caused by rain and such elements by cutting off rainwater in particular, so as to relieve the concerns of possible accident due to damage of the parts.
[0012] In addition, the present emergency evacuation installation at the balcony of a building provides the occupants with a protected rescue pod to enter for evading flames and toxic gases to save casualties before rescue help arrives and usually folds flat with the minimal footprint to block field of vision. At the same time, the present installation with a sturdy fixed frame ensures the user to get a sense of structural and psychological stability. Further, the present installation has a bottom panel deployed by its own weight and the top panel that is deployed with the assistance of a hydraulic cylinder suspension into active service of the emergency evacuation installation with ease.
[0013] Moreover, the present emergency evacuation installation provides emergency ladders adapted to engage installations on lower floors when a floor-to-floor evacuation is available for the occupants to readily escape against inaccessibility to the fire door and emergency staircase to further reduce possible casualties.
DESCRIPTION OF DRAWINGS
[0014] FIGS. 1 to 8 are diagrams of an emergency evacuation installation according to a first embodiment of the present disclosure.
[0015] FIGS. 9 to 11B are diagrams of an emergency evacuation installation according to a second embodiment of the present disclosure.
[0016] FIGS. 12 to 14B are diagrams of an emergency evacuation installation according to a third embodiment of the present disclosure.
[0017] FIGS. 15 to 19G are diagrams of an emergency evacuation installation according to a fourth embodiment of the present disclosure.
[0018] FIG. 20 is diagram of an emergency evacuation installation according to an alternative embodiment of the present disclosure.
[0019] FIGS. 21 to 29E are diagrams of an emergency evacuation installation according to a fifth embodiment of the present disclosure.
[0000]
REFERENCE NUMERALS
1″: Balcony/Veranda
2″: Frame
3″: Rear Panel
4″: Side Panel
5″: Bottom Panel
6″: Top Panel
7″: Emergency Ladder
8″: Locking Means
DETAILED DESCRIPTION
[0020] Therefore, the following detailed description of some embodiments of the present disclosure with reference to the drawings will render those skilled in the art to readily understand and reproduce the exemplary configurations.
[0021] FIG. 1 is a perspective view of an emergency evacuation installation shown as collapsed according to some embodiments of the present disclosure, FIG. 2 a perspective view of an expanded state thereof, FIG. 3 an exploded perspective view, and FIG. 4 a plan view of a collapsed state thereof. Finally, FIG. 5 is a plan view of the expanded state of the evacuation installation.
[0022] As illustrated in the drawings, the emergency evacuation installation according to a first embodiment may be in a rectangular form and fixed to a veranda 1 of a building at a railing 11 . The present installation includes a rectangular frame 2 having an entrance 21 (doors 22 ′ FIG. 18 and 22 ″ FIG. 26 a ) at the front side, a rear panel 3 disposed rearward of the frame 2 and having an exit door 31 , two side panels 4 , a bottom panel 5 and a top panel 6 , which jointly constitute a box-type of emergency escape shelter and is collapsible as bellows.
[0023] The present installation also includes a front cover 7 and a rear cover 8 . The front cover 7 conforms to and tightly surrounds the rectangular frame 2 and extends rearward until it terminates at a first press-fit flange 71 which is bent inwardly at right angle. The rear cover 8 includes a main body fixed to the rear surface of the rear panel 3 with an opening formed not to interfere with the opening and closing of the exit door 31 and outer edges extending forward from the main body at right angle until it terminates at a second press-fit flange 82 from another inward right-angle bending so that the second flange 82 abuts the first flange 71 while the evacuation installation is fully collapsed.
[0024] The present disclosure recognizes that using various fabric or plastic sheets as an easy covering over such emergency installation may become an added risk factor to the actual emergency and time-sensitive situations for the building occupants who are trapped in an abrupt fire, if they are required to find the covered installation and get into the uncovering process with those sheets before using the same. Therefore, the emergency installation in this embodiment is configured to bring no possible interference with its intended operation and to enclose any unsightly and/or sensitive components protectively and invisibly as best as possible. To this end, the first and second press-fit flanges 71 and 82 typically maintain a close contact with each other to prevent damage to the components by reducing water from seeping into the interior of the installation. FIG. 6 is a perspective view in accordance with an extended example of the first embodiment of the present disclosure, FIG. 7 a plan view according to the present embodiment, FIG. 8 a conceptual diagram, wherein the front cover 7 further has a flame deflector 72 formed by gradually enlarging four side walls of the front cover 7 in a slant rearward and then reducing into a stepped end. This deflects and relieves uncontrollable flames from directly or indirectly heating up the inside of the installation even though it is adapted to comprise an insulating member for preventing heat transmission. Here, the flame deflector 72 is configured to guide the flame along inclined surface thereof for reducing the effect of heat or flame on the top panel 6 , bottom panel 5 and especially side panels 4 .
[0025] FIG. 9 is a plan view of a collapsed state of an emergency evacuation installation according to a second embodiment of the present disclosure, FIG. 10 a plan view of an expanded state thereof, and FIGS. 11A and 11B are side cross-sectional views of the same, wherein one of the first and second press-fit flanges 71 , 82 extends further inward and bends right toward the other along a slight extension and then bends again perpendicularly and outwardly to additionally form a draining section 83 .
[0026] It is important to address corrosion which occurs rapidly around the components of the emergency evacuation installation including vulnerable hinges to the direct exposure to rainwater or humid winds causing reduced durability thereof. In view of this, the enclosure of the present embodiment is advantageously provided with a protective means as the draining section 83 arranged for collecting and expelling any intruded water.
[0027] FIG. 12 is a plan view of a collapsed state of an emergency evacuation installation according to a third embodiment of the present disclosure, FIG. 13 a plan view of an expanded state thereof, and FIGS. 14A and 14B are side cross-sectional views of the same, wherein the emergency evacuation installation has sealing mounting ribs 73 , coupling ribs 84 and a sealing member 9 . In this example, the sealing mounting ribs 73 are adjacent to the rear ends of the front cover 7 and extend by branching inwardly followed by rearward extensions to jointly form grooves along the rear boundary line of the front cover 7 . The coupling ribs 84 extend at right angle from the front ends of the rear cover 8 and bend again to the front so that they are distally inserted in the grooves of the sealing mounting ribs 73 . At this time, the sealing member 9 may have the shape of a rectangular ring with a corresponding groove along the rear ends of the front cover 7 .
[0028] As described above, the seal member may be more positive method for resolving the problems of water and air leakages.
[0029] FIG. 15 is a perspective view of an expanded state of an emergency evacuation installation according to a fourth embodiment of the present disclosure, FIG. 16 a rear perspective view of an expanded state of the same installation of FIG. 15 , FIG. 17 an exploded perspective view, and FIG. 18 a perspective view of a collapsed state thereof, wherein the emergency evacuation installation is adapted to be mounted in the form factor of a box normally collapsed and readily deployed for accommodating a plurality of occupants safely in emergency situations such as fires.
[0030] The present emergency evacuation installation includes a rectangular frame 2 ′, a rear panel 3 ′, a couple of side panels 4 ′, a bottom panel 5 ′, a top panel 6 ′ and an activation bar 7 ′. The frame 2 ′ is fixed to the railing 11 ′ of the veranda 1 ′ having double doors 22 ′ respectively hinged on both sides of the frame and each having a knob 21 ′ projecting forward. The rear panel 3 ′ of a generally rectangular shape is disposed rearward of the frame 2 ′ and provided with a bottom flange 31 ′ and a top flange 32 ′ formed respectively by forward right-angled bending of the rear panel 3 ′ at its bottom and top ends with an exit door 33 ′ formed centrally of the rear panel 3 ′ so that it is externally accessed for opening. The side panels 4 ′ each includes a first and a second panel 41 ′ and 42 ′ which are bisected vertically and interconnected in a foldable arrangement by a number of first hinges 43 ′ and each side panel 4 ′ is also connected at its front and rear ends by a number of second and third hinges 44 ′, 45 ′ foldably with the rear portion of the inside of the frame 2 ′ and one lateral end of the rear panel 3 ′, respectably. The bottom panel 5 ′ has a lateral end attached to a number of fourth hinges 51 ′ formed inside of a lower end portion of the frame 2 ′ and at least one air inlet hole 52 ′ with a closing and opening plate 53 ′ adjustably disposed thereover so that the bottom panel 5 ′ is dropped until it is stopped by the bottom flange 31 ′ of the rear panel 3 ′ to complete the floor surface as the emergency evacuation installation is deployed. The top panel 6 ′ has a lateral end attached to a number of fifth hinges 61 ′ formed inside of an upper end portion of the frame 2 ′ and engages, when deployed, the bottom surface of the top flange 32 ′ of rear panel 3 ′. The activation bar 7 ′ is elongated and has one end fixed to the upper surface of the top flange 32 ′ of the rear panel 3 ′ and the opposite end passing through a guide hole 23 ′ formed in the frame 2 ′ and terminating by a handle portion 71 ′. The activation bar 7 ′ is divided into two sections articulated by a hinge 72 ′ so placed that it passes the guide hole 23 ′ with all the panels collapsed and then bends vertically downwards to rest.
[0031] The above-described configuration allows the emergency evacuation installation to be fixedly mounted to the railing 11 ′ of the veranda 1 ′ for the occupants to make a quick temporary escape from the flames and toxic gases of fire. To this end, the emergency evacuation installation basically employs non-combustible materials while maintaining the interior space sealed from outside and allowing fresh air to flow in from the atmosphere selectively through the air inlet hole 52 ′ to prevent the toxic gases from intruding.
[0032] More detailed description of the operation will be provided referring to the illustrative drawings.
[0033] FIGS. 19 a ˜ 19 g are conceptual views of the steps of using the emergency evacuation installation according to the fourth embodiment. The activation bar 7 ′ normally lays flat between the double doors 22 ′ and it may be held under an optional key plate 8 ′ having grooves 81 ′ for inserting both knobs 21 ′ to fasten the activation bar 7 ′ and the double entrance doors 22 ′ altogether. In case of failed evacuation from fire, the user can remove the key plate 8 ′ first, lift the activation bar 7 ′ about the hinge 72 ′ to be horizontal, and then push it by the handle 71 ′.
[0034] Thus, the rear panel 3 ′ is pushed rearward to unfold the side panels 4 ′, i.e., the first and second side panels 41 ′, 42 ′ by means of the first hinges 43 ′ out of their collapsed mode. Such deployments of the side panels 4 ′ are accompanied by horizontal unfolding of the bottom panel 5 ′ by its own weight.
[0035] At this time, in some embodiments of the present disclosure, the frame 2 ′ is additionally provided with a hydraulic cylinder 24 ′ having one end fixed to an interior portion of the frame 2 ′ and the opposite end fixed to the top panel 6 ′ to easily deploy the top panel 6 ′ even without a manual endeavor.
[0036] Further, in other embodiments, two or more ball casters 54 ′ are additionally installed on the bottom panel 5 ′ where it makes close lateral contacts with the side panels 4 ′ to minimize frictions therebetween.
[0037] This is intended to prevent the critical interference of the close side panels 4 ′ with the deployment of the bottom panel 5 ′. In this way, the bottom panel 5 ′ and top panel 6 ′ are adapted to be opened until they come into close contact with the bottom flange 31 ′ and top flange 32 ′ and transform into a full box shaped safety pod where the users enter by the doors 22 ′ and are covered until rescued by people on the ground or rescue workers.
[0038] At this time, the air inlet holes 52 ′ can be installed with an air filter for effectively blocking the toxic gases. In addition, the exit door 33 ′ in the rear panel 3 ′ is desirably arranged to have a lock accessible only from outside for preventing the occupants from opening it inadvertently and thereby precluding the danger of falling until rescue workers get to unlock the door 33 ′. In this case, the bottom panel 5 ′ that takes the load of the occupants can additionally use a reinforcement which includes one or more wires 25 ′ and corresponding wire guides 46 ′ to advantageously distribute the load to bear. The wires 25 ′ each has one end attached to an upper portion of the frame 2 ′ and the other end attached to the bottom panel 5 ′ at either lateral end near where it contacts with the lower flange 31 ′ of the rear panel 3 ′, and the length of the wire 25 ′ is determined to permit the bottom panel 5 ′ to unfold up to the horizontal limit. The wire guide 46 ′ is formed as a long tube installed in the first side panel 4 ′ that is coupled to the frame 2 ′ for the wire 25 ′ to run through the wire guide 46 ′ which is installed in the corresponding orientation to the wire 25 ′ when activated with the bottom panel 5 ′ expanded.
[0039] FIG. 20 is an exploded perspective view of an emergency evacuation installation according to a modified embodiment of FIG. 19 , whereby illustrating a heat insulating material 9 ′ installed on the outer surfaces of the respective panels 2 ′, 3 ′, 4 ′, 5 ′, 6 ′ for example.
[0040] The present embodiment employs the heat insulating material 9 ′ to address the heat of the flame which will be delivered to the occupants through the evacuation installation if it is simply made with metal which then can work as a medium of heat to cause burns or extreme conditions for the occupants to bear.
[0041] FIG. 21 is a perspective view of an emergency evacuation installation when collapsed, according to a fifth embodiment of the present disclosure, FIG. 22 a perspective view of an expanded state, FIG. 23 shows the expanded state in rear perspective view, FIG. 24 a bottom perspective view of the expanded state, and FIG. 25 is an exploded perspective view thereof.
[0042] As illustrated, the emergency evacuation installation is adapted to be attached to one side of a railing 11 ″ of a veranda 1 ″ in a building in the form factor of a box normally collapsed and readily deployed for accommodating a plurality of occupants safely in emergency situations such as fires.
[0043] The present emergency evacuation installation includes a frame 2 ″, a rear panel 3 ″, a couple of side panels 4 ″, a bottom panel 5 ″, a top panel 6 ″ and an emergency ladder 7 ″. The frame 2 ″ is fixed to the railing 11 ″ of the veranda 1 ″ having double entrance doors 22 ″ respectively hinged on both sides of the frame and each having a knob 21 ″ projecting forward and a pair of first ladder docking holes 23 ″ extending vertically through the frame 2 ″ and opening towards the upper surface of the frame 2 ″. The rear panel 3 ″ of a rectangular shape is disposed rearward of the frame 2 ″ and provided with a flange 31 ″ formed by forward right-angled bending of the periphery of the rear panel 3 ″ with an exit door 32 ″ formed centrally of the rear panel 3 ″. The side panels 4 ″ each includes a first and a second panel 41 ″ and 42 ″ which are interconnected in an inwardly folding arrangement by a number of corresponding first hinges 43 ″ and each side panel 4 ″ is also connected at its front and rear ends by a number of second and third hinges 44 ″, 45 ″ foldably with the rear portion of the inside of the frame 2 ″ and one lateral end of the rear panel 3 ″, respectably. The bottom panel 5 ″ has a lateral end attached to a number of fourth hinges 51 ″ formed inside of a lower end portion of the frame 2 ″, at least one air inlet hole 52 ″ with a closing and opening plate 53 ″ adjustably disposed thereover, a lower sliding door 54 ″ configured to be pushed sideways to slide open a predetermined portion of the bottom panel 5 ″, and a pair of second ladder fixture holes 55 ″ extending through the bottom panel 5 ″ and located between the lower sliding door 54 ″ and the double entrance doors 22 ″ so that the bottom panel 5 ″ is expanded until it is stopped by a lower section of the flange 31 ″ of the rear panel 3 ″ to complete the floor surface as the emergency evacuation installation is deployed. The top panel 6 ′ has a lateral end attached to a number of fifth hinges 61 ″ formed inside of an upper end portion of the frame 2 ″ and an upper sliding door 62 ″ configured to be pushed sideways to slide open a predetermined portion of the top panel 6 ″, and engages, when deployed, a downward surface of an upper section of the flange 31 ″. The emergency ladder 7 ″ is installed inside of one of the double entrance doors 22 ″ and has upper hooks 71 ″ each bent into a forward curve terminated by a distal end which can be inserted in each of the second ladder fixture holes 55 ″ and foots which can be inserted in another pair of first ladder docking holes 23 ″ of a downstairs emergency evacuation installation once the emergency evacuation installation is repeatedly attached in a column over the building.
[0044] The above-described configuration allows the emergency evacuation installation to be fixedly mounted to the railing 11 ″ of the veranda 1 ″ for the occupants to make a quick temporary escape from the flames and toxic gases of fire. To this end, the emergency evacuation installation employs non-combustible materials while maintaining the interior space sealed from the outside and allowing fresh air to flow in from the atmosphere selectively through the air inlet hole 52 ″ to prevent the toxic gases from intruding. The emergency evacuation installation further includes the emergency ladder 7 ″ to easily interlink with a similar emergency evacuation installation downstairs and thereby enabling floor-to-floor migrations of the evacuees and escape to safer one of those emergency evacuation installations once they are adopted up and downstairs in the building.
[0045] More detailed description of the operation will be provided referring to the illustrative drawings.
[0046] FIGS. 26 a ˜ 26 g are conceptual diagrams illustrating a process of using the installation for the purposes of emergency evacuation in accordance with the exemplary embodiment of the present disclosure. FIG. 27 is a conceptual diagram of the disclosed installation activated by an occupant according to an embodiment of the present disclosure.
[0047] The aforementioned drawings additionally show a locking means 8 ″ ( FIGS. 23 , 26 b ) including a locking member 82 ″, a rotational link 87 ″, a locking bracket 84 ″ and a first wire 89 ″. The locking member 82 ″ is formed as a U-hook with two arms penetrating the rear panel 3 ″ from its front upper portion towards the rear and secured in place with a pair of cotter pins or locking pins 81 ″ pressed through holes formed distally of the two arms. The locking bracket 84 ″ is attached to a top inner portion of the frame 2 ″ and has a locking groove 83 ″ for accepting an insertion of the front end of the locking member 82 ″. The rotational link 87 ″ is rotatably mounted on the locking bracket 84 ″ and has one end provided with a hook 85 ″ for responsively latching the locking member 82 ″ as it enters the locking groove 83 ″ and the opposite end provided with a wire connecting portion 86 ″. The first wire 89 ″ is connected at its one end to the wire connecting portion 86 ″ of the rotational link 87 ″ and is guided up and then draped down terminating with a release knob 88 ″.
[0048] In the above example, with the entrance doors 22 ″ open, one can recognize the visible release knob 88 ″ of the locking means 8 ″ to pull the rotational link 87 ″ out of engagement with the locking member 82 ″ for releasing it from the locking groove 83 ″ of the locking bracket 84 ″.
[0049] Thus, the back panel 3 ″ may be pushed rearward, the side panels 4 ″, i.e. first and second panels 41 ″, 42 ″ are unfolded about the first hinges 43 ″, when the bottom panel 5 ″ expands horizontally by its own weight about its articulated junction by the fourth hinge 51 ″. To ensure easier performance of the deployment process, the present disclosure in some embodiments additionally installs a first pair of hydraulic cylinders 24 ″, a second pair of hydraulic cylinders 25 ″ and a third pair of hydraulic cylinders 26 ″. The first pair of hydraulic cylinders 24 ″ are fixed at the proximal ends, for example to the interior of the frame 2 ″ with the distal ends being fixed to the top panel 6 ″ to thrust the top panel 6 ″ in the intended direction of deployment. The second pair of hydraulic cylinders 25 ″ is fixed at the proximal ends to the interior of the frame 2 ″ with the distal ends being fixed to the bottom panel 5 ″ to thrust the bottom panel 5 ″ in its intended direction of deployment. And the third pair of hydraulic cylinders 26 ″ is fixed at the proximal ends to the lower rear portion of the frame 2 ″ with the distal ends being fixed to the second side panels 42 ″ to thrust the first and second side panels 41 ″, 42 ″ in their intended direction of deployment.
[0050] The present embodiment uses the first through third pairs of hydraulic cylinders 24 ″, 25 ″ and 26 ″ to obviate the need for a manual endeavor of even the elderly or children, saving the precious energy and attention in the emergency situations.
[0051] Another method for automatically deploying the emergency evacuation installation is to install a torsion spring on each of the hinges. The present disclosure in some embodiments provides torsion springs 46 ″ ( FIG. 24 ) mounted on the rotation axes of the first hinges 43 ″ for interconnecting the first and second side panels 41 ″ and 42 ″ to urge these panels towards their intended positions of deployment.
[0052] Upon expansions of the series of panels in case of fire, victims can enter the established emergency evacuation installation away from the flame and toxic gas until rescue workers and people on the ground come to rescue. At this time, the air inlet holes 52 ′ can be installed with an air filter for effectively blocking the toxic gases. In addition, the contact surface between the entrance doors 22 ″ and the frame 2 ″ may be fitted with a gasket 27 ″ for preventing harmful gas and smoke from entering the interior of the installation through a clearance about the doors 22 ″. In addition, the exit door 33 ″ in the rear panel 3 ″ is desirably arranged to have a lock accessible only from outside for preventing the occupants from opening it inadvertently and thereby precluding the danger of falling until rescue workers get to unlock the door 33 ″.
[0053] FIGS. 28B and 28A are conceptual diagrams illustrating a process by collapsing the emergency evacuation installation according to the present embodiment which further includes at least one second wire 92 ″ having distal ends attached to upper portions of the first side panels 41 ″ near the second side panels 42 ″ and at least one proximal end which extends to the inner upper central portion of the frame 2 ″, passes through a least one opening 91 ″ of the frame 2 ″ and then drape down. Also included is a pull handle 93 ″ attached to the free end of the second wire 92 ″.
[0054] This embodiment addresses the considerable difficulty of refolding the installation after use and eliminates the risk of falling of a user in the process. Specifically, folding the side panels 4 ″ by the pull handle 93 ″ will force the top panel 6 ″ and bottom panel 5 ″ into the collapsed positions, and a further pulling brings the locking member 82 ″ of the locking means 8 ″ to enter the locking groove 83 ″, when the hook 85 ″ of the rotational link 87 ″ keeps the locking member 82 ″ into the latched position.
[0055] FIGS. 29A˜29E are conceptual diagrams for illustrating a process of using the present emergency evacuation installation as an elevation means according to the present embodiment. With a series of such emergency evacuation installations provided up and down on a veranda 1 a ″ and its next veranda 1 b ″ for example, if fire breaks out leaving downstairs less damaged from flame or toxic gas with incapacitated emergency exit and other means of access, the occupants upstairs can first deploy their own evacuation installation to open the lower sliding door 54 ″ of the bottom panel 5 ″, insert the upper hooks 71 ″ of the emergency ladder 7 ″ in the second ladder fixture holes 55 ″, and links the ladder 7 ″ by inserting its foots into the first ladder docking holes 23 ″ of the downstairs emergency evacuation installation. Then, the evacuees can proceed to downstairs to find better routes to evacuate the building.
[0056] As the evacuees find no appropriate means of evacuation downstairs, they can decide to use the downstairs installation while descending by pulling out the locking pins 81 ″ of the locking member 82 ″ to deploy the installation and entering there through the upper sliding door 62 ″ of the top panel 6 ′, which can be repeated down to the ground.
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Disclosed is a fire evacuation installation. When evacuees are not able to evacuate through an emergency exit or other means of evacuation when a fire occurs, the fire evacuation installation may safely protect the evacuees from flames and poisonous gas until rescue workers arrive. Further, the fire evacuation installation may be prevented from being damaged by exposure to rain, and the fire evacuation installation may have an elegant outer appearance and be more easily installed. In addition, the fire evacuation installation may be selectively moved between the floors of a building.
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FIELD OF THE INVENTION AND RELATED ART
[0001] The present invention relates to a driving force transmitting device using a pulley and a belt member and relates to an electrophotographic image forming apparatus, including such a driving force transmitting device, such as a copying machine, a facsimile machine, a printer or a multi-function machine.
[0002] In the image forming apparatus such as the copying machine or a printer, the driving force transmitting device for rotationally driving a photosensitive drum which is an image bearing member or rotationally driving an intermediary transfer belt is required to have a high-precision rotation performance with less rotation non-uniformity. For example, in a color image forming apparatus of a four-drum type in which four drums for yellow (Y), magenta (M), cyan (C) and black (K) are used, belt or color misregistration occurs due to the rotation non-uniformity of the photosensitive drum or the intermediary transfer belt, so that an image quality is impaired. Incidentally, the belt is such a phenomenon that sparseness/denseness of writing intervals by a laser on the photosensitive drum surface occurs with respect to a sub-scan direction due to the rotation non-uniformity of, e.g., the photosensitive drum and thus density non-uniformity occurs no a print.
[0003] As a countermeasure against the belt and the color misregistration, an encoder for monitoring the rotation non-uniformity was provided on a rotational axis of a driving roller for the photosensitive drum or the intermediary transfer belt and on the basis of a signal of the encoder, rotation of the driving source has been controlled. Thus, the rotation non-uniformity of the driving roller for the photosensitive drum or the intermediary transfer belt is suppressed, so that the belt and the color misregistration are prevented. Incidentally, as the driving source used in such a driving device, a DC motor or a stepping motor may be used.
[0004] Further, as a structure for transmitting a driving force from the driving source, a reduction gear train is generally used. That is, a rotational driving force of the driving source is transmitted to the driving roller for the photosensitive drum or the intermediary transfer belt through the reduction gear train in a speed reduction manner. However, in the case where such a reduction gear train is used, the rotation non-uniformity occurs even at an engaging portion between gears due to a manufacturing error of the gears, so that there arises a problem that the belt occurs and thus the image quality is lowered. As a countermeasure against the belt with respect to the reduction gear train, such an attempt that processing accuracy or rigidity of the respective gears was enhanced or that inertial mass (flywheel) was attached on the rotational axis of the driving roller for the photosensitive drum or the intermediary transfer belt has been made.
[0005] However, even when the processing accuracy or rigidity of each of the gears of the reduction gear train is enhanced or the inertial mass (flywheel) is provided, there is a limit to a suppressing effect on the rotation non-uniformity of the photosensitive drum or the intermediary transfer belt. Particularly, in recent years, with high-definition image forming process by formation of toner particles in a small particle size or formation of minute exposure spots, a demand for alleviating the rotation non-uniformity becomes increasingly severe, so that a conventional method is being in a state in which it cannot meet the demand.
[0006] For this reason, a proposal such that a driving force transmitting device using an endless non-toothed belt of steel and a pulley, not a toothed drive transmission means such as a gear or a timing belt was applied to the image forming apparatus has been proposed. That is, a driving device including a driving device for being rotationally driven by a driving source, a driven pulley rotated together with a member to be rotated such as the driving roller for the photosensitive drum or the intermediary transfer belt, and the non-toothed belt member stretched on a cylindrical surface of the driving pulley and the cylindrical surface of the driven pulley has been known. Such a driving device has no tooth at a power transmitting portion, so that it has an advantage that the rotation non-uniformity or belt due to an engaging portion does not occur in principle (e.g., Japanese Laid-Open Patent Application No. Hei 7-36346).
[0007] However, in the conventional driving force transmitting device using the belt member and the pulley, the following problems arise. First, there is a problem of responsiveness of the driving pulley and the driven pulley. For example, similarly as in the above-described case, in the case of the structure in which the encoder for monitoring the rotation non-uniformity is provided on the rotational axis of the driven pulley and the rotation of the driving source is controlled on the basis of the signal of the encoder, there is a need to increase the responsiveness of the driving pulley and the driven pulley. However, e.g., when the belt member is been ton its tension side (where a tension pulley is not provided) by a change in tension of the belt member due to a driven pulley-side load variation, a restrictive property at a phase relation between the driving pulley and the driven pulley is eliminated. That is, to the belt member to be stretched between the driving pulley and the driven pulley, a predetermined tension is applied by the tension pulley. However, when the load variation as described above occurs, the tension of the belt member is changed and thus a position of the tension pulley is also changed, so that the bending occurs on the side where the tension pulley is not provided. As a result, the responsiveness of the driving pulley and the driven pulley is lowered.
[0008] Such lowering in responsiveness occurs when the load on the driven pulley side is abruptly reduced or changed into a reverse load. Specifically, in the case where a cleaner, such as a blade or a brush, of a belt cleaning device for removing residual toner on the intermediary transfer belt is moved toward and away from the intermediary transfer belt, the decrease in load occurs when the cleaner is moved away from the intermediary transfer belt.
[0009] Further, in the case where a difference in rotational speed is provided between the photosensitive drum and the intermediary transfer belt, the reverse load as described below can occur. That is, in the case where a peripheral speed of the intermediary transfer belt is set at a value which is higher than that of the photosensitive drum at a primary transfer portion where a toner image is transferred from the photosensitive drum onto the intermediary transfer belt, when an electrostatic attraction force is generated at the primary transfer portion by application of a high voltage, a force from the intermediary transfer belt acts on the photosensitive drum. In this case, the photosensitive drum is in a state in which it receives the driving force from two members of the intermediary transfer belt and the driving device for the photosensitive drum. In the case where the above-described electrostatic attraction force exceeds, e.g., a brake force of the cleaner of the cleaning device for removing the residual toner on the photosensitive drum, the photosensitive drum is driven by the intermediary transfer belt. That is, the reverse load by which a driving force transmission path in a normal operation is reversed occurs. Further, such a reverse load state is abruptly generated, in the conventional belt driving device, control is lost and thus the color misregistration occurs.
[0010] Further, in the case of the conventional belt driving device, there is a problem such that a lifetime of the device is reduced by a slip (sliding) generated between the pulley and the belt. As described above, the non-toothed driving system is advantageous for belt prevention but is less liable to obtain a power transmitting ability as obtained by engagement by gear teeth. Further, in the case where the slip occurs, the belt is abraded and is liable to be bent, so that the lifetime of the driving device is shortened. Particularly, in the case of a speed reduction mechanism including the driven pulley having an outer diameter larger than that of the driving pulley, a length of winding of the belt about the driving pulley having the smaller outer diameter is short, i.e., a contact area between the driving pulley and the belt is small, so that the slip is liable to occur.
[0011] Further, during actuation of the device, not only frictional loads of the respective members are applied but also inertial load is added, so that the slid is liable to occur particularly. For this reason, as a countermeasure against the slip during the actuation, it would be considered that, e.g., a method in which a motor actuation profile is slowly raised is adopted. However, the method in which the motor actuation profile is slowly raised is effective as the countermeasure against the inertial load but cannot meet such a phenomenon (load) that the friction load is temporarily increased.
[0012] A specific example of the load may include those of the cleaner for the photosensitive drum and a transfer cleaner after these cleaners are left standing. That is, a cleaner blade which is a rubber member of such cleaners closely contacts the photosensitive drum or the intermediary transfer belt by being left standing and thus the load is increased when compared with the case of the normal operation. Further, at a nip of the cleaner blade, collected transfer residual toner is fixedly deposited to increase the load in some cases. Further, also at a seal portion where scattering toner is prevented from entering a portion for supporting an end portion of the photosensitive drum, a similar toner deposition (sticking) phenomenon occurs. Further, in the case of, e.g., a structure for supporting a roller such as a primary transfer roller disposed in the intermediary transfer belt by a sliding bearing, the scattering toner enters and is deposited on a sliding portion of the bearing and can cause the load phenomenon due to a similar a toner deposition. With respect to such a friction load increasing phenomenon, it is effective that the change in state (close contact state or deposition or sticking state) is accelerated by an impulse force (impact force) through instantaneous rising rather than the slow rising. This is contradictory to the slow rising as the counter measure against the inertial load.
[0013] On the other hand, it would also be considered that a method of increasing the drive transmitting force by increasing the tension of the belt is employed but this method causes a decrease in lifetime of the belt by an increase in stress of the belt accompanying the increased tension. Further, radial load acting on each of the pulleys is increased, so that such a problem that the lifetimes of the parts such as the bearings for supporting the respective pulleys are shortened occurs.
SUMMARY OF THE INVENTION
[0014] A principal object of the present invention is to provide a driving force transmitting device, using a pulley and a belt member, capable of enhancing rotation stability of the belt member.
[0015] Another object of the present invention is to provide an image forming apparatus including the driving force transmitting device.
[0016] According to an aspect of the present invention, there is provided
[0017] According to an aspect of the present invention, there is provided a driving force transmitting apparatus comprising a driving source; a drive pulley rotatable by a driving force supplied from said driving source; a follower pulley rotatable with a member to be rotated; a belt member extending around a cylindrical surface of said driving pulley and a cylindrical surface of said follower pulley; and an intermediate transmission member disposed between said driving pulley and said follower pulley, said intermediate transmission member having a rigidity higher than that of said belt member and contacted to said pulley or opposed to said pulley with said belt member therebetween.
[0018] These and other objects, features and advantages of the present invention will become more apparent upon a consideration of the following description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a schematic view for illustrating an image forming apparatus including a driving device in First Embodiment according to the present invention.
[0020] FIG. 2 is a partly cutaway view for illustrating the driving device in First Embodiment.
[0021] FIG. 3 is a sectional view taken along A-A line indicated in FIG. 2 .
[0022] FIG. 4 is a schematic view showing a state in which a load variation occurs in a conventional structure.
[0023] FIG. 5 is a graph showing a relationship between the load variation and positional deviation amount in the conventional structure.
[0024] FIG. 6 is a graph showing a relationship between the load variation and the positional deviation amount in First Embodiment.
[0025] FIG. 7 is a schematic view of a driving device in Second Embodiment.
[0026] FIG. 8 is a sectional view taken along B-B line indicated in FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
[0027] Next, referring to FIGS. 1-6 , the first preferred embodiment of the present invention will be described. First, the image forming apparatus in this embodiment will be described with reference to FIG. 1 . The image forming apparatus in this embodiment is a full-color laser beam printer of the intermediary transfer type, and also, of the tandem type. That is, it has four image formation stations, more specifically, yellow (Y), magenta (M), cyan (c), and black (K) image formation stations, which are in parallel to each other. An image forming apparatus of this type has a printer portion P and a reader portion R. Generally speaking, the printer portion P is made up of an image forming portion 11 , a recording medium (paper) feeder unit 12 , an intermediary transfer unit 13 , a fixation unit 14 , and a control unit (unshown). The image forming portion 11 has four image formation stations which are the same in structure.
[0028] The structure of the image forming portion 11 is as follows: The image forming portion 11 has multiple (four) photosensitive drums 15 , which are image bearing members. Each photosensitive drum 15 is supported at the lengthwise ends of its shaft (drum shaft 15 a ). It is rotated in the counterclockwise direction indicated by an arrow mark in FIG. 1 , by a driving apparatus 50 which is actually a driving force transmitting apparatus. The driving apparatus 50 will be described later. Each image formation station has a charging device 16 , a developing device 17 , and a cleaning apparatus 18 , which are sequentially positioned in the adjacencies of the peripheral surface of the photosensitive drum 15 , in the listed order. The image forming operation of this image forming apparatus is as follows. First, the peripheral surface of the photosensitive drum 15 is uniformly charged to preset polarity and potential level by the charging device 16 , such as a charging device of the corona type. Next, a beam of light, for example, a beam of laser light, is projected, while being modulated with the image formation signals obtained by the reader portion R, upon the charged area of the peripheral surface of the photosensitive drum 15 , by an optical system apparatus 19 provided with a light source, etc. In other words, the charged area of the peripheral surface of the photosensitive drum 15 is exposed to form an electrostatic latent image on the peripheral surface of the photosensitive drum 15 . Then, the electrostatic latent image is developed by the developing device 17 , which contains toner (developer) which is Y, M, C, or K in color, into a visible image formed of the toner (which hereafter will be referred to simply as toner image); the toner is adhered to the electrostatic latent image on the peripheral surface of the photosensitive drum 15 by the developing device 17 . This toner image is transferred (first transfer) onto an intermediary transfer belt 21 , in the first transfer portion T 1 ; four toner images, different in color, are sequentially transferred onto the intermediary transfer belt 21 , in the four first transfer portions T 1 , one for one. The toner remaining on the peripheral surface of the photosensitive drum 15 after the first transfer is removed by the cleaning apparatus 18 .
[0029] The recording medium feeder unit 12 is made up of the recording medium feeder cassette 22 , a recording medium feeder tray 23 , a pickup roller 24 , a recording medium conveyance path 25 , a pair of registration rollers 26 , etc. The sheets of recording mediums S in the recording medium feeder cassette 22 or recording medium feeder tray 23 are send one by one into the recording medium conveyance path 25 by the corresponding pickup roller 24 , and are conveyed through the recording medium conveyance path 25 to the pair of registration rollers 26 . Then, each sheet of recording medium S (which hereafter will be referred to simply as recording medium S) is sent to the second transfer portion T 2 by the pair of registration rollers 26 in synchronism with the progression of the image formation.
[0030] The intermediary transfer unit 13 has the intermediary transfer belt 21 , which is an endless image bearing member which is supported and kept stretched in such a manner that it can be circularly moved. More specifically, the intermediary transfer belt 21 is supported, and kept stretched, by a driver roller 27 , a tension roller 28 , and a belt backing roller 29 (which hereafter may be referred to simply as backup roller 29 ) which backs up the intermediary transfer belt 21 against a second transfer roller. Among the three rollers 27 , 28 , and 29 , the driver roller 27 is driven by the aforementioned driving apparatus 50 , which will be described later. The tension roller 28 provides the intermediary transfer belt 21 with a preset amount of tension, in coordination with an unshown pressure applying means. The backup roller 29 opposes the second transfer roller, with the presence of the intermediary transfer belt 21 between the two rollers, forming thereby the second transfer portion T 2 . The backup roller 29 is rotated by the movement of the intermediary transfer belt 21 ; it is rotated by utilizing the friction between the intermediary transfer belt 21 and backup roller 29 . The portion of the intermediary transfer belt 21 , which is moving between the driver roller 27 and tension roller 28 , opposes each of the four photosensitive drums 15 . There are four charging blades 30 for the first transfer, which oppose the four photosensitive drums 15 , one for one, in such a manner that the intermediary transfer belt 21 is pinched between the peripheral surface of each photosensitive drum 15 and each of the four charging blades 30 . There is also a belt cleaning apparatus 31 , which opposes the driver roller 27 with the presence of the intermediary transfer belt 21 between the belt cleaning apparatus 31 and driver roller 27 .
[0031] The four toner images formed on the four photosensitive drums 15 , one for one, are sequentially transferred (first transfer) onto the intermediary transfer belt 21 in the first transfer portion T 1 , by applying a preset voltage to the intermediary transfer belt 21 by the charge blades 30 . After being transferred onto the intermediary transfer belt 21 , the toner images on the intermediary transfer belt 21 are conveyed to the second transfer portion T 2 , in which they are transferred from the intermediary transfer belt 21 onto the recording medium S which is delivered to the second transfer portion T 2 by the registration rollers 26 in synchronism with the arrival of the toner images on the intermediary transfer belt 21 at the second transfer portion T 2 . The toner on the intermediary transfer belt 21 , which was not transferred in the second transfer portion T 2 , that is, the toner remaining on the intermediary transfer belt 21 after the second transfer, is removed by the belt cleaning apparatus 31 , and conveyed to an unshown waste toner box.
[0032] The fixation unit 14 is provided with a fixation roller 33 and a pressure roller 34 , which have an internal heat source 32 , such as a halogen heater. It fixes the toner images (unfixed toner images), which have just been transferred onto the recording medium S in the second transfer portion T 2 , to the recording medium S. After the fixation of the toner images to the recording medium S, the recording medium S is discharged into a delivery tray 36 by a pair of discharge rollers 35 . The operation of each of the mechanical or electro-mechanical portions described above is controlled by an unshown control unit. The image forming apparatus may be designed so that this control unit integrally controls the entirety of the operation of the image forming apparatus, including the aforementioned driving apparatus 50 , which will be described next.
[0033] Next, referring to FIGS. 2 and 3 , the driving apparatus 50 will be described. The driving apparatus 50 is a driving force transmitting apparatus which transmits driving force to the photosensitive drums 15 and the driver roller 27 of the intermediary transfer unit 13 . Incidentally, the apparatus for driving the driver roller 27 of the intermediary transfer unit 13 is the same as the apparatus 50 for driving the photosensitive drum 15 . Thus, only the driving apparatus for the photosensitive drum 15 will be described. The driving apparatus 50 is an apparatus which transmits the rotational force of a DC motor 51 , which is the mechanical power source, to the photosensitive drum 15 , while reducing the force in velocity. Thus, the driving apparatus 50 has: a driver pulley 52 which is rotationally driven by the DC motor 51 ; a follower pulley 53 with which the photosensitive drum 15 rotates; a toothless belt 54 stretched around the cylindrical peripheral surface 52 a of the driver pulley 52 and the cylindrical surface 53 a of the follower pulley 53 . The driving force is transmitted from the pulley 52 to the pulley 53 by utilizing the friction between the belt 54 and the two pulleys 52 and 53 . The belt 54 in this embodiment is toothless. However, the belt 54 may be in such a form that its cross section has multiple indentations, or is wavy. Further, it may be toothed. In other words, the present invention is applicable to any driving force transmitting apparatus, as long as it is structured so that driving force is transmitted between the two pulleys 52 and 53 by the utilization of the friction between the belt 54 and the two pulleys 52 and 53 .
[0034] More specifically, the driver pulley 52 , which is cylindrical, is in connection to the output shaft 51 a of the DC motor 51 . The driver pulley 51 is made of a metallic substance, and is roughly cylindrical. It has a circumferential groove 52 b , which is in the middle of the driver pulley 51 in terms of the axial direction of the driver pulley 52 . The bottom surface 52 a of the circumferential groove 52 b is toothless. The depth of the groove 52 b is greater than the thickness of the aforementioned belt 54 , which will be described later. Both of the lengthwise end portions 52 c , relative to the groove 52 b , of the driver pulley 52 are cylindrical, and engage with a driving force transmitting intermediary member 56 of the apparatus 50 ; the peripheral surface of each of the lengthwise end portions 52 c engages with the peripheral surface of the driving force transmitting intermediary member 56 (which hereafter will be referred to simply as intermediary transmitting member 56 , which will be will be described later. Hereafter, the lengthwise end portions 52 c , which engage with the intermediary transmitting member 56 , may be referred to as engaging portions 52 c.
[0035] The aforementioned follower pulley 53 is in connection with the drum shaft 15 a of the photosensitive drum 15 . The follower pulley 53 also is made of a metallic substance, and is roughly cylindrical, like the driver pulley 52 . It has a circumferential groove 53 b , which is in the middle of the follower pulley 53 , n terms of the axial direction of the follower pulley 53 . The bottom surface 53 a of the circumferential groove 53 b is toothless. The depth of the groove 53 b is also greater than the thickness of the belt 54 . Both of the lengthwise end portions 53 c , relative to the groove 53 b , of the follower pulley 53 are cylindrical, and engage with the intermediary transmitting member 56 of the apparatus 50 ; the peripheral surface of each of the lengthwise end portions 53 c engages with the peripheral surface of the intermediary transmitting member 56 . Hereafter, the lengthwise end portion 53 c , which engage with the intermediary transmitting member 56 , may be referred to as engaging portions 53 c . The follower pulley 53 is greater in diameter than the driver pulley 52 . The dimension of the follower pulley 53 in terms of its axial direction is roughly the same as the dimension of the driver pulley 52 in terms of its axial direction. The material for the driver pulley 52 and follower pulley 53 is desired to be a hard metallic substance, such as stainless steel.
[0036] The toothless belt 54 is made of a ferric material such as stainless steel, and is wrapped around, being thereby kept stretched, by the driver pulley 52 and follower puller 53 , bridging thereby between the bottom surface 52 a of the groove 52 c of the driver pulley 52 , and the bottom surface 53 a of the groove 53 b of the follower pulley 53 . The depth of the grooves 52 b and 53 b , which correspond to the bottom surfaces 52 a and 53 a , respectively, is greater than the thickness of the belt 54 . Therefore, after the fitting of the belt 54 into the grooves 52 b and 53 b , the belt 54 does not protrude above the peripheral surface of engaging portion 52 c and that of the engaging portion 53 c . Further, the belt 54 is wrapped around a tension pulley 55 , which is on the downstream side of the driver pulley 52 in terms of the moving direction of the belt 54 . The tension pulley 55 is under the pressure from springs 56 , and provides the belt 54 with a proper amount of tension.
[0037] Further, there is an intermediary transmission member 57 between the driver pulley 52 and follower pulley 53 . The intermediary member 57 is also cylindrical. The belt 54 is wrapped around also the peripheral surface 57 a of the intermediary transmitting member 57 . The intermediary transmitting member 57 is a piece of a hollow cylinder (having through hole 58 ) made of a very hard and rigid metallic substance, such as stainless steel. It has a circumferential groove 57 b , which is in the middle in terms of the axial direction of the intermediary transmitting member 57 . The bottom surface 57 a of the groove 57 b is toothless. The depth of the groove 57 b is also greater than the thickness of the belt 54 . The intermediary transmitting member 57 is formed of a substance which is higher in rigidity than the material for the belt 54 .
[0038] The lengthwise end portions of the intermediary transmitting member 57 are cylindrical, and function as engaging portions 57 c , which engage with the engaging portion 52 c of the driver pulley 52 , and the engaging portion 53 c of the follower pulley 53 , one for one. The external diameter of each of the engaging portions 57 c of the intermediary transmitting member 57 is greater than the distance between the engaging portion 52 c of the driver pulley 52 and the engaging portion 53 c of the follower pulley 53 . The relationship in terms of external diameter among the engaging portions 57 c , 52 c , and 53 c is to be set in consideration of the relationship between the efficiency with which the driving force is transmittable by the belt 54 and the reduction ratio (between driver pulley 52 and follower pulley 53 in terms of peripheral velocity), and the transmission efficiency of the intermediary transmitting member 57 . For example, it is set so that external diameter of engaging portion 52 c :external diameter of engaging portion 57 c :external diameter of engaging portion 53 c= 1:2:8. In terms of axial direction, the dimension of the intermediary transmitting member 57 is roughly the same as the dimension of the driver pulley 52 and the dimension of the follower pulley 53 . The peripheral surface of the engaging portions 57 c of the intermediary transmitting member 57 is also minimized in coefficient of friction.
[0039] The intermediary transmitting member 57 is supported by a supporting shaft 59 , which is put through the through hole 58 of the intermediary transmitting member 57 . The supporting shaft 59 is rotatably supported by a pair of bearings 60 , which are plane bearings, roller bearings, ball bearings, or the like. The lengthwise end portions of the supporting shaft 59 are loosely fitted in the cylindrical holes of the unshown frame of the apparatus; the diameter of the cylindrical holes is slightly larger than the external diameter of the supporting shaft 59 . Further, the supporting shaft 59 is under the pressure applied to its lengthwise end portions by a pair of springs 61 . More specifically, the base portion of each of the springs 61 is anchored to a part of the frame, and the opposite end of the spring 61 from the base portion is attached to the corresponding lengthwise end of the supporting shaft 59 . Therefore, the intermediary transmitting member 57 supported by the supporting shaft 59 is also kept pressured in the preset direction by this pair of springs 61 . The direction in which the intermediary transmitting member 57 is kept pressed by the pair of springs 61 is such direction that causes the intermediary transmitting member 57 to move into the gap between the driver pulley 52 and follower pulley 53 , that is, toward where the gap between the driver pulley 52 and follower pulley 35 is narrowest. In the case of the structural setup shown in the drawing, however, the intermediary transmitting member 57 is on the tension pulley side (left side in FIG. 2 ) of the theoretical line L (dotted line) which connects the center of the driver pulley 52 and the center of the follower pulley 53 . Therefore, the pressure applied to the intermediary transmitting member 57 by the pair of springs 61 works in the direction to increase the distance between the intermediary transmitting member 57 and tension pulley 55 . Since the driving apparatus 50 is structured as described above, the intermediary transmitting member 57 is afforded a certain amount of positional latitude, and is properly positioned by being kept in contact with the driver pulley 52 and follower pulley 53 . In comparison, the driver pulley 52 and follower pulley 53 are rotatably supported with the presence of no play relative to the frames, and therefore, they are stable in the position of their rotational axis.
[0040] The belt 54 is stretched in such a manner that it wraps the tension pulley side of the peripheral surface 57 a of the intermediary transmitting member 57 . Thus, the intermediary transmitting member 57 is kept wedged between the driver pulley 52 and follower pulley 53 by the tension of the belt 54 . That is, the intermediary transmitting member 57 is on the tension pulley side of the aforementioned theoretical line L, as described above. Further, the belt 54 is stretched so that it wraps around the tension pulley side of the intermediary transmitting member 57 to keep the intermediary transmitting member 57 pressed by the tension of the belt 54 , toward where the gaps between the driver pulley 52 and follower pulley 53 is narrowest. Therefore, it is ensured that the engaging portions 57 c of the intermediary transmitting member 57 are kept in contact with the engaging portions 52 a of the driver pulley 52 , and the engaging portions 53 a of the follower pulley 53 , by the coordination of the tension of the intermediary transmitting member 57 and the pressure from the above described pair of springs 61 , providing thereby a proper amount of contact pressure between the intermediary transmitting member 57 and driver pulley 52 , and between the intermediary transmitting member 57 and follower pulley 53 . Incidentally, as long as the proper amount of contact pressure can be provided between the engaging portions 57 c of the intermediary transmitting member 57 and the engaging portions 52 a of the driver pulley 52 , and between the engaging portions 57 c of the intermediary transmitting member 57 and the engaging portions 53 a of the follower pulley 53 , by the belt tension alone, the pair springs 61 may be eliminated.
[0041] Referring to FIG. 2 , since the driving apparatus 50 is structured so that the intermediary transmitting member 57 is between the driver pulley 52 and follower pulley 53 , and the belt 54 is wrapped around the tension pulley side of the intermediary transmitting member 57 . Therefore, the belt 54 is wrapped around the driver pulley 52 and follower pulley 53 by a sufficient angle. In other words, the area of contact between the belt 54 and peripheral surface 52 a of the driver pulley 52 , and the area of contact between the belt 54 and the peripheral surface 53 a of the follower pulley 53 , are substantial in size. Therefore, it is ensured that the driving force is reliably transmitted from the driver pulley 52 to the follower pulley 53 by the belt 54 . Incidentally, the intermediary transmitting member 57 may be positioned on the opposite side (right side in FIG. 2 ) of the theoretical line L from the tension pulley 55 . In such a case, however, the intermediary transmitting member 57 is kept pressed by the tension of the belt 54 , in the direction to increase the distance between the intermediary transmitting member 57 and driver pulley 52 , and the distance between the intermediary transmitting member 57 and follower pulley 53 . Therefore, the pair of springs 61 have to be made large enough in resiliency to keep the intermediary transmitting member 57 wedged between the two pulleys 52 and 53 .
[0042] Further, the driving apparatus 50 has an encoder wheel 62 , which is solidly attached to the shaft 15 a of the photosensitive drum 15 . It has also at least one detecting portion 63 , which is in the adjacencies of the peripheral surface of the encoder wheel 62 . The encoder wheel 62 and detecting portion 63 make up a rotational speed detecting means 64 , making it possible to detect the rotational speed of the photosensitive drum 15 . The signals outputted as the detecting portion 63 detects the rotational speed of the photosensitive drum 15 are sent to a control portion 65 as a controlling means. The control portion 65 controls the DC motor 51 in response to the signals sent from the detecting portion 63 , controlling thereby the driver pulley 52 in rotational speed. Incidentally, the control portion 64 may be a part of the control unit described above, or independent from the control unit.
[0043] The driving apparatus 50 structured as described above rotates the photosensitive drums 15 by transmitting driving force from the DC motor 51 to the photosensitive drums 15 by transmitting the driving force from the driver pulley 52 to the follower pulley 53 through the belt 54 and intermediary transmitting member 57 . As long as the image forming apparatus is normally operating, that is, as long as the load resulting from the driving of the image forming portions does not substantially change, the driving force from the DC motor 51 is satisfactorily transmitted by way of the belt 54 . However, if the load to which the follower pulley 53 is subjected suddenly reduce in amount, or reverses in direction, that is, if the load to which the follower pulley 53 is subjected changes in amount, the belt 54 is allowed to slacken, failing thereby to transmit the diving force by a satisfactorily amount. In this embodiment, however, when the image forming apparatus is in the above described condition, the driving force from the DC motor 51 is transmitted from the driver pulley 52 to the follower pulley 53 by the intermediary transmitting member 57 , and therefore, the driving force is reliably transmitted to the follower pulley 53 . To describe in more detail, the intermediary transmitting member 57 is higher in rigidity than the belt 54 . Therefore, even if the load to which the follower pulley 53 is subjected changes in amount and/or direction, the intermediary transmitting member 57 does not deform like the belt 54 . Therefore, it is ensured that the driving force from the DC motor 51 is satisfactorily transmitted to the follower pulley 53 by being transmitted by way of the intermediary transmitting member 57 . Therefore, it does not occur that the image forming portions reduces in responsiveness. Next, referring to FIGS. 4 to 6 , this feature of the driving apparatus 50 in this embodiment will be described in detail.
[0044] FIG. 4 is a schematic sectional view of a driving force transmitting apparatus which does not have the intermediary transmitting member 57 . The inventors of the present invention performed the following experiments to compare, in structure, the driving force transmitting apparatus in FIG. 4 with the driving apparatus 50 , or the driving force transmitting apparatus in this embodiment. That is, the distance between the drum shaft 15 a and output shaft 51 a was measured while the amount of torque (load) to which the follower pulleys 53 and 53 A are subjected was varied by controlling the rotational speed of the photosensitive drum 15 . FIGS. 5 and 6 show the results of this experiment. In FIGS. 5 and 6 , the vertical axis stands for the amount of torque (load) to which the follower pulleys 53 and 53 a were subjected, and the amount of the positional deviation of the follower pulleys 53 and 53 a , and rotational axis (output shaft 51 a ) of the driver pulleys 52 and 52 A, whereas the horizontal axis stands for the elapsed time. FIG. 5 shows the test results of the driving force transmitting apparatus shown in FIG. 4 , that is, a driving force transmitting apparatus which does not have the intermediary transmitting member 57 . FIG. 6 shows the test results of the driving apparatus 50 , that is, the driving force transmitting apparatus in this embodiment, which is structured as shown in FIGS. 2 and 3 . The amounts of positional deviation shown in FIGS. 5 and 6 are represented by the values equivalent to the positional deviation of the peripheral surface of the photosensitive drum 15 . These experiments were performed under the following conditions.
[0045] The photosensitive drum 15 was 30 mm in diameter, and the driver pulley 52 was 12.06 mm in diameter. The follower pulley 53 was 96.48 mm in diameter, and the intermediary transmitting member 57 was 24.12 mm in diameter. Further, the tension pulley 55 was 23.96 mm in diameter. Further, the driver pulley 52 A and follower pulley 53 A were 11.96 mm and 95.96 mm, respectively, in diameter. Incidentally, the abovementioned diameters of the driver pulley 52 , follower pulley 53 , and intermediary transmitting member 57 are the diameters of the engaging portions 52 c , 53 c , and 57 c , respectively. The depths of the grooves 52 b , 53 b , and 57 b are 0.05 mm, 0.26 mm, and 0.08 mm, respectively. As the material for each pulley and intermediary transmitting member, stainless steel was used. The belt 54 was 0.04 mm in thickness, 12 mm in width, and 420 mm in length. It was made of stainless steel. The revolution of the DC motor (hence, revolution of driver pulleys 52 and 52 A) was 1,068 rpm, and the target revolution for the follower pulleys 53 and 53 A and the photosensitive drum 15 was 133.5 rpm. Each of the pair of springs 56 by which the tension pulley 55 was kept pressed was 31 N in resiliency, providing thereby the belt 54 with 46 N of tension when the belt 54 is under no load (when driving force is not transmitted).
[0046] Referring to FIGS. 5 and 6 , in both the case of the structural arrangement, the test results of which are shown in FIG. 5 , and the case of the structural arrangement, the test results of which are given in FIG. 6 , the drum shaft 15 a slightly shifted relative to the output shaft 51 a in the direction in which the belt 54 was moved, that is, the positive direction in the graphs ( FIGS. 5 and 6 ), even if there is no change in the amount of the load. On the other hand, as the amount of the load changed in the positive direction, the drum shafts 15 a gradually shifted in the negative direction. In either case, however, the positional deviation (shifting) was slight. In comparison, in the case where the load reversed in direction, that is, the sign of the value which shows the amount of the load changed from plus to minus, the amount by which the positional deviation occurred to the drive shaft 15 a (photosensitive drum 15 ) of the driving force transmitting apparatus which does not have the intermediary transmitting member 57 was very large, as shown in FIG. 5 . Consequently, a certain amount of play (slackening) occurred to the portion of the belt 54 , which was between the upstream side of the driver pulley 52 A and the downstream side of the follower pulley 53 A in terms of the belt movement direction, as depicted by the solid line in FIG. 4 . Thus, the follower pulley 53 A becomes unsynchronized relative to the driver pulley 52 A by a rotational angle of θ.
[0047] To describe this subject in more detail, in more detail, if the load to which the follower pulley 53 A is subjected suddenly reduces, the torque stored in the driving system is instantly released, whereby the follower pulley 53 A is made to temporarily overrun in the moving direction of the belt 54 (this phenomenon is similar in nature to the temporary vibrations which occurs as the right hand is moved away from an object which is being dragged by the left hand, with the presence of a piece of rubber band between the left hand and the object, while securing the object with the right hand). In particular, as the load becomes negative (reverse in direction), the follower pulley 53 A is driven by the downstream portions of the image forming apparatus in terms of the direction in which the driving force is normally transmitted, the follower pulley 53 A becomes large in the amount of its overrun. In the case of the driving force transmitting apparatus which is not provided with the intermediary transmitting member 57 , the relationship, in terms of rotational phase, between the driver pulley 52 A and follower pulley 53 A cannot be precisely regulated. Therefore, the amount of the overrun such as the above-described one, is large. Therefore, the amount of the positional deviation of the drum shaft 15 a (photosensitive drum 15 ) is substantial. Thus, in the case of a driving force transmitting apparatus structured as shown in FIG. 4 , it is difficult to keep the speed of the follower pulley 53 A at a preset value by controlling the drum shaft 15 a in rotational speed.
[0048] In comparison, in this embodiment, the follower pulley 53 is driven by utilizing the friction between the driver pulley 52 and intermediary transmitting member 37 , and the friction between the intermediary transmitting member 57 and follower pulley 53 , by placing the intermediary transmitting member 57 in contact with the driver pulley 52 and follower pulley 53 . Therefore, the relationship, in angle of rotation, between the driver pulley 52 and follower pulley 53 can be more strictly controlled than in the case of the conventional driving force transmitting apparatuses. Being able to more strictly controlling the relationship, in rotational angle, between the driver pulley and follower pulley can more effectively control the transmission of driving force, based on the detected rotational speed of the photosensitive drum 15 . As will be evident from the comparison between the results given in FIG. 5 and those in FIG. 6 , in the case of the driving force transmitting apparatus, the test results of which are given in FIG. 5 , the positional deviation (shifting) of the drive shaft 15 a (photosensitive drum 15 ) was roughly 40 μm, whereas in the case of the driving apparatus 50 , that is, the driving force transmitting apparatus in this embodiment, the test results of which are given in FIG. 6 , the positional deviation (shifting) of the drive shaft 15 a (photosensitive drum 15 ) was roughly 10 μm. In other words, the experiments confirmed that the driving apparatus 50 , that is, the driving force transmitting apparatus in accordance with the present invention, was a substantial improvement over the conventional ones. That is, if an image forming apparatus of the tandem type, such as the one shown in FIG. 1 , can be reduced in the amount of the positional deviation of its photosensitive drum 15 , it is possible to prevent the misalignment among the monochromatic images, which occurs in the image forming portions. Therefore, it is possible to prevent a full-color image forming apparatus of the tandem type from outputting multicolor images (which are obtained by layering multiple monochromatic images different in color) which suffer from color deviation.
[0049] Also in the case of this embodiment, even if the image forming apparatus is in the condition in which the belt 54 might slip at the time of startup, the driving force is transmitted by the intermediary transmitting member 57 , and therefore, the driving force transmission failure, which might have occurred, due to the slippage, in the case of conventional driving force transmitting apparatuses, does not occur. Thus, the driving apparatus 50 , that is, the driving force transmitting apparatus in this embodiment, last substantially longer than any of the conventional driving force transmitting apparatuses for an image forming apparatus. To describe this subject in more detail, the length by which the belt 54 is wrapped around the driver pulley 52 is less than the length by which the belt 54 is wrapped around the follower pulley 53 . Thus, it is between the driver pulley 52 and belt 54 that slipping is likely to occur as the DC motor 51 is started up. In this embodiment, however, the driving force from the DC motor 51 can be transmitted from the driver pulley 52 to the follower pulley 53 by way of the intermediary transmitting member 57 . That is, the driving force can be transmitted through the engaging portions 52 c , 53 c , and 57 c . Thus, as the DC motor 51 is started up, the intermediary transmitting member 57 is initially driven directly by the driver pulley 52 , whereby the follower pulley 53 is driven by the rotationally driven by the intermediary transmitting member 57 . Then, the follower pulley 53 is rotationally driven by the belt 54 , with no slipping. In other words, even if the image forming apparatus is in the condition in which the belt 54 might slip, the driving force is transmitted to the follower pulley 53 by way of the intermediary transmitting member 57 . Therefore, the belt 54 does not slip. Incidentally, in order to make it easier to understand the mechanism of the transmission of the driving force from the DC motor 51 , the mechanism was described in steps. In reality, however, the movement of these components virtually instantly (simultaneously) occurs.
[0050] In this embodiment, the intermediary transmitting member 57 is positioned on the tension roller side (opposite side from side from which belt 54 is wrapped around intermediary transmitting member 57 ) of the theoretical line L which connects the center of the driver pulley 52 and the center of the follower pulley 53 . Therefore, as the DC motor 51 is started, the intermediary transmitting member 57 is pressed by the tension of the belt 54 in the direction to wedge into the gap between the driver pulley 52 and follower pulley 53 , whereby friction is increased across the areas of contact between the engaging portions 52 a , 53 a , and 57 a and the belt 54 , ensuring thereby further that the belt 54 is unlikely to slip. As long as the belt 54 can be prevented from slipping, it is possible to prevent the belt 54 from being prematurely worn and/or breaking. In other words, the present invention can makes a driving force transmitting apparatus ( 50 ) more durable.
[0051] Also in this embodiment, not only is the driving force transmitted by the belt 54 , but also, by the intermediary transmitting member 57 . Therefore, the amount of the tension with which the belt 54 needs to be provided to prevent the positional deviation of the photosensitive drum 15 does not need to be as large as that in the case of conventional driving force transmitting apparatuses. Therefore, the amount of the load which is applied to the driver pulley 52 and follower pulley 53 by the tension of the belt 54 in their radial direction of the pulleys is smaller than that in the case of the conventional driving force transmitting apparatuses. Therefore, the driving apparatus 50 , that is, the driving force transmitting apparatus in this embodiment, is significantly less likely to collapse, and also, is significantly smaller in the amount of the frictional wear of the driver pulley 52 and follower pulley 53 , than the conventional driving force transmitting apparatuses. In other words, the present invention can provide a driving force transmitting apparatus which is substantially more durable than the conventional ones.
[0052] Further, because the driving force transmitting apparatus in this embodiment is provided with the intermediary transmitting member 57 , it is substantially greater in the angle by which the belt 54 is wrapped around the driver pulley 52 and follower pulley 53 , than the conventional ones, as described above. Therefore, it is substantially greater than conventional ones, in the efficiency with which the driving force is transmitted by the belt 54 . That is, as long as a driving force transmitting apparatus can be improved in the efficiency with which the driving force is transmitted by the belt 54 , it is unnecessary to increase the apparatus in the efficiency with which the driving force is transmitted by the intermediary transmitting member 57 , and therefore, it is unnecessary to increase the apparatus in the amount of contact pressure among the engaging portions 52 c , 53 c , and 57 c , and the belt 54 . Thus, the driving force transmitting apparatus in this embodiment is substantially smaller in the amount of the frictional wear of these engaging portions 52 c , 53 c , and 57 c , and therefore, the driving force transmitting apparatus in this embodiment is significantly more durable than the conventional ones. For example, in the case of a driving force transmitting apparatus which transmits driving force only by the intermediary transmitting member 57 , that is, without employing the belt 54 , the apparatus has be greater in the amount of the contact pressure across the areas of contact among the engaging portions 52 c , 53 c , and 57 c than a driving force transmitting apparatus having the intermediary transmitting member 57 . In the case of the driving force transmitting apparatus in this embodiment, both the belt 54 and intermediary transmitting member 57 are used for driving force transmission. Therefore, the contact pressure among the engaging portions 52 c , 53 c , and 57 c of the apparatus in this embodiment does not need to be as high as that in the conventional ones. Thus, the driving force transmitting apparatus in this embodiment is significantly more durable than the conventional ones.
Embodiment 2
[0053] Next, referring to FIGS. 7 and 8 , the second preferred embodiment of the present invention will be described. In this embodiment, the intermediary transmitting member 57 A is not directly in contact with the driver pulley 52 B and follower pulley 53 B because of the presence of the belt 54 between the intermediary transmitting member 57 and driver pulley 52 , and also, between the intermediary transmitting member 57 and follower pulley 53 B. That is, the belt 57 remains pinched by the peripheral surface of the driver pulley 52 B and the peripheral surface of the intermediary transmitting member 57 , and also, by the peripheral surface of the follower pulley 53 B and the peripheral surface of the intermediary transmitting member 57 (forming thereby nips 66 a and 66 b ). That is, in this embodiment, the two pulleys 52 B and 53 B, and the intermediary transmitting member 57 , are in the form of a plane cylindrical member; the peripheral surface of the driver pulley 52 B, peripheral surface of the 53 B, and peripheral surface of the intermediary transmitting member 57 , do not have a groove. Otherwise, the driving force transmitting apparatus in this embodiment is the same in structure as the driving force transmitting apparatus in the first embodiment. Therefore, the structural components, members, etc., of the apparatus in this embodiment, are given the same referential codes as those given to their counterparts of the apparatus in the first embodiment, and will not described here.
[0054] In this embodiment, the intermediary transmitting member 57 A is kept wedged between the two pulleys 52 B and 53 B by a pair of springs 61 . Therefore, the driving force transmitting apparatus in this embodiment is higher in the amount of force with which the belt 54 is pinched in the nips 66 a and 66 b than the conventional ones. Further, in the case of the driving force transmitting apparatus in this embodiment, the belt 54 is wrapped around the tension pulley side of the intermediary transmitting member 57 A, and the intermediary transmitting member 57 A is kept under the pressure which works in the direction to wedge the intermediary transmitting member 57 A into the gap between the two pulleys 52 B and 53 B. Therefore, not only is the belt 54 of the driving force transmitting apparatus in this embodiment less likely to slacken than that of the conventional ones, but also, the driving force transmitting apparatus in this embodiment is greater than the conventional ones, in the amount of force with which the belt 57 is pinched in the nips 66 a and 66 b . Thus, in this embodiment, the relationship, in terms of rotational phase, between the driver pulley 52 B and follower pulley 53 B is more strictly regulated, being therefore more desirable in terms of the response to a control command. In other words, this embodiment of the present invention also proved that the present invention can prevent the photosensitive drum 15 from deviating in position, and therefore, can prevent an image forming apparatus from outputting multicolor images, that is, images made up of layered monochromatic images, different in color, which suffer from chromatic deviation.
[0055] Further, the driver pulley wrapping portion of the belt 54 , which is in the nip 66 a , that is, the nip resulting from the pinching of the belt 54 by the driver pulley 52 B and intermediary transmitting member 57 A, is different in the distribution of the normal force from the comparable portion of the belt 54 of any of the conventional driving force transmitting apparatuses. Ordinarily, the distribution of the normal force across the pulley wrapping portion of the belt 54 is such that the normal force is higher across the center of the pulley wrapping portion of the belt 54 than across the end portions of the pulley wrapping portion of the belt 54 , and is zero at the ends. In this embodiment, however, one of the ends of the pulley wrapping portion of the belt 54 coincides with the nip 66 a in which the belt 54 is pinched by the driver pulley 52 and intermediary transmitting member 57 A, being therefore greater in the normal force. Therefore, the total amount of the normal force in this embodiment is greater than that of any of the conventional driving force transmitting apparatuses. Therefore, the amount of torque transmitted between the driver pulley 52 B and intermediary transmitting is greater; the belt 54 is prevented from slipping.
[0056] Further, the intermediary transmitting member 57 A is positioned on the tension roller side of the theoretical line L which connects the center of the driver pulley 52 B and the center of the follower pulley 53 B. Therefore, as the DC motor 51 is started, the intermediary transmitting member 57 is subjected to such a force that works in direction to cause the intermediary transmitting member 57 to wedge into the gap between the driver pulley 52 B and follower pulley 53 B, whereby the normal force is increased, which in turn makes it unlikely for the belt 54 to slip.
[0057] The embodiments described above are effective even if the driving force transmitting apparatus is not controlled in response to the detected rotational speed of the photosensitive drum 15 . That is, the structural arrangements, in the first and second embodiments, for the driving force transmitting apparatus is for strictly regulating the relationship in terms of rotational phase between the driver pulley 52 ( 52 B) and follower pulley 53 ( 53 B) (for improving driving force transmitting apparatus in responsiveness). Therefore, the structural arrangements make it easier for the changes in the load to which the follower pulley 53 and 53 B are subjected, to be transmitted to the drive shaft of the DC motor. Ordinarily, a motor is under its own internal control so that it remains stable in rotational speed. Therefore, the faster the speed with which the changes in the rotation of the follower pulleys 53 and 53 B are transmitted, the faster, the recovery, and therefore, the smaller the position deviation of the photosensitive drum 15 . Further, even if the motor D is not controlled by its own control system so that it remains stable in rotational speed, the inertia of the drive shaft of the motor D (rotor inertia) functions as a force which counters the changes in the load to which the follower pulleys 53 and 53 A are subjected. The amount of this force equals the square of the reduction ratio. Therefore, the driving force transmitting apparatus in this embodiment is smaller in the amount of the positional deviation of the drum shaft 15 a than any of the conventional ones, even if the motor D is not controlled in rotation speed.
[0058] Further, the driver pulleys 52 and 52 B, follower pulleys 53 and 53 B, intermediary transferring members 56 and 56 A, and tension pulley 55 , may be shaped, as necessary, so that in terms of the cross-sectional view, their peripheral portions (peripheral surfaces 52 a and 53 a ) arc outward. The employment of this structural arrangement can easily prevent the belt 54 from shifting in the direction perpendicular to the direction in which the belt 54 is driven. Further, the materials for the pulleys 52 , 52 B, 53 , 53 B, and intermediary transferring members 56 and 56 A are desired to be a highly rigid metallic substance. However, a substance other than the highly rigid metallic substance may be employed as the material for these components, provided that these components are for a driving force transmitting apparatus which is relatively low in the changes in the amount of the load, or according to the target amount of color deviation. When a substance other than the rigid metallic substance is used as the material for these components, the material for the belt 54 should be a substance which is lower in hardness than the material for the metallic belt. For example, it should be rubber.
[0059] According to the present invention, even if the load to which the follower pulley is subjected changes, the driving force is transmitted by the intermediary transmitting member, which is higher in rigidity than the belt 54 . Therefore, it is ensured that the driver pulley and follower pulley quickly and accurately respond to each other in terms of rotation. Further, if an image forming apparatus is used under the condition in which the belt of its driving force transmitting apparatus may slip, the driving force is transmitted by the intermediary transmitting member, preventing thereby the belt from slipping. In other words, the present invention can provide a driving force transmitting apparatus which is substantially more durable than any of the conventional driving force transmitting apparatuses.
[0060] While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
[0061] This application claims priority from Japanese Patent Application No. 185128/2009 filed Aug. 7, 2009 which is hereby incorporated by reference.
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A driving force transmitting apparatus includes a driving source; a drive pulley rotatable by a driving force supplied from the driving source; a follower pulley rotatable with a member to be rotated; a belt member extending around a cylindrical surface of the driving pulley and a cylindrical surface of the follower pulley; and an intermediate transmission member disposed between the driving pulley and the follower pulley, the intermediate transmission member having a rigidity higher than that of the belt member and contacted to the pulleys or opposed to the pulleys with the belt member therebetween.
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[0001] This is a Rule 53b Divisional application of Ser. No. 10/885,589 filed Jul. 8, 2004 which is a Rule 53b Continuation application of Ser. No. 10/772,364 filed Feb. 6, 2004 (issued on Nov. 29, 2005, U.S. Pat. No. 6,971,037) which is a Rule 53b Divisional application of Ser. No. 10/194,687 filed Jul. 24, 2002 (issued on Oct. 12, 2004, U.S. Pat. No. 6,804,791) which is a Rule 53b Divisional application of Ser. No. 09/583,168 filed May 30, 2000 (issued on Mar. 18, 2003, U.S. Pat. No. 6,535,168), which is a Rule 53b Continuation application of Ser. No. 08/283,165 filed Aug. 3, 1994 which is abandoned, which is a Rule 62 Continuation application of Ser. No. 07/671,929 filed Mar. 20, 1991 which is abandoned.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a data processing apparatus provided with a display device.
[0004] 2. Description of the Prior Art
[0005] Among compact and lightweight microcomputers, portable type computers powered by batteries are now used extensively. Particularly, one of them known as a note-size computer is lighter in weight and smaller in size, yet provides equal capabilities to those of a desktop or laptop computer. The note-size computer powered by batteries is handy for use in a place where a power supply facility is rarely available, e.g. a meeting room or a lecture hall.
[0006] However, the disadvantage of such handy use is that the life of batteries is short and limited. When used to record a business meeting or a college lecture, the service duration of such a note-size computer with fully charged batteries is preferably 10 hours nonstop; more preferably, 20 to 30 hours. If possible, more than 100 hours-a standard of hand calculators-is most desired.
[0007] So far, the service operation of a commercially available note-size computer lasts 2 to 3 hours at best. This results in battery runout in the middle of a meeting or college lecture causing an interruption during input work. As a result, troublesome replacement of batteries with new ones will be needed at considerable frequency.
[0008] Such a drawback of the note-size computer tends to offset the portability in spite of its light weight and compactness.
[0009] It is understood that known pocket-type portable data processing apparatuses including hand calculators and electronic notebooks are much slower in processing speeds than common microcomputers and thus, exhibit less power requirements. They are capable of servicing for years with the use of a common primary cell(s) of which life will thus be no matter of concern. The note-size computer, however, has a processing speed as high as that of a desktop computer and consumes a considerable amount of electric energy-namely, 10 to 1000 times the power consumption of any pocket-type portable data processing apparatus. Even with the application of up-to-date high quality rechargeable batteries, the serving period will be 2 to 3 hours at maximum. This is far from a desired duration demanded by the users. For the purpose of compensating the short life of batteries, a number of techniques for energy saving have been developed and some are now in practical use.
[0010] The most well known technique will now be explained.
[0011] A “resume” function is widely used in a common note-size computer. It works in a manner that when no input action continues for a given period of time, the data needed for restarting the computer with corresponding information is saved in a nonvolatile IC memory and then, a CPU and a display are systematically turned off. For restart, a power switch is closed and the data stored in the IC memory is instantly retrieved for display of the preceding data provided before disconnection of the power supply. This technique is effective for extension of the battery servicing time and suitable in practical use.
[0012] However, a specified duration, e.g. 5 minutes, of no key entry results in de-energization of the entire system of the computer and thus, disappearance of display data. Accordingly, the operator loses information and his input action is interrupted. For reviewing the display data or continuing the input action, the power switch has to be turned on each time. This procedure is a nuisance for the operator. The resume technique is advantageous in saving energy of battery power but very disadvantageous in operability of the note-size computer.
[0013] More specifically, the foregoing technique incorporates as a means for energy saving a system which de-energizes all the components including a processing circuit and a display circuit. The operator is thus requested to turn on the power switch of the computer at considerable frequencies during intermittent data input action because each no data entry duration of a given length triggers automatic disconnection of the switch. In particular, the data input operation with a note-size computer is commonly intermittent and thus, the foregoing disadvantage will be much emphasized.
SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to provide an improved data processing apparatus capable of substantially reducing power consumption while performing required data processing operations.
[0015] A data processing apparatus according to the present invention comprises: a data input unit for input of external data; a first processing unit for processing the data inputted through the data input unit; a second processing unit for processing the data inputted through the data input unit and/or an output data of the first processing unit; and a display unit for displaying an output data of the first and/or second processing units, wherein the display unit has a memory function for maintaining a display state without being energized, and the first processing unit has a means for actuating the second processing unit according to a timing or a kind of the input data.
[0016] For example, when no data entry continues, the second processing unit or the display unit is inactivated or decreased in clock rate thus diminishing power consumption. Also, the present invention allows the display of data to remain intact. Upon occurrence an input data, the first processing unit activates the second processing unit to process the data. Thus, the operator can prosecute his job without knowledge of an interrupted de-energization. As a result, an appreciable degree of energy saving is guaranteed without affecting the operability and thus, the service life of batteries will largely be increased.
[0017] In another aspect, the first processing unit may activate the second processing unit according to the kind of the input data. When the input data is such a data that requires a processing in the second processing unit, the first processing unit activates the second processing unit. The second processing unit, after completing a required operation or processing, may enter an inactive state by itself or may be forced into the inactive state by the first processing unit. Thus, the power consumption will be reduced to a considerable rate without affecting the operability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a block diagram of a data processing apparatus showing a first embodiment of the present invention;
[0019] FIG. 2 is a timing chart;
[0020] FIG. 3 is a view showing the arrangement of a display unit;
[0021] FIG. 4 is a cross sectional view explaining the operating principle of the display unit;
[0022] FIGS. 5 ( a ) and 5 ( b ) are views showing displayed images on the display unit;
[0023] FIG. 6 is a flow chart;
[0024] FIG. 7 - a is a block diagram showing an arrangement of components; FIG. 7 - b is a block diagram showing another arrangement; FIG. 7 - c is a block diagram showing a further arrangement; FIG. 7 - d is a flow chart;
[0025] FIG. 8 ( a ) through 8 ( f ) illustrate the operating principle of a reflective device with the use of different reflecting plates;
[0026] FIG. 9 is a block diagram showing a second embodiment of the present invention;
[0027] FIG. 10 - a is a block diagram associated with a first processing unit; FIG. 10 - b is a block diagram associated with a second processing unit;
[0028] FIGS. 11 - a and 11 - b are flow charts:
[0029] FIG. 12 is a timing chart;
[0030] FIG. 13 is a view explaining the representation of a cursor;
[0031] FIG. 14 is a view showing a sequence of translation procedures;
[0032] FIG. 15 is a view explaining data insertion;
[0033] FIG. 16 is a view explaining a copy mode;
[0034] FIG. 17 is a block diagram showing a modification of the second embodiment;
[0035] FIG. 18 is a block diagram showing a third embodiment of the present invention;
[0036] FIG. 19 is a flow chart;
[0037] FIG. 20 is a block diagram showing a fourth embodiment of the present invention;
[0038] FIG. 21 is a timing chart of the fourth embodiment;
[0039] FIG. 22 is a block diagram showing a fifth embodiment of the present invention;
[0040] FIG. 23 is a timing chart of the fifth embodiment;
[0041] FIG. 24 is a block diagram showing a data input unit; and
[0042] FIG. 25 is a block diagram showing a combination of the first and second processing units.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] Preferred embodiments of the present invention will be described referring to the accompanying drawings.
Embodiment 1
[0044] FIG. 1 is a block diagram of a data processing apparatus showing a first embodiment of the present invention.
[0045] The data processing apparatus comprises a data input unit 3 , a first processing block 1 , a second processing block 98 , and a display block 99 .
[0046] In operation, a data input which is fed to the data input unit 3 of the data processing apparatus by means of key entry with a key-board or communications interface is transferred to the first processing block 1 in which a first processor 4 examines which key in key entry is pressed or what sorts of data are input from the outside and determines the subsequent procedure according to the information from a first memory 5 .
[0047] If no input is supplied to the data input unit 3 throughout a given period of time as shown in FIG. 2 - a and also, the action of a second processor 7 has been completed, the feeding of clock signals to the second processor 7 and a display circuit 8 is halted by an interruption controller 6 and/or a process of energy saving is systematically executed.
[0048] The energy saving process will now be described referring to FIG. 2 .
[0049] As shown in FIG. 2 - a, a data input entered at t 1 using an n-th key of the key-board is transferred from the data input unit 3 to the first processor 4 .
[0050] The first processor 4 when examining the data input and determining that further processing at the second processor 7 is needed delivers a start instruction via the interruption controller 6 and a start instruction line 80 to the second processor 7 which thus commences receiving the data input from the first processor 4 . The second processor 7 starts processing the data input when t=t 3 as shown in FIG. 2 - c and upon finishing, sends an end signal to the first processor 4 . In turn, either the first processor 4 or the interruption controller 6 delivers a stop instruction to the second processor 4 via the startup instruction line 80 . Accordingly, the second processor 4 transfers finally processed data from its RAM memory or register to the second memory for temporary storage and then, stops processing action when t=t 5 as shown in FIG. 2 - c or enters into an energy saving mode where a consuming power is sharply attenuated. After t 5 where the actuation of the second processor 7 is ceased, the data remains held in the second memory 9 due to its nonvolatile properties or due to the action of a back-up battery. If display change is needed, the second processor 4 sends a display change signal to the first processor 4 . The first processor 4 then delivers a display start instruction via a display start instruction line 81 to the display circuit 8 for starting actuation. When t=t 4 as shown in FIG. 2 - d, the command signal is transmitted to the display circuit 8 which in turn retrieves the data of a previous display text from a video memory 82 or the second memory 9 and displays a new image corresponding to the display change signal and data from the second processor 7 . When t=t 6 , the display circuit 8 sends its own instruction or an end signal via the interruption controller 6 to the first processor 4 and upon receiving an instruction from the first processor 4 , stops or diminishes clock generation to enter a display energy saving mode. Thereafter, the power consumption of the display circuit 8 will largely be declined as illustrated after t 6 in FIG. 2 - d.
[0051] After t 6 , the display circuit 8 stays fully or nearly inactivated but a display 2 which is substantially consisted of memory retainable devices, e.g. ferroelectric liquid crystal devices, continues to hold the display image. The arrangement of the display 2 will now be described. The display 2 , e.g. a simple matrix type liquid crystal display, contains a matrix of electrodes in which horizontal drive lines 13 and vertical drive lines 14 coupled to a horizontal driver 11 and a vertical driver 12 respectively intersect each other, as best shown in FIG. 3 . FIG. 4 illustrates a pixel of the display 2 in action with a voltage being applied.
[0052] In each pixel, a ferroelectric liquid crystal 17 is energized by the two, horizontal and vertical lines 13 , 14 which serve as electrodes and are provided on glass plates 15 and 16 respectively.
[0053] More particularly, FIG. 4 - a shows a state where light is transmitted through. When a signal is given, the ferroelectric liquid crystal 17 changes its crystalline orientation and acts as a polarizer in which an angle of polarization is altered, thus allowing the light to pass through.
[0054] When a voltage is applied in the reverse direction, the ferroelectric liquid crystal 17 causes the angle of polarization to turn 90 degrees and inhibits the passage of light with polarization effects, as shown in FIG. 4 - b. The ferroelectric liquid crystal 17 also has a memory retainable effect as being capable of remaining unchanged in the crystalline orientation after the supply of voltage is stopped, as shown in FIG. 4 - c. Accordingly, throughout a duration from t=t 6 to t=t 14 , explained later, the display remains intact without any operation of the display circuit 8 . While the energy saving mode is involved after t 6 , both the data input unit 3 and the first processor 4 are only in action.
[0055] The first processor 4 performs only conversion of key entry to letter code or the like. In general, the key entry is conducted by a human operator and executed some tens times in a second at best. The speed of data entry by a human operator is 100 times or more slower than the processing speed of any microcomputer. Hence, the processing speed of the first processor 4 may be as low as that of a known hand calculator and the power consumption will be decreased to hundredths or thousandths of one watt as compared with that of a main CPU in a desktop computer. As shown in FIG. 2 - b, the first processor 4 continues operating while a power switch 20 of the data processing unit 1 is closed. However, it consumes a lesser amount of energy and thus, the power consumption of the apparatus will be low.
[0056] When n+1-th key entry is made at t 11 , the first processor 4 examines the data of the entry at t 12 and if necessary, delivers a start instruction via the interruption controller 6 or directly to the second processor 7 for actuation. Upon receiving the start instruction, the second processor 7 starts processing again with the use of clock signals so that the data stored in the second memory 9 , i.e. data at a previous stop when t=t 5 , such as memory data, register information, or display data, is read out and the CPU environment when t=t 5 can fully be restored. When t=t 13 , the data in the first processor 4 is transferred to the second processor 7 for reprocessing. The second processor 7 is arranged to operate at high speeds and its power consumption is as high as that of a desk-top computer. If the second processor 7 is continuously activated, the life of batteries will be shortened as well as in a known note computer. The present invention however provides a series of energy saving mode actions during the operation, whereby the energy consumption will be minimized.
[0057] The energy saving mode is advantageous. For example, the duration required for processing the data of a word processing software is commonly less than 1 ms while the key entry by a human operator takes several tens of milliseconds at maximum. Hence, although the peak of energy consumption during a period from t 13 to t 15 is fairly high in the second processor 7 as shown in FIG. 2 - c, the average is not more than a tenth or a hundredth of the peak value. It is now understood that the energy saving mode allows lower power consumption.
[0058] When t=t 14 , the second processor 7 sends a desired portion of the display data to the display 2 . Before t 14 , the display 2 continues to display the text altered at t 6 due to the memory effects of the ferroelectric liquid crystal 17 while the display circuit 8 remains inactivated. The desired data given through the key entry at t 11 is written at t 14 for regional replacement. The replacement of one to several lines of display text is executed by means of voltage application to corresponding numbers of the horizontal and vertical drive lines 13 and 14 . This procedure requires a shorter period of processing time and thus, consumes a lesser amount of energy as compared with replacement of the entire display text.
[0059] The second processor 7 then stops operation when t=t 15 and enters into the energy saving mode again as shown in FIG. 2 - c.
[0060] At the moment when the operation of the second processor 7 has been finished before t 15 or when a stop instruction from the first processor 4 is received, the second processor 7 saves the latest data in the second memory 9 .
[0061] When t=t 14 , the second processor 7 stops operation or diminishes an operating speed and enters into the energy saving mode.
[0062] When the input data is fed at short intervals, e.g. at t 21 , t 31 , t 41 , and t 51 , through a series of key entry actions or from a communications port, the second processor 7 shifts to the energy saving mode at t 23 , t 33 , and t 43 as shown in FIG. 2 - c. If the first processor 4 detects that the interval between data inputs is shorter than a predetermined time, it delivers an energy saving mode stop instruction to the second processor 7 which thus remains activated without forced de-energization and no longer enters into the energy saving mode. The energy saving mode is called back only when the interval between two data inputs becomes sufficiently long.
[0063] Also, when the first processor 4 detects that the key entry is absent during a given length of time, it actuates to disconnect the power supply to primary components including the first processor 4 for shift to a power supply stop mode. The memory data is being saved by the back-up battery while the power supply is fully disconnected.
[0064] Before disconnection of the power supply, the first processor 4 however sends a power supply stop display instruction directly or via the second processor 7 to the display circuit 8 for display of an “OFF” sign 21 shown in FIG. 5 - b and then, enters into the power supply stop mode. The OFF sign 21 remains displayed due to the memory effects of the display 2 after the power supply is disconnected, thus allowing the operator to distinguish the power supply stop mode from the energy saving mode.
[0065] In the energy saving mode, the operation can be started again by key entry action and thus, the operator will perceive no interruption in the processing action.
[0066] In the power supply stop mode, the OFF sign 21 is displayed and the operator can restart the operation in succession with the previous data retrieved from the second memory 9 by the second processor 9 when the power switch 20 is turned on. This procedure is similar to that in the conventional “resume” mode.
[0067] The foregoing operation will now be described in more detail referring to a flow chart of FIG. 6 . When the power switch 20 is turned on at Step 101 , the first processor 4 starts activating at Step 102 . The input data given by key entry is transferred from the data input unit 3 to the first processor 4 at Step 103 . At Step 104 , it is examined whether the duration of no-data entry lasts for a predetermined time or not. If the no-data entry duration t is greater than the predetermined time, the procedure moves to Step 105 where the actuation of the second processor 7 is examined. If the second processor 7 is in action, the procedure moves back to Step 103 . If not, the entire apparatus is de-energized, at Step 106 , and stops actuating at Step 107 before restarting with Step 101 where the power supply switch 20 is closed.
[0068] If the no-data entry duration t is greater than the predetermined time, but is as short as a few minutes, the procedure is shifted from Step 104 to Step 108 . When the processing frequency in the first and second processors 4 and 7 is low, the procedure moves from Step 108 to Step 109 where a back light is turned off for energy saving.
[0069] If the no-data entry duration t is not greater than the predetermined time, the operation in the first processor 4 is prosecuted at Step 110 . Also, it is examined at Step 100 a whether the data of text is kept displayed throughout a considerable length of time or not. If too long, refreshing action of the data display is executed at Step 110 b for prevention of an image burn on the screen. At Step 110 c, the processing frequency in the second processor 7 is examined and if it is high, the second processor 7 is kept in action at Step 110 d. If the processing frequency is low, the procedure moves to Step 111 . When it is determined at Step 111 that no further processing in the second processor 7 is needed, the procedure returns to Step 103 .
[0070] When further processing in the second processor 7 is required, the procedure moves from Step 111 to Step 112 a where the actuation of the second processor 7 is examined. If the second processor 7 is not in action, a start instruction is fed at Step 112 b to the second processor 7 which is in turn activated at Step 113 by the first processor 4 and the interruption controller 6 . The second processor 7 then starts processing action at Step 114 . If it is determined at Step 115 that a change in the text of display is needed, the procedure moves to Step 116 a where a display change instruction is supplied to both the interruption controller 6 and the first processor 4 . Then, the interruption controller 6 delivers a display energizing instruction to the display block 99 at Step 116 b. The display circuit 8 is activated at Step 116 c and the display change on the display 2 including the replacement of a regional data with a desired data is carried out at Step 117 . After the display change is checked at Step 118 , a display change completion signal is sent to the first processor 4 at Step 117 a. When the display change completion signal is accepted at Step 117 b, the display 2 is turned off at Step 119 .
[0071] If no change in the display text is needed, the procedure moves from Step 115 to Step 120 where the completion of the processing in the second processor 7 is examined. If yes, a processing completion signal is released at Step 120 a. As a result, the second processor 7 stops operation at Step 121 upon receiving a stop signal produced at Step 120 b and the procedure returns back to Step 103 .
[0072] FIGS. 7 - a and 7 - b are block diagrams of a note-size computer according to the first embodiment of the present invention.
[0073] As shown in FIG. 7 - a, a data input block 97 comprises a keyboard 201 , a communication port 51 with RS232C, and a floppy disk controller 202 . Also, a hard disk unit 203 is provided separately. A first processing block 1 is mainly consisted of a first processor 4 . A second processing block 98 contains a second processor 7 which is a CPU arranged for shift to and back from the energy saving mode upon stopping and feeding of a clock signal respectively and is coupled to a bus line 210 . Also, a ROM 204 for start action, a second memory 9 of DRAM, and a backup RAM 205 which is an SRAM for storage of individual data of returning from the resume mode are coupled to the bus line 210 . Both ends of the bus line 210 are connected to the first processor 4 and a display block 99 respectively. The display block 99 has a graphic controller 206 and a liquid crystal controller driver 207 arranged in a display circuit. There are also provided a video RAM 209 and a liquid crystal display 208 . For energy saving operation, corresponding components only in the arrangement are activated while the remaining components are de-energized. This energy saving technique is illustrated in more detail in Table 1. In general, input operation for e.g. word processing involves an intermittent action of keyboard entry. Hence, the power supply is connected to every component except the communications I/O unit. While a clock signal is fed to the first processing block 1 , no clock signals are supplied to the second processing block 98 and the display block 99 . Power is thus consumed only in the first processing block 1 . If necessary, the second block 98 and/or the display block 99 are activated within a short period of time. If more frequent operations are needed, the second processing block 98 is kept activated for acceleration of processing speeds.
[0074] When the key entry is absent for a given time, the second processing block 98 is disconnected and simultaneously, its processing data is stored in a backup memory for retrieval in response to the next key entry.
[0075] FIG. 7 - b is similar to FIG. 7 - a, except that the first processor 4 having a lower clock frequency is used as a “monitor” for the total system and the processing will be executed by the second processor 7 having a higher clock frequency. The first processor 4 is adapted for operating an event processing method by which the second processor 7 is activated for processing action corresponding to data of the keyboard entry. The second processor 7 stops operation for the purpose of energy saving when the processing action is finished and remains inactivated until another key entry commences. The display block 99 starts operating in response to a display signal from the second processor 7 and stops automatically after completion of display. This procedure can be executed with a common operating system similar to any known operating system, thus ensuring high software compatibility. For example, MS-DOS is designed to run with the use of one complete CPU. Hence, the energy saving effect will hardly be expected during operation with conventional application software programs. It is then a good idea that a specific operating system and a corresponding word processing software which are installed in two CPUs are provided in addition to the conventional operating system. Accordingly, a word processing job can be performed using the specific software with the operating system of the present invention and thus, the power consumption will be reduced to less than a tenth or hundredth. Also, general purpose software programs can work with the conventional operating system-although the energy saving effect will be diminished. It would be understood that about 80% of the job on a note-size computer is word processing and the foregoing arrangement can contribute to the energy saving.
[0076] FIG. 7 - c is a block diagram of another example according to the first embodiment and FIG. 7 - d is a flow chart showing a procedure with the use of a conventional operating system such as MS-DOS. The second processor 7 is a CPU capable of holding data from its register and internal RAM during actuation of no clock or de-energization. When key entry is made at Step 251 , a keyboard code signal from the keyboard 201 is transferred by the first processor 4 to a start device 221 which remains activated, at Step 252 . At Step 253 , the start device 221 delivers a clock signal to a main processor 222 which is de-energized. Both of the register 223 and the internal RAM 224 are coupled to a backup source and thus, start operating upon receipt of the clock signal. At Step 254 , the main processor 222 starts the program which has been on stand-by for key entry. The program is then processed for e.g. word processing according to data of the key entry, at Step 255 . At Step 257 , a display instruction is released for replacement of display text if required at Step 256 . At Step 258 , the graphic controller 206 is activated. The data in the video RAM 209 is thus rewritten at Step 259 . After the liquid crystal controller driver 207 is activated at Step 261 , a desired change in the display text is made on the liquid crystal display 208 formed of ferroelectric liquid crystal. Then, the video RAM 209 is backup energized at Step 262 and the display block 99 is de-energized, at Step 263 , thus entering into the energy saving mode. When the processing in the second processor 7 is completed at Step 270 , the program stops and moves into a “keyboard entry stand-by” stage at Step 271 . At Step 272 , the data required for re-actuation of the register 223 and the internal RAM 234 is saved and the second memory 9 is backup energized before a clock in the CPU is stopped. Then, the second processor 7 stops operation, at Step 273 , thus entering into the energy saving mode. As the start device 221 remains activated, the second processor 7 stays on stand-by for input through keyboard entry at Step 251 or from the communications port 5 . As understood, the start device 221 only is kept activated in the second processing block 98 . The CPU shown in FIG. 7 - c provides backup of registers with its clock unactuated and ensures instant return to operation upon actuation of the clock. As a single unit of the CPU is commonly activated, a conventional operating system can be used with equal success. Also, existing software programs including word processing programs can be processed with less assignment and thus, private data stock will be permitted for optimum use. Consequently, it would be apparent that this method is eligible. In addition, the consumption of electric energy will be much decreased using a technique of direct control of the first processor 1 on display text change which will be described later with a second embodiment of the present invention. As understood, the resume mode allows most components to remain de-energized when no keyboard entry lasts for a long time.
[0077] As a ferroelectric liquid crystal material has a memory effect, permanent memory results known as protracted metastable phenomenon will appear when the same text is displayed for a longer time. For prevention of such phenomenon, a display change instruction is given to the first processor 4 and the power switch 20 upon detection with the timer 22 that the display duration exceeds a predetermined time in the energy saving mode or power supply stop mode. Accordingly, the display circuit 8 actuates the display 2 to change the whole or a part of the display text, whereby permanent memory drawbacks will be eliminated.
[0078] If it is happened that the persistence of such permanent memory effects allows no change in the display text on the display 2 , the crystalline orientation of liquid crystal is realigned by heating up the display 2 with a heater 24 triggered by a display reset switch 23 . Then, arbitrary change in the display text on the display 2 will be possible.
[0079] Energy saving can be promoted by stopping the clock in the second processor 7 during the energy saving mode. When more or full energy saving is wanted, the power supply to the second processor 7 or the display circuit 8 is disconnected by the interruption controller 6 .
[0080] As understood, the power supply stop mode requires a minimum of power consumption for backup of the second memory 9 .
[0081] As shown in FIG. 1 , the back light 25 is turned off when the power source is a battery and a reflective device 27 is activated by a reflection circuit 26 for display with a reflection mode.
[0082] The reflective device 27 is composed of a film of ferroelectric liquid crystal which provides a transparent mode for transmission of light, as shown in FIG. 8 - a, and an opaque mode for reflection as shown in FIG. 8 - b, for alternative action. Incoming light 32 is reflected on the reflective device 27 and runs back as reflected light 33 . At this time, polarization is also effected by the polarizers in the display 2 and the reflective device 27 , whereby the number of components will be reduced. Also, a film-form electrochromic display device may be used for providing a transmission mode and a white diffusion screen mode in which it appears like a sheet of white paper.
[0083] The reflective device 27 may be of fixed type, as shown in FIGS. 8 - c and 8 - d , comprising a light transmitting layer composed of low refraction transmitting regions 28 and high refraction transmitting regions 29 and a reflecting layer 31 having apertures 30 therein.
[0084] As shown in FIG. 8 - c, light emitted from the back light 25 enters the high refraction transmitting regions 29 where it is fully reflected on the interface between the high and low refraction transmitting regions 29 , 28 and passes across the apertures 31 to a polarizer plate 35 . The polarized light is then transmitted to a liquid crystal layer 17 for producing optical display with outwardly emitted light.
[0085] During the reflection mode in battery operation, outside light 32 passes the liquid crystal layer 17 and is reflected by the reflecting layer 31 formed by vapor deposition of aluminum and reflected light 33 runs across the liquid crystal layer 17 again for providing optical display.
[0086] The reflective device 27 requires no external drive circuit, thus contributing to the simple arrangement of a total system. It is known that such a combination of high and low refraction transmitting regions is easily fabricated by a fused salt immersion method which is commonly used for making refraction distributed lenses.
[0087] Although such a transmission/reflection combination type liquid crystal display is disadvantageous in the quality of a display image as compared with a transmission or reflection speciality type liquid crystal display, the foregoing switching between transmission and reflection allows display of as good an image as of the speciality type display in both the transmission and reflection modes. This technique is thus suited to two-source, battery and AC application.
[0088] When the external power source is connected, the back light 25 is lit upon receiving an instruction from the first processor 4 which also delivers a transmission instruction to the reflection circuit 26 and thus, the reflective device 27 becomes transparent simultaneously. Accordingly, transmitting light can illuminate the display as shown in FIG. 8 - a.
[0089] When the battery is connected, the first processor 4 delivers a reflection signal to the reflection circuit 26 and the reflective device 27 becomes opaque to cause reflection and diffusion. As a result, the display is made by reflected outside light as shown in FIG. 8 - b while an amount of electric energy required for actuation of the back light 25 is saved.
[0090] Also, the same result as shown in FIGS. 8 - c and 8 - d may be provided with the use of a transmitting reflective plate 34 which is formed of a metal plate, e.g. of aluminum, having a multiplicity of tapered round apertures therein, as illustrated in FIGS. 8 - e and 8 - f.
[0091] As set forth above, the CPU in this arrangement provides intermittent actuation in response to the intermittent key entry and the average power consumption of the apparatus will be declined to an appreciable rate.
[0092] Also, the text remains on display during the operation and thus, the operator can perceive no sign of abnormality when the processing unit is inactivated. More particularly, a great degree of energy saving will be ensured without affecting the operability.
[0093] More particularly, each key entry action takes several tens of milliseconds while the average of CPU processing durations in word processing is about tens to hundreds of microseconds. Hence, the CPU is activated 1/100 to 1/1000 of the key entry action time for accomplishing the task and its energy consumption will thus be reduced in proportion. However, while the energy consumption of the CPU is reduced to 1/1000, 1/10 to 1/20 of the overall consumption remains intact because the display unit consumes about 10 to 20%, namely 0.5 to 1 W, of the entire power requirement. According to the present invention, the display unit employs a memory effect display device provided with e.g. ferroelectric liquid crystal and thus, its power consumption will be minimized through intermittent activation as well as the CPU.
[0094] As the result, the overall power consumption during mainly key entry operation for e.g. word processing will be reduced to 1/100 to 1/1000.
Embodiment 2
[0095] FIG. 9 is a block diagram showing a second embodiment of the present invention.
[0096] In the second embodiment, the first processor 4 is improved in the operational capability and the second processor 7 of which energy requirement is relatively great is reduced in the frequency of actuation so that energy saving can be encouraged.
[0097] As shown in FIG. 9 , the arrangement of the second embodiment is distinguished from that of the first embodiment by having a signal line 97 for transmission of a display instruction signal from the first processing block 1 to the display block 99 . In operation, the first processor 4 of the first processing block 1 delivers a display change signal to the display circuit 8 of the display block 99 for change of the display text on the display 2 . As understood, the second processor 7 delivers such a display change signal to the display circuit 8 according to the first embodiment.
[0098] FIG. 10 - a is a block diagram showing in more detail the connection of the first processor 4 , in which the first memory 5 comprises a first font ROM 40 for storage of dot patterns of alphabet and Japanese character fonts or the like in a ROM, an image memory 41 , and a general memory 42 .
[0099] As shown in FIG. 10 b, the second memory 9 may contain a second font ROM 43 which serves as a font memory.
[0100] In operation, a series of simple actions for display text change can be executed using the first processor 4 . Character codes are produced in response to the key entry and font patterns corresponding to the character codes are read from the first 40 or second font memory 43 for display on the display 2 after passing the display circuit 8 . The second memory 9 may also contain a second general memory 44 .
[0101] During input of a series of data characters which requires no large scale of processing, the first processor 4 having less energy requirement is actuated for operation of the display text change. If large scale of processing is needed, the second processor 7 is then utilized. Accordingly, the frequency of actuation of the second processor 7 is minimized and energy saving will be guaranteed. Also, as shown in FIG. 11 , the memory size of the first memory 5 can be decreased because of retrieval of font patterns from the second font ROM 43 of the second memory 9 .
[0102] The operation according to the second embodiment will now be described in more detail referring to flow charts of FIGS. 11 - a and 11 - b. FIG. 11 - a is substantially similar to FIG. 6 which shows a flow chart in the first embodiment.
[0103] A difference is that as the first processor 4 directly actuates the display circuit 8 , a step 130 and a display flow chart 131 are added. When the first processor 4 judges that the display is to be changed in Step 130 and that a desired data for replacement in the display text is simple enough to be processed by the first processor 4 at Step 111 , the procedure moves to the display flow chart 131 . The display flow chart 131 will now be described briefly. It starts with Step 132 where the display block 99 is activated. At Step 133 , the display text is changed and the change is examined at Step 133 . After the confirmation of the completion of the text change at Step 134 , the display block 99 is de-energized at Step 135 and the procedure returns back to Step 103 for stand-by for succeeding data input. FIG. 11 - b illustrates the step 133 in more detail. After the display block 99 is activated, at Step 132 , by a start instruction from the first processing block 1 , the movement of a cursor with no restriction is examined at Step 140 . If yes, data input throughout the cursor movement is executed at Step 141 . If not, it is then examined whether the desired input area on the display 2 is occupied by existing data or not at Step 142 . This procedure can be carried out by reading the data in the image memory 41 with the first processor 4 . If no, partial text replacement with desired data is executed at Step 143 . If yes, the procedure moves to Step 144 where the existing data in the input area of the display block 99 is checked using the image memory 41 and examined whether it is necessarily associated or not with the desired data to be input. If no, overwriting of the desired data is executed at Step 143 . If yes, the existing data is retrieved from the image memory 41 or read from the second font ROM 9 and coupled with the desired data for composition, at Step 145 . At Step 146 , it is examined whether a black/white inversion mode is involved or not. If yes, the data is displayed in reverse color at Step 147 . If no, the text change with the composite data is carried out at Step 148 . Then, the completion of the text change is confirmed at Step 134 and the display block 99 is turned off at Step 99 .
[0104] For a more particular explanation, the processing action of corresponding components when the key entry is made is illustrated in FIG. 12 . When the key entry with “I” is conducted at t 1 as shown in FIG. 12 - e, the first processor 4 shifts input data into a letter “I” code, reads a font pattern of the letter code from the first font ROM 40 shown in FIG. 10 , and actuates the display circuit for display of the letter “I” on the display 2 . With the memory effect display having ferroelectric crystal liquid, partial replacement in a character can be made. The partial replacement is feasible in two different manners; one for change dot by dot and the other for change of a vertical or horizontal line of dots at once. The dot-by-dot change is executed with less energy requirement but at a higher voltage, thus resulting in high cost. The line change has to be done in the group of dots at once even when one dot only is replaced but at relatively lower voltages. Both manners in this embodiment will now be explained.
[0105] When the horizontal and vertical drivers 11 , 12 shown in FIG. 3 accept higher voltages, it is possible to fill the dots forming the letter “I” one by one. Accordingly, the letter “I” can be displayed by having a font data of a corresponding character pattern supplied from the first processor 4 . However, ICs accepting such a high voltage are costly. It is thus desired for cost saving that the operating voltage is low. It is now understood that every data processing apparatus is preferably arranged, in view of capability of up-to-date semiconductors, for providing line-by-line text change operation.
[0106] It is also necessary that the first memory 5 of the first processor 4 carries at least data of one text line.
[0107] For Japanese characters, the one text line data is equal to 640×24 dots. The writing of the letter “I” thus involves replacement of 24 of 640-dot lines.
[0108] In operation, the previous data of a target line is retrieved from the image memory 41 of the first memory 5 and also, the pattern data of the letter “I” is read from the first font ROM 40 . Then, the two data are combined together to a composite data which is then fed to the display circuit 8 for rewriting of one text line on the display 2 . Simultaneously, the same data is stored into the image memory 41 . The input of “I” is now completed.
[0109] None of the first font ROM 40 and the image memory 41 is needed when the second font ROM 43 is employed for the same operation, which is capable of processing coded data. In particular, the same text line can be expressed with about 40 of 2-byte characters and thus, 40×2=80 bytes per line. Therefore, the first memory 5 may carry coded data of the entire screen image.
[0110] During the processing of data input “I” in either of the two foregoing manners, the second processor 7 provides no processing action as shown in FIG. 12 - c.
[0111] Similarly, a series of key inputs are prosecuted by the first processor 4 , “space” at t 2 , “L” at t 3 , “i” at t 4 , “v” at t 5 , and “e” at t 6 . Although the first processor 4 is much slower in the processing speed than the second processor 7 , the replacement of one text line on display can be pursued at an acceptable speed with less energy consumption.
[0112] As shown in FIG. 12 , t 7 represents the key input of an instruction for processing a large amount of data, e.g. spelling check in word processing, translation from Japanese to English, conversion of Japanese characters into Chinese characters, or calculation of chart data.
[0113] When the first processor 4 determines that the processing at the second processor 7 is needed, the second processor 7 is turned on at t 71 . The start-up of the second processor 7 is the same as of Embodiment 1. As shown in FIG. 12 - c, the second processor 7 upon being activated at t 71 returns to the original state prior to interruption and starts processing the data of text lines fed from the first processor 4 . As the processing is prosecuted, each character of changed text is displayed on the display 2 through the display circuit 8 as shown at t 72 in FIG. 12 - d.
[0114] This procedure will now be explained in the form of data entry for translation from Japanese to English. After the letter k is input at t 1 , as shown in FIG. 12 - f, and displayed on the screen, as shown in FIG. 12 - h. Then, the letter a is input at t 2 and the display reads “ka” as shown in FIG. 12 - h.
[0115] By then, the second processor 7 remains inactivated as shown in FIG. 12 - c. When a key of translating conversion is pressed at t 7 , the second processor 7 starts processing at t 71 . Accordingly, the Japanese paragraph “kareha” is translated to “He is” in English. The resultant data is sent to the display circuit 8 for dot-by-dot replacement for display.
[0116] Now, the display reads “He is” as shown in FIG. 12 - h. The dot-by-dot character replacement shown in FIG. 12 - g requires less electric energy than the text line replacement shown in FIG. 12 - d.
[0117] For the purpose of saving energy during the movement of the cursor, the black/white inversion or negative mode is used as shown in FIGS. 13 - a and 13 - b. This however increases the power consumption in the line replacement. When a bar between the lines is used for display of the cursor as shown in FIGS. 13 - c and 13 - d, the replacement of the full line is not needed and thus, energy saving will be expected. Also, the speed of processing is increased and the response will speed up during processing with the low speed first processor 4 . This advantage is equally undertaken in the dot-by-dot replacement.
[0118] As shown in FIG. 14 - a, the movement of the cursor is expressed by the bar. For ease of viewing, the bar may be lit at intervals by means of control with the first processor 4 . When a key data input is given, a corresponding character is displayed in the reverse color as shown in FIG. 14 - b. This technique will also reduce the energy consumption at least during the cursor movement.
[0119] FIGS. 14 - a to 14 - g illustrate the steps of display corresponding to t 1 to t 7 . FIG. 14 - h shows the conversion of the input text.
[0120] FIGS. 15 - a to 15 - f shows the insertion of a word during dot-by-dot replacement. It is necessary with the use of the second font ROM 43 in the arrangement shown in FIG. 10 that the data of one text line is saved in the image memory 41 because the first font ROM 40 does not carry all the Chinese characters. When the cursor moves backward as shown in FIGS. 15 - c and 15 - d, the letter n is called back from the image memory 41 . Accordingly, the data prior to insertion can be restored without the use of the second processor 7 or the second front ROM 43 as shown in FIG. 15 - d.
[0121] FIGS. 16 - a to 16 - g show the copy of a sentence “He is a man”. The procedure from FIG. 16 - a to FIG. 16 - f can be carried out with the first processor 4 . The step of FIG. 16 - g involves an insertion action which is executed by the second processor 7 .
[0122] According to the second embodiment, most of the job which is processed by the second processor 7 in the first embodiment is executed by the low power consuming first processor 4 . Thereby, the average energy consumption will be much lower than that of the first embodiment.
[0123] The optimum of a job sharing ratio between the first and second processors 4 and 7 may vary depending on particulars of a program for e.g. word processing or chart calculation. Hence, a share of the first processor 4 in operation of a software program can be controlled by adjustment on the program so as to give an optimum balance between the energy consumption and the processing speed. Also, a video memory 82 may be provided in the display block 99 for connection via a connecting line 96 with the first processor 4 . This allows the data prior to replacement to be stored in the video memory 82 and thus, the image memory 41 shown in FIG. 10 - a will be eliminated.
Embodiment 3
[0124] FIG. 18 is a block diagram showing a third embodiment of the present invention. The difference of the third embodiment from the first and second embodiments will now be described. As shown in FIG. 1 , the first embodiment has the display start instruction line 81 along which both a start instruction and a stop instruction are transferred from the first processing block 1 to the display block 99 while equal instructions are transferred by the start instruction line 80 from the same to the second processing block 98 .
[0125] The third embodiment contains no display start instruction line 81 to the display block 99 as shown in FIG. 18 . Also, the start instruction line 80 of the third embodiment allows only a start instruction but not a stop instruction to be transmitted from the first processing block 1 to the second processing block 98 .
[0126] The second processor 7 stops itself upon finishing the processing and enters into the energy saving mode. When the second processor 7 determines that the display change is needed, it delivers a display start instruction via a data line 84 to the display block 99 which is then activated. After the display change on the display 2 is completed, the display block 99 stops operation and enters into the display energy saving mode. This procedure will be explained in more detail using a flow chart of FIG. 19 . The flow chart is composed of a first processing step group 151 , a second processing step group 152 , and a third processing step group 153 . At first, the difference of this flow chart will be described in respect to the sequence from start to stop of the second processing block 98 .
[0127] There is no control flow from the second processing step group 152 of the second processing block 98 to the first processing step group 151 , unlike the flow chart of the first embodiment shown in FIG. 6 . More specifically, the first processor 4 delivers, at Step 112 , a start instruction to the second processor 7 which is then activated. This step is equal to that of the first embodiment. However, the second processor 7 is automatically inactivated at Step 121 , as compared with de-energization by an instruction from the first processor 4 in the first embodiment. At Step 103 , the second processor 7 is turned to a data input stand-by state.
[0128] The difference will further be described in respect to the sequence from start to stop of the display block 99 .
[0129] In the first embodiment, a display start instruction to the display block 99 is given by the second processor 7 after completion of display data processing. According to the third embodiment, the start instruction is delivered by the second processing block 98 to the display block 99 , at Step 11 5 a shown in FIG. 19 . Then, the display block 99 is activated at Step 116 and the display change is conducted at Step 117 . After the display change is examined at Step 118 , the display block 99 stops itself at Step 119 .
[0130] As understood, the third embodiment which is similar in the function to the first embodiment provides the self-controlled de-energization of both the second processing block 98 and the display block 99 .
[0131] Also, a start instruction to the display block 99 is given by the second processing block 98 . Accordingly, the task of the first processing block 1 is lessened, whereby the overall processing speed will be increased and the arrangement itself will be facilitated.
Embodiment 4
[0132] FIG. 20 is a block diagram showing a fourth embodiment of the present invention, in which an energy saving manner is disclosed with the use of an input/output port for communications with the outside. A data processing apparatus of the fourth embodiment incorporates an input/output unit 50 mounted in its data input block 97 . The input/output unit 50 contains a communications port 51 and an external interface 52 . In operation, the unit 50 performs actions as shown in a timing chart of FIG. 21 which is similar to the timing chart of key data entry shown in FIG. 12 . When a series of inputs from the communications port are introduced at t 1 to t 74 , as shown in FIG. 21 - a, the input/output unit 50 delivers corresponding signals to the first processing block 1 . The first processor 4 sends an input data at t 1 to the display circuit 8 which in turn actuates, as shown in FIG. 21 - d, for display of a data string as illustrated in FIG. 21 - e. If an input at t 7 is bulky, the second processor 7 is activated at t 7 1 as shown in FIG. 21 - c.
[0133] The second processor 7 delivers a start instruction at t 72 to the display circuit 8 which is then actuated for data replacement on the display 2 . If the input through the communications port is not bulky, it is processed in the first processor 4 or the input/output unit 50 while the second processor 7 remains inactivated. Accordingly, energy saving during the input and output action will be ensured.
Embodiment 5
[0134] FIG. 22 is a block diagram showing a fifth embodiment of the present invention, in which a solar battery 60 is added as an extra power source. The first processor 4 operates at low speeds thus consuming a small amount of electric energy. Accordingly, the apparatus can be powered by the solar battery 60 . While the action is almost equal to that of the first embodiment, the solar battery however stops power supply when the amount of incident light is decreased considerably. If the supply is stopped, it is shifted to from the source 61 . When no key entry is made throughout a length of time and no power supply from the solar battery 60 is fed, the source stop mode is called for as shown in FIG. 23 - b. The first processor 4 saves processing data into the first memory 5 and then, stops operation. Thus, the power consumption will be reduced. When a power supply from the solar battery 60 is fed again at t 71 or another key input data is fed from the data input unit 3 , the first processor 4 starts actuating for performance of an equal action from t 72 .
[0135] One example of the start procedure of the first processor 4 will now be described. As shown in FIG. 24 , a key input device 62 of the data input unit 3 feeds a voltage from the battery 64 to a hold circuit 63 . The hold circuit 63 upon pressing of a key connects the power source to the first processor 4 for energization. Simultaneously, the key input device 62 transfers a key input data to the first processor 4 and processing will start.
[0136] Each key of the key input device 62 may have a couple of switches; one for power supply and the other for data entry.
[0137] Accordingly, as the solar battery is equipped, the power consumption will be minimized and the operating life of the apparatus will last much longer.
[0138] The solar battery 60 , which becomes inactive when no incoming light falls, may be mounted on the same plane as of the display 2 so that no display is made including text and keyboard when the solar battery 60 is inactivated.
[0139] Hence, no particular trouble will arise in practice. In case of word processing in the dark e.g. during projection of slide pictures in a lecture, a key entry action triggers the hold circuit 3 for actuation of the first processor 4 .
[0140] As the data processing apparatus of the fifth embodiment provides more energy saving, it may be realized in the form of a note-size microcomputer featuring no battery replacement for years. Also, the first and second processors in any of the first to fifth embodiments may be integrated to a single unit as shown in FIG. 25 .
[0141] It was found through experiments of simulative calculation conducted by us that the average power consumption during a word processing program was reduced from 5 w of a reference value to as small as several hundredths of a watt when the present invention was associated. This means that a conventional secondary cell lasts hundreds of hours and a primary cell, e.g. a highly efficient lithium cell, lasts more than 1000 hours. In other words, a note-size computer will be available which lasts, like a pocket calculator, over one year in use of 5-hour a day without replacement of batteries. As understood, intensive attempts at higher-speed operation and more-pixel display are concurrently being prosecuted and also, troublesome recharging of rechargeable batteries needs to be avoided. The present invention is intended to free note-size computers from tangling cords and time-consuming rechargers.
[0142] The advantages of high speed and high resolution attributed to ferroelectric liquid crystal materials have been known.
[0143] The present invention in particular focuses more attention on the energy saving effects of the ferroelectric liquid crystal which have been less regarded.
[0144] No such approach has been previously made. The energy saving effects will surely contribute to low power requirements of portable data processing apparatuses such as note-size computers.
[0145] Although the embodiments of the present invention employ a display device of ferroelectric liquid crystal for utilization of memory effects, other memory devices of smectic liquid crystal or electrochromic material will be used with equal success. The liquid crystal display is not limited to a matrix drive as described and may be driven by a TFT drive system.
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A data processing apparatus has a first processing unit for processing an input data, a second processing unit responsive to the data processed by the first processing unit for executing a processing dependent on the data and producing a display data, and a display unit having a display drive unit and a display device for displaying the display data. The second processing unit is selectively inactivated and activated under control of the first processing unit to reduce power consumption in the second processing unit. The display drive unit is also selectively inactivated and activated under control of the first processing unit to reduce power consumption in the display unit. The display device has a memory function that maintains its display image even when supply of a display drive signal from the display drive unit is stopped, so that a latest image before inactivation of the second processing unit and/or the display drive unit for power consumption reduction is visible by an operator during the inactivated and low power consumption state of the apparatus.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to and the benefit of Korean Patent Application No. 10-2011-0104654 filed in the Korean Intellectual Property Office on Oct. 13, 2011, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a laser apparatus for welding. More particularly, the present invention relates to a laser apparatus for welding that enables brazing or laser welding that joins two joining members or panels by using a laser beam through one apparatus.
BACKGROUND OF THE INVENTION
Recently, a laser beam is increasingly used in cutting, welding, and heat treatment of metal members due to cost reduction, factory automation, and quality improvement.
Primary issues required for applying the laser beam are such that energy distribution of the laser beam is uniformized, laser output is controlled so as to maintain a constant heat treatment temperature, shooting speed of the laser beam is optimized so as to satisfy productivity and quality, and energy absorption ratio is maximized. That is, cost reduction and quality improvement can be achieved when applying the laser beam if the primary issues are satisfied.
Herein, joining method for joining two joining members or panels by using the laser beam is divided into brazing and welding.
Firstly, brazing is a metal-joining process where the joining members are not melted but a filler metal is melted since non-ferrous metal or non-ferrous metal alloy (e.g., solder or braze) having a lower melting point than the joining members is used as the filler metal. In this case, the molten filler metal is diffused between the joining members by capillary phenomenon and a base metal constituting the joining members is wet by the molten filler metal. After that, if the filler metal and the joining member are cooled, the joining members are joined.
The laser brazing, compared with spot welding, can enhance degree of design freedom and productivity due to beautiful appearance, reduce cost since there is no need to spray molding or sealer into a joining portion, and improve strength of a vehicle body due to spreading stress of the joining portion. So as to obtain good brazing quality, the panels, focus of the laser beam, and an end of a filler wire should be aligned.
In addition, the laser welding is a metal-joining process where, in a state that two joining members (panels) are overlapped with each other, the laser beam is shot into a welding portion (joining portion) so as to melt the panels. In this case, a molten metal is pushed to an opposite direction of welding progress by a pressure of plasma occurring around a laser welding portion. After that, the molten metal is solidified and a welding bead is produced such that the joining members (panels) are joined by the welding bead.
Quality of laser welding is affected by gap size between the joining members. If sufficient space for expanding gasses to pass does not exist, the gas breaks through or caves the welding bead. Therefore, breakage of the welding portion can occur.
Accordingly, an additional apparatus for applying pressure to or clamping the joining members is essentially required so as to maintain a gap between the joining members.
A laser apparatus used in the laser brazing or welding includes a laser optic head in which a plurality of lenses is provided. The laser optic head is adapted to shoot the laser beam oscillated by the laser oscillator into the welding portion.
According to a conventional laser apparatus, an apparatus for supplying the filler metal is essentially required when the brazing, and the additional apparatus for applying pressure to or clamping the joining members is essentially required when welding. Therefore, initial investment cost can increase.
In a case that the laser brazing and the laser welding are simultaneously used for joining two joining members, one of the brazing and the welding should be performed after the other of the brazing and the welding was performed. Therefore, working hours are very long.
Because the brazing and the welding cannot be performed by one laser apparatus, manufacturing cost can increase.
The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it can contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY OF THE INVENTION
The present invention has been made in an effort to provide a laser apparatus for welding having advantages of reducing manufacturing cost, shortening working hours, and enhancing productivity by enabling of brazing or laser welding that joins two joining members or panels through one apparatus.
A laser apparatus for welding according to one or more exemplary embodiments of the present invention includes: a laser optic head adapted and configured to modify a spot size of a laser beam oscillated by a laser oscillator and to project the laser beam into a joining portion of joining members, wherein the laser optic head is adapted and configured to modify the spot size to selectively perform brazing or welding.
In one or more exemplary embodiments of the present invention, the laser apparatus further includes a mounting frame
In one or more exemplary embodiments of the present invention, the laser apparatus further includes a wire feeder supplying a filler metal into the laser beam projected by the laser optic head so as to perform the brazing.
In one or more exemplary embodiments of the present invention, the wire feeder is disposed at a side portion of the laser optic head and is mounted at the mounting frame.
In one or more exemplary embodiments of the present invention, the laser apparatus further includes a roller unit adapted to apply pressure to an upper portion of the joining members so as to control a gap between the joining members when laser welding the joining members.
In one or more exemplary embodiments of the present invention, the roller unit is mounted at the mounting frame and is movable upwardly or downwardly to the mounting frame.
In one or more exemplary embodiments of the present invention, the roller unit includes: a mounting bracket mounted at the mounting frame ahead of the laser optic head; an operating cylinder provided with an operating rod and mounted at a side portion of the mounting bracket, the operating rod being mounted at the operating rod so as to be movable upwardly or downwardly; and a roller connected to a front end of the operating rod, movably mounted at the operating cylinder through guide means, and adapted to slidably contact on an upper surface of the joining member according to the movement of the operating rod and to apply pressure to the joining members.
In one or more exemplary embodiments of the present invention, the guide means includes: a rail mounted at a surface of the operating cylinder along a length direction thereof; and a rail block slidably mounted on the rail, connected to the operating rod, and having a front end at which the roller is mounted through a connecting block.
In one or more exemplary embodiments of the present invention, the roller unit further includes an air blower for removing spatters when laser welding.
In one or more exemplary embodiments of the present invention, the laser optic head includes: a head housing mounted at the lower portion of the mounting frame, and provided with an upper portion having a side connected to an optical fiber cable for transmitting the laser beam oscillated by the laser oscillator and a lower portion formed of a laser shooting hole; a collimation lens mounted at an extended portion of the head housing so as to be movable upwardly or downwardly through driving means and adapted to control the size of the laser beam oscillated by the laser oscillator; a first reflector mounted at a side portion in the head housing on a vertical line of the collimation lens and adapted to totally reflect the laser beam in a horizontal direction; a second reflector mounted at the other side in the head housing on a horizontal line of the first reflector and adapted to totally reflect the laser beam reflected by the first reflector in a vertical direction; and a focus lens mounted corresponding to the laser shooting hole of the head housing on the vertical line of the second reflector, and adapted to form a focus of the laser beam reflected by the second reflector and to shoot the laser beam into the joining portion of the joining members.
In one or more exemplary embodiments of the present invention, the driving means includes: a guide rail mounted at both sides of an interior circumference of the extended portion and adapted to guide the collimation lens; a drive motor mounted at an exterior of the extended portion and having a rotation shaft facing downwardly; a driving screw connected to the rotation shaft of the drive motor; and a screw block engaged with the driving screw at the exterior of the extended portion in a state of being connected to the collimation lens.
In one or more exemplary embodiments of the present invention, the drive motor is a step motor, rotation speed and rotating direction of which can be controlled.
A method of selectively brazing or welding according to one or more exemplary embodiments of the present invention includes: providing a laser apparatus of as described herein; and actuating the laser optic head to modify the spot size of the laser beam and project the laser beam into the joining portion of the joining members to selectively perform brazing or welding.
In one or more exemplary embodiments of the present invention, the spot size approximates a width of the joining portion.
In one or more exemplary embodiments of the present invention, the method further includes supplying a filler metal into the laser beam projected by the laser optic head.
In one or more exemplary embodiments of the present invention, the method further includes applying pressure to an upper portion of the joining members so as to control a gap between the joining members when laser welding the joining members.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a laser apparatus for welding according to an exemplary embodiment of the present invention.
FIG. 2 is another perspective view of a laser apparatus for welding according to an exemplary embodiment of the present invention.
FIG. 3 is a cross-sectional view of a laser optic head applied to a laser apparatus for welding according to an exemplary embodiment of the present invention.
FIG. 4 is an operational state diagram of a laser optic head applied to a laser apparatus for welding according to an exemplary embodiment of the present invention.
FIG. 5 is an operational state diagram of a laser apparatus for welding according to an exemplary embodiment of the present invention.
The following legend of the reference numerals is provided for convenience:
1: laser apparatus
3: arm of robot
5: mounting frame
10: laser optic head
11: laser oscillator
13: head housing
14: extended portion
15: laser shooting hole
16: collimation lens
17: first reflector
18: second reflector
19: focus lens
20: driving means
21: guide rail
22: drive motor
23: driving screw
24: screw block
25: controller
30: wire feeder
40: roller unit
41: mounting bracket
43: operating cylinder
45: rail
47: rail block
48: connecting block
49: roller
50: air blower
60: sensor
P: joining member
B: laser beam
G: gap
DETAILED DESCRIPTION OF THE EMBODIMENTS
An exemplary embodiment of the present invention will hereinafter be described in detail with reference to the accompanying drawings.
Exemplary embodiments described in this specification and drawings are just exemplary embodiments of the present invention. It is to be understood that there can be various modifications and equivalents included in the spirit of the present invention at the filing of this application.
FIG. 1 is a perspective view of a laser apparatus for welding according to an exemplary embodiment of the present invention; FIG. 2 is another perspective view of a laser apparatus for welding according to an exemplary embodiment of the present invention; and FIG. 3 is a cross-sectional view of a laser optic head applied to a laser apparatus for welding according to an exemplary embodiment of the present invention.
Referring to the drawings, a laser apparatus 1 for welding according to an exemplary embodiment of the present invention enables of brazing or laser welding that joins two joining members or panels through one apparatus. Therefore, manufacturing cost and working hours can be reduced and productivity can be improved.
For achieving these purposes, the laser apparatus 1 for welding according to an exemplary embodiment of the present invention, as shown in FIG. 1 and FIG. 2 , includes a mounting frame 5 , a laser optic head 10 , a wire feeder 30 , and a roller unit 40 , and each element will be described in detail.
Firstly, the mounting frame 5 is mounted at a front end of an arm of a robot 3 .
In the present exemplary embodiment, the laser optic head 10 is mounted at a lower portion of the mounting frame 5 , changes a spot size of a laser beam B oscillated by a laser oscillator 11 , and projects the laser beam B into a joining portion of the joining members P.
The laser optic head 10 , as shown in FIG. 3 , includes a head housing 13 , a collimation lens 16 , first and second reflectors 17 and 18 , and a focus lens 19 .
The head housing 13 substantially has a rectangular shape having a space therein. An upper end of the head housing 13 is mounted at the lower portion of the mounting frame 5 .
An extended portion 14 is formed at a side of an upper portion of the head housing 13 , and an optical fiber cable is connected to the extended portion 14 . The optical fiber cable is adapted to transmit the laser beam oscillated by the laser oscillator 11 . A laser shooting hole 15 is formed at a lower portion of the head housing 13 .
The collimation lens 16 is mounted at the extended portion 14 of the head housing 13 and is movable upwardly or downwardly through driving means 20 . The collimation lens 16 is adapted to control the size (spot size) of the laser beam B oscillated by the laser oscillator 11 .
Herein, the driving means 20 include a guide rail 21 , a drive motor 22 , a driving screw 23 , and a screw block 24 , and each element will be described in detail.
The guide rail 21 is mounted at both sides of an interior circumference of the extended portion 14 and is adapted to guide the collimation lens 16 stably.
In the present exemplary embodiment, the drive motor 22 is mounted at an exterior of the extended portion 14 and has a rotation shaft facing downwardly. The driving screw 23 is connected to the rotation shaft of the drive motor 22 .
Herein, the drive motor 22 is electrically coupled with a controller 25 , and can be a step motor. Rotation speed and rotating direction of the drive motor 22 can be controlled according to an output signal of the controller 25 .
The driving screw 23 is connected to the rotation shaft of the drive motor 22 so as to rotate according to rotation of the drive motor 22 .
In addition, the screw block 24 is engaged with the driving screw 23 at the exterior of the extended portion 14 in a state of being connected to the collimation lens 16 .
Therefore, if the drive motor 22 is operated by a control signal of the controller 25 , the driving screw 23 rotates clockwise or counterclockwise and the screw block 24 engaged with the driving screw 23 moves upwardly or downwardly on the driving screw 23 .
Accordingly, the collimation lens 16 connected to the screw block 24 slides upwardly or downwardly along the guide rail 21 in the extended portion 14 .
In the present exemplary embodiment, the first reflector 17 is mounted at a side portion in the head housing 13 on a vertical line of the collimation lens 16 and is adapted to totally reflect the laser beam B in a horizontal direction.
In addition, the second reflector 18 is mounted at the other side portion in the head housing 13 on a horizontal line of the first reflector 17 and is adapted to totally reflect the laser beam B reflected by the first reflector 17 in a vertical direction.
That is, the first reflector 17 and the second reflector 18 reflects the laser beam B oscillated by the laser oscillator 11 and forming the focus controlled through the collimation lens 16 respectively in the horizontal and vertical direction so as to lead the laser beam B into the laser shooting hole 15 .
In the present exemplary embodiment, the focus lens 19 is mounted corresponding to the laser shooting hole 15 of the head housing 13 on the vertical line of the second reflector 18 .
The focus lens 19 is adapted to form the focus F of the laser beam B reflected from the second reflector 18 and to shoot the laser beam B of high power into the joining portion of the joining members P.
The laser optic head 10 changes the spot size of the laser beam B according to laser brazing or laser welding of the joining members P. These processes will be described in detail, referring to FIG. 4 .
FIG. 4 is an operational state diagram of a laser optic head applied to a laser apparatus for welding according to an exemplary embodiment of the present invention.
Referring to FIG. 4 , the screw block 24 of the driving means 20 is disposed on the driving screw 23 close to the drive motor 22 when laser brazing the joining member P. Therefore, the collimation lens 16 is positioned at an upper portion of the extended portion 14 .
Accordingly, a diameter of the laser beam B oscillated by the laser oscillator 11 is formed to be small by the collimation lens 16 disposed at the upper portion of the extended portion 14 of the head housing 13 . The laser beam B passes through the focus lens 19 as a consequence of being reflected by the first and second reflectors 17 and 18 .
Then, the laser beam B forms the focus F at a position apart from and above the joining members P by the focus lens 19 , and the laser beam B spreads toward the joining members P with respect to the focus F so as to be shot into joining members P with the diameter thereof increased. Therefore, the laser brazing is performed.
On the contrary, the driving screw 23 rotates through the operation of the drive motor 22 and the screw block 24 moves downwardly from an initial position when laser welding joining members P. Therefore, the collimation lens 16 moves downwardly along the guide rail 21 together with the screw block 24 and is disposed at a lower portion of the extended portion 14 .
Accordingly, the diameter of the laser beam B oscillated by the laser oscillator 11 becomes larger than that of the laser beam B at the brazing by the collimation lens 16 positioned at the lower portion of the extended portion 14 . The laser beam B passes through the focus lens 19 as a consequence of being reflected by the first and second reflectors 17 and 18 .
Then, the laser beam B is shot into the joining members P with the focus F formed on a surface of the joining portion of the joining members P by the focus lens 19 . Therefore, the laser welding is performed.
In the present exemplary embodiment, the wire feeder 30 is adapted to supply a filler metal into the laser beam B shot from the laser optic head 10 . The wire feeder 30 is disposed at a side of the laser optic head 10 and is mounted at the mounting frame 5 . The filler metal is melted by the laser beam B.
The wire feeder 30 is used only when the laser brazing. That is, the filler metal supplied into the laser beam B shot from the laser optic head 10 is melted and the joining members P are brazed by the molten filler metal.
In addition, the roller unit 40 , as shown in FIG. 2 , is adapted to apply pressure to an upper portion of the joining members P so as to control a gap between the joining members P when the laser welding of the joining members P. The roller unit 40 is mounted at the mounting frame 5 ahead of the laser optic head 10 and is movable upwardly or downwardly to the mounting frame 5 .
The roller unit 40 includes a mounting bracket 41 , an operating cylinder 43 , and a roller 49 .
The mounting bracket 40 is mounted at the mounting frame 5 ahead of the laser optic head 10 .
Herein, the mounting bracket 41 can be slanted with reference to the mounting frame 5 by a predetermined angle.
In the present exemplary embodiment, the operating cylinder 43 includes an operating rod R and is mounted at a side portion of the mounting bracket 41 . The operating rod R is mounted at the operating cylinder 43 and is movable upwardly or downwardly with reference to the operating cylinder 43 .
In addition, the roller 49 is connected to a front end of the operating rod R of the operating cylinder 43 , and is movably mounted at the operating cylinder 43 through guide means 42 . Therefore, the roller 49 is slidably contacted to an upper surface of the joining members P depending on movement of the operating rod R so as to apply pressure to the joining members P.
Herein, the guide means 42 includes a rail 45 mounted at a surface of the operating cylinder 43 along a length direction thereof and a rail block 47 slidably mounted on the rail 45 . The rail block 47 is connected to the operating rod R of the operating cylinder 43 , and the roller 49 is mounted at a front end of the rail block 47 through a connecting block 48 .
The guide means 42 guides movement of the roller 49 stably when the operating rod R moves upwardly or downwardly.
In addition, the guide means 42 supports the roller 49 so as to apply pressure to the joining members P stably when the roller 49 applies the pressure to the joining members P.
In the present exemplary embodiment, the roller unit 40 further includes an air blower 50 beside the roller 49 so as to remove spatters generated when the laser welding.
When the joining members P are welded by the laser beam B shot by the laser optic head 10 , the air blower 50 prevents the spatters generated from the joining members P from being attached to a surface of the joining member P or the focus lens 19 of the laser optic head 10 .
Meanwhile, a sensor 60 is mounted at the mounting bracket 41 according to the present exemplary embodiment. The sensor 60 is used for inspecting welding quality when the laser welding.
Hereinafter, operation of the laser apparatus 1 for welding according to an exemplary embodiment of the present invention will be described in detail.
FIG. 5 is an operational state diagram of a laser apparatus for welding according to an exemplary embodiment of the present invention.
As shown in FIG. 4 , the laser apparatus 1 for welding according to an exemplary embodiment of the present invention changes a position of the collimation lens 16 in the head housing 13 by the driving means 20 when laser brazing of the joining members P. Therefore, the diameter of the laser beam B oscillated by the laser oscillator 11 is controlled to perform the brazing of the joining members P.
At this time, the wire feeder 30 supplies the filler metal into the laser beam B continuously until the brazing is completed such that the brazing of the joining members P is smoothly performed.
In addition, the collimation lens 16 , as shown in FIG. 4 , is moved to the lower portion of the extended portion 14 by the driving means 20 when the laser welding of the joining members P is performed.
Therefore, the focus F of the laser beam B, as shown in <S 1 > of FIG. 5 , is positioned on the surface of the joining portion of the joining member P.
In this case, the gap G 1 formed between the joining member P 1 and the joining member P 2 is larger than that required for the laser welding.
At this state, the operating rod R of the roller unit 40 moves downwardly and the rail block 47 as well as the operating rod R slides downwardly along the rail 45 .
Then, the roller 49 mounted at the front end of the rail block 47 applies load of the operating cylinder 43 to the joining members P 1 in a state of being slidably contacted on the surface of the joining members P 1 .
Therefore, the gap G 2 formed between the joining member P 1 and the joining member P 2 becomes smaller than the gap G 1 shown in <S 1 > of FIG. 5 .
That is, the roller unit 40 controls a size of the gap formed between the joining member P 1 and the joining member P 2 to a size required for the laser welding and maintains the gap to have a constant size during the laser welding. Therefore, welding quality can be improved.
As described above, the laser apparatus 1 for welding according to an exemplary embodiment of the present invention enables of brazing or laser welding that joins two joining members P or the panels through one apparatus. Therefore, manufacturing cost and working hours can be reduced and productivity can be improved.
In addition, (i) it is possible to change the spot size of the laser beam B, (ii) the wire feeder 30 enables supplying of filler metal, and (iii) the roller unit 40 can apply pressure to the joining members so as to maintain the gap G between the joining members P. Therefore, laser brazing and welding can be simultaneously performed without an additional apparatus and at a higher quality.
While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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A laser apparatus for welding is disclosed. The laser apparatus includes: a laser optic head adapted and configured to modify a spot size of a laser beam oscillated by a laser oscillator and to project the laser beam into a joining portion of joining members, wherein the laser optic head is adapted and configured to modify the spot size to selectively perform brazing or welding. A method of selectively brazing or welding according to one or more exemplary embodiments of the present invention includes: providing a laser apparatus of as described herein; and actuating the laser optic head to modify the spot size of the laser beam and project the laser beam into the joining portion of the joining members to selectively perform brazing or welding.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relate to a process for the optical resolution of (±)-cis or (±)-trans-permethric acid.
2. Description of the Prior Art
(±)-Cis or (±)-trans-permethric acid is a carboxylic acid, whose side chain substituent may be modified, and is used; as one ingredient of the esters called pyrethroid. Pyrethroid is an insecticidal component of pyrethrum. The (±)-cis or (±)-trans-permethric acid prepared by chemical synthesis is generally obtained in the form of optically inactive racemates; namely (±)-carboxylic acids. (-)-Cis or (-)-trans-permethric acid contained in the (±)-cis or (±)-trans-permethric acid is far poorer in insecticidal activity than (+)-cis or (+)-trans-permethric acid. Accordingly, there is a demand of the development of a technique in which (±)-cis or (±)-trans-permethric acid is optically resolved in an efficient manner to obtain highly pure (+)-cis or (+)-trans-permethric acid.
Several processes of obtaining an optically active product of cis-permethric acid are known including processes of using, on (±)-cis-permethric acid, resolving agents such as optically active N-benzyl-2-aminobutanol (U.S. Pat. No. 4,599,444), N-(2,2,2-trichloro-1-formamidoethyl)piperazine (U.S. Pat. No. 4,508,919), and 1-phenyl-2-(p-tolyl)ethylamine (U.S. Pat. No. 4,327,038). Also, there are known processes in which the acid is introduced into various derivatives and then resolved. However, the resolving agents used in these processes are relatively expensive and the yield of the optically active cis-permethric acid obtained by the resolution is not high, thus leading to the problem that the optically active cispermethric acid is expensive.
For obtaining an optically active product of transpermethric acid, there have been hitherto proposed a process in which optically active β'-dimethylamino-α,α-dimethyl-β-phenethyl alcohol is used with (±)-transpermethric acid (Japanese Patent Publication No. 8815/81) and a process in which ephedrine is used with (U.S. Pat. No. 4,328,173). Similar to the optical resolution processes of the cis-permethric acid, these resolving agents are relatively expensive and the optically active transpermethric acid obtained by the resolution is not high in yield. As a result, there arises the same problem that the optically active trans-permethric acid is also expensive.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a process for optically resolving (±)-cis or (±)-transpermethric acid to obtain intended products of high purity in high yield at low costs.
According to the invention, there is provided a process for the optical resolution of (±)-cis or (±)-transpermethric acid which comprises reacting (±)-cis-permethric acid with a resolving agent of optically active 1-(p-tolyl)ethylamine or optically active cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine, or reacting (±)-transpermethric acid with a resolving agent of optically active 1-(p-isopropylphenyl)ethylamine, 1-ethylbenzylamine or cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine.
According to the above process, when reacted with an above-defined resolving agent, (+)-permethric acid and (-)permethric acid are, respectively, converted into the corresponding diastereomer salts. These diastereomer salts can be separated from each other by relying on their difference in solubility. More particularly, (±)-cispermethric acid can be optically resolved into (+)-cispermethric acid and (-)-cis-permethric acid. Likewise, (±)-trans-permethric acid can be optically dissolved into (+)-trans-permethric acid and (-)-trans-permethric acid.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the practice of the invention, the molar ratio of the resolving agent and the (±)-cis or (±)-trans-permethric acid is not critical and the resolving agent is preferably used in an amount of from 0.5 to 1.2 equivalents, more preferably from 0.8 to 1 equivalent, of the (±)-cis or (±)-trans-permethric acid in order to optically resolve the (±)-cis or (±)-trans-permethric acid efficiently and in high purity. The resolving agent is generally used in a solvent. The solvents used for this purpose include lower alcohols such as methanol, ethanol, 2-propanol, 1-propanol, 1-butanol and the like, lower alkyl methyl ketones such as acetone, methyl ethyl ketone and the like, and water. Of these, methanol is preferred because highly pure, optically active cis or trans-permethric acid can be obtained.
The amount of the solvent, more or less, varies depending upon the type of resolving agent, so that it may be difficult to determine the range of the amount in the same category. Typically, for the optical resolution of (±)-cis-permethric acid, the amount is from 2 to 10 liters per mole of the acid. For the optical resolution of (±)-trans-permethric acid, the amount is from 0.5 to 5 liters per mole of the acid.
The process of the invention is carried out, for example, in the following manner.
(±)-Cis-permethric acid and 0.8 to 1 equivalent, based on the permethric acid, of optically active cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine are added to a solvent, followed by heating for dissolution. Subsequently, the solution is cooled and supersaturated. Preferably, a (±)-cis-permethric acid/(-)-cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine salt or a (-)-cis-permethric acid/(+)-cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine salt is added only in small amounts, thereby permitting the same kind of sparingly soluble diastereomer salt to be precipitated, followed by separation of this salt. The separation of the diastereomer salt may be effected by filtration or centrifugal separation. The thus separated diastereomer salt is treated with a base such as sodium hydroxide, potassium hydroxide, sodium methoxide or the like to collect (-) or (+) cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine, followed by further treatment with an acid such as hydrochloric acid, sulfuric acid, phosphoric acid, p-toluenesulfonic acid or the like to obtain (+)-cis-permethric acid.
For the optical resolution of (±)-cis-permethric acid by the use of 1-(p-tolyl)ethylamine, (+)-cis-permethric acid/(-)-1-(p-tolyl)ethylamine and (-)-cis-permethric acid/(+)-1-(p-tolyl)ethylamine are precipitated as diastereomer salts. These salts are separated and subsequently treated with a base such as sodium hydroxide, potassium hydroxide, sodium methoxide or the like to collect (-) or (+)-1-(p-tolyl)ethylamine, followed by further treatment with an acid such as hydrochloric acid, sulfuric acid, phosphoric acid, p-toluenesulfonic acid or the like to obtain (+) or (-)-cis-permethric acid.
Where (±)-cis-permethric acid is optically resolved by the use of cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine as the resolving agent, (±)-cis-permethric acid and 0.8 to 1 equivalent of optically active cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine based on the (±)-cispermethric acid are added to a solvent and thermally dissolved, followed by cooling for supersaturation. Preferably, a small amount of (+)-trans-permethric acid/(-)-cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine salt or (-)-trans-permethric acid/(+)-cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine salt is added to permit to same kind of sparingly soluble diastereomer salt and separated. The separation of the diastereomer is effected by filtration, centrifugal separation or the like. The resultant diastereomer salt is subsequently treated with a base such as sodium hydroxide, potassium hydroxide, sodium ethoxide or the like to collect (-) or (+)-cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine and further treated with an acid such as hydrochloric acid, sulfuric acid, phosphoric acid, p-toluenesulfonic acid or the like, thereby obtaining (+) or (-)-trans-permethric acid.
For the optical resolution of (±)-cis-permethric acid by the use of optically active 1-(p-isopropylphenyl)ethylamine as an optical resolving agent, (+)-trans-permethric acid/(+)-1-(p-isopropylphenyl)ethylamine salt or (-)-trans-permethric acid/(-)-1-(p-isopropylphenyl)ethylamine salt is precipitated as a sparingly soluble diastereomer salt. This salt is separated, after which it is treated with a base such as sodium hydroxide, potassium hydroxide, sodium methoxide or the like to collect (+) or (-)-1-(p-isopropylphenl)ethylamine, followed by further treatment with an acid such as hydrochloric acid, sulfuric acid, phosphoric acid, p-toluenesulfonic acid or the like, thereby obtaining (+) or (-)-trans-permethric acid.
Moreover, for the optical resolution of (±)-cispermethric acid by the use of optically active 1-ethylbenzylamine as a resolving agent, (+)-trans-permethric acid/(-)-1-ethylbenzylamine salt or (-)-trans-permethric acid/(+)-1-ethylbenzylamine salt is precipitated as a sparingly soluble diastereomer. After separation of the salt, it is treated with a base such as sodium hydroxide, potassium hydroxide, sodium methoxide or the like to collect (-) or (+)-1-ethylbenzylamine, followed by further treatment with an acid such as hydrochloric acid, sulfuric acid, phosphoric acid, p-toluenesulfonic acid or the like to obtain (+) or (-)-trans-permethric acid.
The present invention is described in more detail by way of examples.
EXAMPLE 1
0.42 g (2 mmols) of (±)-cis-permethric acid (hereinafter abbreviated as (±)-1) and 0.27 g (2 mmols) of (-)-1-(p-tolyl)ethylamine (hereinafter abbreviated as (-)-2) were added to 6 ml of methanol and heated for dissolution, followed by gradual cooling to room temperature. The solution was allowed to stand overnight, after which the resultant crystals were filtered to obtain 0.31 g (0.90 mmols) of (+)-1/(-)-2 salt.
This salt was recrystallized from 3.9 ml of methanol to obtain 0.20 g (0.57 mmols) of (+)-1/(-)-2 salt. The yield based on the employed (±)-1 was 57.0%. m.p.=194°-199° C. and [α] 589 =28.3° (C=1, methanol). 1 ml of a 1N sodium hydroxide aqueous solution was added to the salt and subjected to ether extraction. To the resultant aqueous phase was added 1.1 ml of 1N hydrochloric acid, which was extracted with ether, followed by drying the resultant organic phase with anhydrous sodium sulfate and removing the solvent by distillation under reduced pressure to obtain 0.12 g (0.57 mmols) of (+)-1. The yield was 57.0%. m.p.=88°-90° C. and [α] 589 =+31.6° (C=1, chloroform). The optical purity was 98.1%.
EXAMPLE 2
0.42 g (2 mmols) of (±)-1 and 0.44 g (2 mmols) of (+)-cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine (hereinafter abbreviated as (+)-3) were added to 11 m of methanol and heated for dissolution, followed by gradual cooling to room temperature. The solution was allowed to stand for 4.5 hours and the resultant crystals were filtered to obtain 0.38 g (0.92 mmols) of (-)-1/(+)-3 salt.
The salt was recrystallized from 9 ml of methanol to obtain 0.31 g (0.73 mmols) of (-)-1/(+)-3 salt. The yield was 73.0% based on the employed (+)-1. m.p.=183°-185° C. and [α] 589 =+18.9° (C=0.6, methanol), 1.1 ml of a 1N sodium hydroxide solution was added to the salt, followed by ether extraction, 1.5 ml of 1N hydrochloric acid was added to the resultant aqueous phase and extracted with ether. The organic phase was dried with anhydrous sodium sulfate and subjected to distillation under reduced pressure to remove the solvent, thereby obtaining 0.13 g (0.62 mmols) of (-)-1. Yield=62.0%. m.p.=90°-91° C. and [α] 589 =-32.2° (C=1, chloroform), The optical purity was 100%.
EXAMPLE 3
4.18 g (20 mmols) of (±)-1 and 4.39 g (20 mmols) of (-)3 were added to 110 ml of methanol and heated for dissolution, followed by gradual cooling to room temperature. The solution was allowed to stand for 4.5 hours and the resultant crystals were filtered to obtain 3.78 g (8.81 mmols) of (+)-1/(+)-3 salt. The yield based on the starting (±)-1 was 88.1%. m.p.=183°-185° C. and [α] 589 =18.4° (C=0.7, methanol). 4.4 ml of a 3N sodium hydroxide solution was added to the salt and subjected to ether extraction. 3.2 ml of 6N hydrochloric acid was added to the resultant aqueous phase and extracted with ether, followed by drying the organic phase with anhydrous sodium sulfate and removing the solvent by distillation under reduced pressure to obtain 1.83 g (8.75 mmols) of (+)-1. Yield=87.5%. m.p.=87.90° C. and [α] 589 =+30.1° (C=1.4, chloroform). The optical purity was 93.5%.
EXAMPLE 4
4.18 g (20 mmols) of (±)=1 and 3.50 g (16 mmols) of (+)-3 were added to 90 ml of methanol and heated for dissolution, followed by gradual cooling to room temperature. The solution was allowed to stand for 4.5 hours and the resultant crystals were filtered to obtain 3.64 g (8.50 mmols) of (+)-1/(-)-3 salt. The yield based on the starting (±)-1 was 85.0%. m.p.=180°-181° C. and [α] 589 =++17.0° (C=0.7, methanol). 4.0 ml of a 3N sodium hydroxide solution was added to the salt and subjected to ether extraction. 2.5 ml of 6N hydrochloric acid was added to the resultant aqueous phase and extracted with ether, followed by drying the organic phase with anhydrous sodium sulfate and removing the solvent by distillation under reduced pressure to obtain 1.77 g (8.46 mmols) of (-)-1. Yield=84.6%. m.p.=85°-88° C. and [α] 589 =-29.3° (C=1.0, chloroform). The optical purity was 93.5%.
Reference 1
4.18 g (20 mmols) of (±)-1 and 4.23 g (20 mmols) of (-)-1-phenyl-2-(p-tolyl)ethylamine (hereinafter abbreviated as (-)-4) were added to 30 ml of methanol and heated for dissolution, followed by cooling to room temperature. The solution was allowed to stand for 4.5 hours and the resultant crystals were filtered to obtain 5.17 g (12.3 mmols) of crude (-)-1/(+)-4 salt.
The salt was recrystallized from 19 ml of methanol to obtain 3.15 g (7.5 mmols) of (-)-1/(+)-4 salt. The yield based on the starting (±)-1 was 75%. [α] 589 =-27.8°. 3 ml of a 3N sodium hydroxide solution was added to the salt and subjected to ether extraction. 1.5 ml of 6N hydrochloric acid was added to the resultant aqueous phase and extracted with ether, after which the organic phase was dried with anhydrous sodium sulfate and the solvent was removed by distillation under reduced pressure to obtain 1.52 g of (-)-1. Yield=73%. [α] 589 =-15.4° (C=1.0, cloroform). The optical purity was found to be 47.7%.
EXAMPLE 5
0.42 g (2 mmols of (±)-trans-permethric acid (hereinafter abbreviated as (±)-11) and 0.33 g (2 mmols) of (+)-1-(p-isopropylphenyl)ethylamine (hereinafter abbreviated as (+)-12) were added to 3 ml of methanol and heated for dissolution, followed by cooling down to room temperature. The solution was allowed to stand overnight and the resultant crystals were filtered to obtain 0.23 g (0.62 mmols) of (+)-11/(+)-12 salt. The yield based on the starting (+)-11 was 62.0%. m.p.=186°-192° C. and [α] 589 =+13.5° (C=1.5, methanol). 0.7 ml of a 1N sodium hydroxide solution was added to the salt and subjected to ether extraction. 0.8 ml of 1N hydrochloric acid was added to the resultant aqueous phase and subjected to extraction with ether, followed by drying the organic phase with anhydrous sodium sulfate and removing the solvent by distillation under reduced pressure to obtain 0.13 g (0.62 mmols) of (+)-11, Yield=62.0%, m.p.=69°-76° C. and [α] 589 =+26.3° (C=1.2, chloroform). The optical purity was 73.7%.
EXAMPLE 6
0.42 g (2 mmols) of (±)-11 and 0.27 g (2 mmols) of (-)-1-ethylbenzylamine (hereinafter abbreviated as (-)-13) were added to 5 ml of methanol and heated for dissolution, followed by gradual cooling to room temperature. The solution was allowed to stand overnight and the resultant crystals were filtered to obtain 0.21 g (0.61 mmols) of (+)-11/(+)-13 salt. The yield based on the starting (+)-11 was 61.0%. m.p.=186°-191° C. and [α] 589 =+16.6° (C=1.1, methanol). 0.7 ml of a 1N sodium hydroxide solution was added to the salt and subjected to ether extraction. 0.8 ml of 1N hydrochloric acid was added to the resultant aqueous phase and subjected to extraction with ether, followed by drying the organic phase with anhydrous sodium sulfate and removing the solvent by distillation under reduced pressure to obtain 0.12 g (0.57 mmols) of (+)-11. Yield=57.0%, m.p.=69°-76° C. and [α] 589 =+27.6° (C=1.2, chloroform). The optical purity was 77.3%.
EXAMPLE 7
160 g (7.65 mmols) of (±)-11 and 1.03 g (7.62 mmols) of (-)-13 were added to 16 ml of methanol, and heated for dissolution, followed by gradual cooling to room temperature. The solution was allowed to stand overnight and the resultant crystals were filtered to obtain 0.86 g (2.5 mmols) of (+)-11/(-)-13 salt. This salt was recrystallized from 5 ml of methanol to obtain 0.70 g (2.03 mmols) of (+)-11/(-)-13 salt. The yield based on the starting (+)11 was 53.1%. m.p.=187°-193° C. and [α] 589 =+18.9° (C=1), methanol). 3 ml of a 1N sodium hydroxide aqueous solution was added to the salt and extracted with ether. 4 ml of 1N hydrochloric acid was added to the resultant aqueous phase and subjected to extraction with ether, followed by drying the organic phase with anhydrous sodium sulfate and removing the solvent by distillation under reduced pressure to obtain 0.41 g (1.96 mmols) of (+)-11. Yield=51.2%, m.p.=67°-70° C., and [α] 589 =+34.1° (C=1.8, chloroform). The optical purity was 95.5%.
EXAMPLE 8
2.09 g (10 mmols) of (+)-11 and 2.19 g (10 mmols) of (-)-3 were added to 10 ml of methanol and heated for dissolution, followed by gradual cooling to room temperature. The solution was allowed to stand overnight and the resultant crystals were filtered to obtain 1.81 g (4.23 mmols) of (+)-11/(-)-3 salt. The salt was recrystallized from 6.5 ml of methanol to obtain 1.20 g (2.80 mmols) of (+)-11/-(-)-3 salt. The yield on the starting (+)-11 was 56.0%. m.p.=160°-162° C. and [α] 589 =+9.94° (C=1.2, methanol). 3.1 ml of a 1N sodium hydroxide solution was added to the salt and subjected to ether extraction. 3.5 ml of 1N hydrochloric acid was added to the resultant aqueous phase and extracted with ether, followed by drying the organic phase with anhydrous sodium sulfate and removing the solvent by distillation under reduced pressure to obtain 0.58 g (2.77 mmols) of (+)-11. Yield=55.4%, m.p.=67°-72° C., and [α] 589 =+34.7° (C=1, chloroform). The optical purity was 97.2%.
EXAMPLE 9
2.09 g (10 mmols) of (±)-11 and 1.75 g (8 mmols) of (-)-3 were added to 8 ml of methanol and heated for dissolution, followed by gradual cooling to room temperature. The solution was allowed to stand overnight and the resultant crystals were filtered to obtain 1.67 g (3.90 mmols) of (+)-11/(-)-3 salt. The salt was recrystallized from 5.5 ml of methanol to obtain 1.15 g (2.68 mmols) of (+)-11/-(-)-3 salt. The yield on the starting (+)-11 was 53.6%. m.p.=155°-160° C. and [α] 589 =+9.19° (C=1.3, methanol). 3.3 ml of a 1N sodium hydroxide solution was added to the salt and subjected to ether extraction. 4 ml of 1N hydrochloric acid was added to the resultant aqueous phase and extracted with ether, followed by drying the organic phase with anhydrous sodium sulfate and removing the solvent by distillation under reduced pressure to obtain 0.53 g (2.53 mmols) of (+)-11. Yield=50.6%, m.p.=68°-71° C., and [α] 589 =+34.8° (C=1.3, chloroform). The optical purity was 97.5°.
Reference 2
2.09 g (10 mmols) of (±)-11 and 1.35 g (10 mmols) of (+)-2 were added to 10 ml of methanol and heated for dissolution, followed by gradual cooling to room temperature. The solution was allowed to stand overnight and the resultant crystals were filtered to obtain 2.05 g of a salt of both compounds. [α] 589 =+4.1° (C=1, methanol). This salt was recrystallized from 7.6 ml of methanol to obtain 1.09 g of the salt. [α] 589 =+4.4° (C=1, methanol). 5 ml of a 1N sodium hydroxide solution was added to the salt and subjected to ether extraction. 1.1 ml of 1N hydrochloric acid was added to the resultant aqueous phase and extracted with ether, followed by drying the organic phase with anhydrous sodium sulfate and removing the solvent by distillation under reduced pressure to obtain 0.65 g of (±)-11. [α] 589 =-0.39° (C=1, chloroform) and optical purity=1.1%.
Reference 3
2.09 g (10 mmols) of (±)-11 and 1.21 g (10 mmols) of (-)-1-phenylethylamine were added to 7.6 ml of methanol and heated for dissolution, followed by gradual cooling to room temperature. The solution was allowed to stand overnight and the resultant crystals were filtered to obtain 1.52 g of a salt of both compounds. [α] 589 =-5.23° (C=1, methanol). 5 ml of a 1N sodium hydroxide solution was added to the salt and subjected to ether extraction. 1.1 ml of 1N hydrochloric acid was added to the resultant aqueous phase and extracted with ether, followed by drying the organic phase with anhydrous sodium sulfate and removing the solvent by distillation under reduced pressure to obtain 0.96 g of (-)-11. [α] 589 =-5.21° (C=1, chloroform) and optical purity=14.6%.
Reference 4
2.09 g (10 mmols) of (±)-11 and 1.77 g (10 mmols) of (-)-3-methyl-2-(p-tolyl-butylamine were added to 22 ml of methanol and heated for dissolution, followed by gradual cooling to room temperature. The solution was allowed to stand overnight and the resultant crystals were filtered to obtain 2.51 g of a salt of both compound. [α] 589 =-9.82° (C=1, methanol). The salt was recrystallized from 22.6 ml of methanol to obtain 0.89 g of the salt. [α] 589 =-8.60° (C=1, methanol).
5 ml of a 1N sodium hydroxide solution was added to the salt. 1.1 ml of 1N hydrochloric acid was added to the resultant aqueous phase and subjected to ether extraction, after which the organic phase was dried with anhydrous sodium sulfate and the solvent was removed by distillation under reduced pressure to obtain 0.48 g of (±)-11. [α] 589 =-0.43° (C=1, chloroform) and optical purity=1.1%.
Reference 5
0.55 g (2.63 mmols) of (±)-11 and 0.45 g (2.63 mmols) of (+)-1-(1-naphthyl)ethylamine were added to 5.3 ml of methanol and heated for dissolution, followed by cooling to room temperature and allowing to stand overnight. The resultant crystals were removed by filtration to obtain 0.42 g of a salt of both compounds. The yield based on the total amount of the (±)-trans-permethric acid was 42%.
This salt was decomposed with sodium hydroxide and hydrochloric acid to obtain 0.23 g (1.1 mmols) of (+)-transpermethric acid. [α] 589 =+0.42° (C=1.7, chloroform) and optical purity=1.2%.
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A method for optically resolving (±)-cis or (±)-trans-permethric acid which comprises reacting (±)-cis-permethric acid and optically active 1-(p-tolyl)ethylamine or optically active cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine, or reaction (±)-trans-permethric acid and optically active 1-(p-isopropylphenyl)ethylamine, optically active 1-ethylbenzylamine or optically active cis-N-benzyl-2-(hydroxymethyl)cyclohexylamine.
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This is a continuation of application Ser. No. 08/422,662, now U.S. Pat. No. 5,575,777, filed Apr. 10, 1995 which is a continuation of application Ser. No. 08/152,401, now abandoned, filed Nov. 15, 1993.
BACKGROUND
1. Field of the Invention
This invention relates generally to medical appliances; and more particularly to a device for inserting into a patient's body a medical appliance such as a cannula, e.g., an intravascular cannula, or such as a guidewire used for emplacing catheters etc. The invention is for helping protect people from contracting diseases (particularly fatal diseases such as AIDS and hepatitis) through accidental puncture by needles that have been used in diseased patients.
2. Prior Art
U.S. Pat. No. 4,747,831 to Kulli sets forth the state of the pertinent art and is, in its entirety, incorporated herein by reference. Kulli teaches a safety device for use in inserting a cannula into a patient and for thereafter protecting people from contact with portions of the device that have been within the patient.
(For purposes of this document as in the Kulli patent, the term "cannula" means a catheter assembly consisting of primarily a hub and short tube--as pictured and described in the Kulli patent column 3, lines 25 through 37! and herein. As already mentioned the technology is not necessarily limited to use with cannulae directly but is useful as well in insertion of other medical appliances such as catheter guidewires.)
Kulli's device includes a needle for piercing a patient and for guiding and carrying a cannula or other appliance into place within such a patient; the needle has a shaft with at least one sharp end. His device also includes a hollow handle adapted to enclose at least the sharp end of the needle beyond reach of people's fingers.
In one major facet or aspect of preferred embodiments of Kulli's invention, the invention also includes some means (denominated the "securing means") for securing the shaft to the handle, with the sharp end projecting from the handle. It also includes some means (the "releasing means") for releasing the securing means and for substantially permanently retracting the sharp end of the needle into the handle and beyond reach of people's fingers. The releasing and retracting means are manually actuable by a simple unitary motion, of amplitude that is substantially shorter than the shaft of the needle.
In a second major aspect or facet, Kulli's invention also includes (in addition to the needle and hollow handle) a block fixed to and extending from the needle. The block is restrained within the handle with the sharp end of the needle projecting out of the handle through the aperture, and adapted for motion within the handle to withdraw the needle into the handle. The invention in this second major aspect further includes a trigger mechanism, which is actuable from outside the handle for releasing the block. The trigger mechanism also includes positive biasing means for forcibly moving the block within the handle to substantially permanently retract the sharp end of the needle into the handle and beyond reach of people's fingers.
Many other details of the Kulli invention are discussed at length in his '831 patent and for economy's sake will not be repeated directly here, though as already noted they are all incorporated into this document by reference.
In the course of very extensive efforts directed toward preparation of the Kulli invention for the marketplace, it has been confirmed that his invention is entirely operational and serviceable for all the purposes described. No criticism of the structure or function of Kulli's invention is intended by, and none should be inferred from, anything in the present document.
To enhance acceptance of such a device by the medical community and regulatory authorities, it has been found desirable to focus attention upon certain operating characteristics of the Kulli device--particularly as they relate to peripheral but very important matters. Such matters include (1) manufacturing economics, and possible resulting variations in operation, (2) variations in skill of--and consequently variations in handling by--operating personnel, and resulting perceptions of medical appliances by operating personnel, and (3) potential misuse of the device, due for example to prevailing societal conditions.
It will now be understood that none of these considerations can properly be regarded as in the nature of a defect or limitation of Kulli's invention. Rather they are in the nature of areas in which that invention leaves room for further refinement.
None of these considerations is, in substance, a part of the prior art; instead they have been adduced through work leading to the present invention, and are regarded as at least in part components of the creative and innovative processes of making the present invention. Accordingly in this document these considerations will be detailed in a later section, not addressed to the prior art.
For reference purposes, however, the present section will now describe the overall procedure for inserting a cannula or the like--whether using the Kulli device or essentially any other cannula insertion set--as this procedure itself is a part of the prior art and will be of interest in later discussion of the present invention. Typically a doctor, nurse, paramedic or other medical staff person first locates a target blood vessel chosen for catheter insertion, and then pierces the patient's skin and blood-vessel wall--inserting the pointed end of the needle and a portion of the catheter (see FIG. 16 of Kulli).
Next the practitioner almost always deliberately permits a small quantity of the patient's blood to flow through the hollow needle--impelled by the patient's own blood pressure--so that the small quantity of blood can be seen at the rear of the needle. The blood which thus flows from the needle enters some sort of chamber that is part of the cannula insertion set, and which ordinarily is made of transparent material to afford a view of the interior and thus of the blood therein.
This practice of allowing some blood to flow into a viewing chamber is known in jargon of the medical field as "flashing", and the blood that enters the chamber is sometimes called the "flash" quantity. The flashing step has the purpose of confirming that the catheter is indeed inserted into the blood vessel.
In the instance of Kulli's invention, the chamber is the hollow handle into which the needle will later be retracted, and which thus serves double duty as a viewing chamber.
In other types of cannula insertion sets too the chamber may be a hollow handle, but may take other forms. In such other types of sets, the chamber is generally configured in one way or another to permit the flash blood to enter the chamber--but then to retain that blood.
To permit entry of that blood into the solid chamber, some provision must be made for escape of air that is initially in the chamber; on the other hand, retention of the blood once it has entered the chamber requires that the chamber be to some extent fluid sealed. These two seemingly contradictory requirements can be and are satisfied in a variety of ways, including careful placement of breather holes or tubes to permit air escape--and so accommodate the slow passage of blood into the chamber--while presenting a relatively long, high-impedance path to obstruct liquid flow out of the chamber.
More often modernly these requirements are met by providing--for instance at the rear end of the handle--a relatively large orifice that is closed by a selective filter to pass air somewhat readily, at least at the flow rates typically associated with blood flow into the chamber, but block passage of blood out of the chamber. As will be understood such purposes may be best served by for example a hydrophilic filter; such filters are sometimes used.
Once a desired flash quantity of blood is observed, as mentioned in the Kulli patent the medical practitioner usually provides temporary stoppage of the blood flow by placing a finger or other hand portion upon the blood vessel to squeeze off the vessel. While maintaining this stoppage the practitioner carefully withdraws the needle, leaving the inserted end of the cannula or other appliance in place--and then secures an appropriate intravascular connecting tube, most typically a delivery tube, to the hub of the cannula etc.
Next the practitioner fixes the cannula or like appliance to the patient's body, usually employing a small piece of tape, and releases the manually applied closing pressure upon the vessel. Various liquids may then be introduced through the appliance into the patient's blood stream, the patient's blood pressure may be monitored, etc., all as well known.
Also part of the prior art are teachings of certain other Kulli patents, including U.S. Pat. Nos. 4,900,307, 4,904,242, 4,927,414 and 4,929,241--some of which disclose features related to deterrence of needle reuse, but in different contexts.
Important aspects of the technology used in the field of the invention are amenable to useful refinement.
SUMMARY OF THE DISCLOSURE
The present invention introduces such refinement. Before offering a relatively rigorous discussion of the present invention, some informal orientation will be provided here.
It is to be understood that these first comments are not intended as a statement of the invention. They are simply in the nature of insights that will be helpful in recognizing the underlying character of the special considerations alluded to above (such insights are considered to be a part of the inventive contribution associated with the present invention)--or in comprehending the underlying principles upon which the invention is based.
Flash leakage--Through extensive work with devices constructed according to Kulli's disclosure, it has been discovered for example that some personnel sometimes handle the devices in such a way that blood from a patient can leak rearward or forward from the handle of the device, or forward from the needle. Some of the procedures leading to such leakage are necessary parts of the usage of the device--detailed in the preceding section of this document--and others are in the nature of variations in operator skill, attentiveness or anticipation, and the like.
In any event, for success of a device to be used in very large numbers throughout the medical industry it is highly desirable to minimize the potentiality for blood leakage resulting from such handling variations. The portion of procedures that sometimes leads to blood leakage is the so-called flashing step already described in the previous section of this document.
At the outset it may be noted that the Kulli disclosure does not propose to position a filter over the rearward orifice 13 etc. of the hollow handle, or otherwise to provide for selective passage of air but not blood as in some other insertion devices. Kulli instead proposes that the rearward orifice 13 etc. may be preserved open and at substantially the same internal diameter as the cannula hub--thus making possible a temporary attachment of intravascular tubing through the handle, as is sometimes desired by some medical professionals, preparatory to shifting the attachment to the cannula hub.
In the present state of medical practice, however, such temporary attachments are disfavored and retention of the flash blood is regarded as more important. It might be supposed accordingly that the Kulli device should simply be fitted with a suitable filter at its rear orifice 13 etc.--or that the rear orifice should be eliminated by sealing the rearward end of the handle and some other provision (e.g., small vent holes or tubes) incorporated for escape of air to accommodate incoming flash blood.
In efforts toward resolving this consideration, however, it was learned with some surprise that such emplacement of a filter or a fine vent was not sufficient. The reason is that the retraction of Kulli's needle, or needle and block, into the hollow handle tends to displace a volume of flash blood collected in the handle. This displacement tends to expel blood abruptly out of the enclosure by whatever path is available.
One leakage path is forward through the needle and its carrier block. In other words, in such a device when the retraction button is operated blood can be squirted out of the front end of the needle--an unacceptable result, not merely because of the untidiness involved but more importantly on account of the exposure of people in the vicinity to the patient's blood. The latter is particularly troublesome since an important objective in providing a retracting needle is to minimize such exposure.
Another path--once the needle carrier block has retracted out of its initial or forward-locked rest position with minimal radial clearance--is forward around the needle and block. In this instance the blood leaks out of the assembly by issuing through the forward apertures of the Kulli handle or housing.
This path, utilizing only incidental clearances in the apparatus, tends to create smaller leakage than that through the needle--particularly with respect to the immediate, piston-driven expulsion of blood at the time of retraction. This second path, however, remains important because of a potential for somewhat slower but more protracted trickling of blood from the front of the chamber, sometimes occurring after use of the device is nominally complete and it has been laid down on a table or tray--so that personnel may no longer be attentive to the possibility of blood leakage.
Further, in the course of development, it was noted that the possibility of abrupt expulsion of blood through the needle was reduced very greatly through fabrication of the needle carrier block with relatively greater radial clearance--and by instructing medical personnel not to fill the handle more than about three-quarters full. These two provisions, coupled with the relatively high viscosity of blood in the needle, allowed enough mechanical volume for rearrangement of the blood within the chamber, upon retraction, and thereby nearly eliminated the squirting of blood through the needle.
In some cases, however, it is not possible to avoid filling the chamber beyond the three-quarters point; with patients who have large blood vessels and high blood pressure, for example, the chamber may be filled with flash blood very quickly. It was found that highly skilled and specially instructed personnel could reliably avoid overfilling, by anticipating rapid filling in appropriate cases, and by particularly dextrous manipulations; but in general use the volumetric suitability of the flash is simply outside the control of the insertion-set manufacturer.
Furthermore, providing a relatively high clearance around the needle block--while reducing the potentiality for abrupt expulsion of blood through the needle--has the undesirable effect of aggravating the potentiality for longer-term leakage of blood along the incidental clearances around the needle. Efforts to resolve the latter complication through incorporation of a specially sized resilient seal at the forward end of the device were operationally successful but objectionably expensive, and in particular also objectionably cumbersome in assembly--and as will be understood could not address the former matter of flash-volume control.
As can now be appreciated, the seemingly simple initial expedient of providing a substantially conventional flash-chamber enclosure for the Kulli device--as by placing a filter at the rear aperture of that unit, or by otherwise closing that orifice and incorporating vents--can lead to blood expulsion or leakage concerns of magnitude at least equal to the initial desire to enclose the flash.
Only after very extensive experimentation and trial-and-error efforts was it realized that the source of this concern is the implicit initial choice of enclosing or barring the flash blood at a point that is fixed relative to the handle. This choice in turn implies relative motion between that blood, in the handle, and the piston formed by the moving needle block.
It is this relative motion, particularly motion of the carrier block moving through the blood, which causes the primary concern over leakage--that is, the abrupt expulsion of blood forward through the needle. Accordingly a resolution of this concern can be sought in the alternative of enclosing or barring the flash blood at a point that is effectively fixed relative to, instead, the movable needle--thereby enabling elimination of effective relative motion between the blood and the moving needle block.
The words "effectively" and "effective" have been used above because, as will be seen, some configurations that prevent application of retraction forces to the flash blood involve pneumatic association of the blood enclosure with the moving needle even though the enclosure may be fixed to the handle.
As will be seen, this change of focus opens a variety of possibilities for allowing air to escape from the enclosure so that flash blood can flow from the rear of the needle--and for then holding the blood safely enclosed even during needle retraction. In particular, in such a configuration a filter or vent too can be associated with the moving needle.
That association yields the beneficial result that the limited airflow capacity of the filter or vent (relative to air moved by the piston effect during retraction) now works favorably toward leak-free operation. The limited-airflow filter or vent does so by isolating the flash blood in the chamber against the air-pressure increase developed in retraction.
Hence the moving needle, carrier block, chamber, filter or vent, and flash blood all together form and act as a composite piston upon the air in the hollow handle. Furthermore the handle itself no longer need be sealed by a filter or fine vent, and the air moved by the composite piston can be rapidly relieved to ambient.
Still another alternative for resolving leakage concerns can be found in the isolation of flash blood in the needle (as distinguished from the receiving chamber) from air-pressure increases developed in retraction. A check valve, for example, can be provided to perform this function.
Retraction speed--Retraction of the Kulli needle and block are, in some preferred embodiments, effectuated by a biasing means such as for example a coil spring. Whatever propulsion unit is used, the resulting retraction speed is subject to variations in biasing force--which are compounded by variations due to dimensional tolerances for the needle, block and handle; and particularly by highly variable lateral and torsional forces developed on the needle tip, as for example by the manual pressure mentioned earlier.
These factors together create a very large range of variation in the final resultant retraction speed. In consequence, if the various tolerances are chosen to be substantially certain of positive and prompt retraction when all factors tend toward minimum retraction force and speed, then objectionably high speed results when all factors tend toward maximum force and speed.
Retraction speed may be objectionably high even though the mechanism functions perfectly and poses no threat of injury or damage--either to itself or to anything else. The objectionability of high speed arises rather from the perceptions of some medical personnel, for whom unusually forcible or loud retraction may be startling or annoying, or simply may seem unprofessional.
It will be understood that a high range of variation in speeds--leading, as explained above, to quite high speed in some cases--can be avoided by constraining mechanical tolerances more closely. Such resort to tighter specifications, however, is itself objectionable on account of the associated higher cost.
As implied already, objectionably high speeds and consequent loud clicking or snapping sounds can be avoided by using lower spring pressure, closer clearances, etc.--but not without shifting the problem to the low-speed end of the overall range of variations, or in other words causing some needles to retract unreliably or too slowly.
Part of the present invention accordingly resides in recognition that retraction can be both (1) made reliable and (2) controlled in speed--but within a very economical device--by in essence assigning these two functions to two different mechanical elements respectively. More specifically, positive and prompt retraction can be assured by selecting a sufficiently strong spring or other biasing means; and it is possible to prevent or compensate for excessive retraction speed by incorporating a damping or other energy-absorbing provision.
A suitable energy-absorbing element can for instance take the form of a viscous lubricant interposed between the needle carrier block and the interior bore of the hollow handle; and means (such as a lubricating port) for facilitating placement of the lubricant. This type of energy-absorbing provision may not provide a resistive force that is consistent over the full travel of the needle; rather the consequent speed-limiting action appears to be concentrated at the beginning of the stroke and may result in part from thixotropic or stiction-like effects.
Such effects may include, for example, (1) a tendency of the lubricant to make spring coils stick together, and for the spring coils to break loose only gradually to begin the stroke, and similarly (2) a tendency for the lubricant to make the needle carrier block stick in place against the interior bore of the handle, and for the block to break loose from the bore surface only gradually at first. In any event, whether or not the operative mechanisms of the technique are fully understood at a physics or classical-mechanics level, this form of energy absorbing has been found very satisfactory.
This type of energy absorbing also offers an additional benefit of sealing the carrier block against the interior bore, before the needle is retracted. Under these conditions suction (e.g., from an external plunger), can be applied to the interior passage, and thereby to the flash chamber and needle lumen, to assist in drawing flash blood into the chamber. Such a suction boost is desirable to assist in the flashing procedure on some occasions, as when for instance the patient's blood pressure is very low.
Other energy-absorbing elements, however, are believed to be usable and within the scope of the invention. For example a separate mechanical element can be disposed within the hollow handle and biased laterally (e.g., radially) against the needle or carrier block to impose frictional force tending to retard the retraction; in such a system, biasing force and surface materials are selectable to obtain desired damping levels. In such a configuration the biasing force may preferably be varied along the stroke--as for example by using or exaggerating the draft generally employed in molding of hollow shapes such as a handle housing.
As another example, a dashpot device may be formed by separate or preferably existing elements within the hollow handle. In this case the energy-absorbing effect would appear to be more in the nature of true damping than the viscous-lubricant system, but may tend to be concentrated near the end of the retraction stroke, whereas in the case of the preferred viscous-lubricant technique the damping action tends to be concentrated near the beginning of the retraction stroke.
Risk of Abuse--Unfortunately in present-day society a widespread phenomenon is use of discarded medical needles by drug addicts to inject themselves with hallucinogenic drugs and the like. Apart from the social evils of addiction and resulting crime, such abuse of discarded medical equipment poses a risk of spreading disease from the blood of diseased patients.
Thus in addition to its primary function of deterring the inadvertent infection of medical personnel through accidental needle punctures, it is desirable that any disposable medical appliances which include needles be configured to deter or discourage later reuse.
Study of the '831 patent suggests that the needle and its carrier block might be reset forward within the handle by insertion of an elongated tool such as a screwdriver blade, to push against the rear end of the needle or block. While the block and needle are thus held in a forward position, they can once again be locked in that position by resetting the latch button outward.
Alternatively, even a relatively short tool may be used to start the sharp needle tip back through the forward end of the handle. A person may thereby be enabled to grasp the tip with fingers, pliers or the like and pull it forward to complete the forward-resetting motion.
In either of these ways a person may be able to fully or partially redeploy--and thereby prepare to abuse--potentially contaminated medical needles following their disposal by hospitals and other medical facilities.
Such abuses can be frustrated by configurations that obstruct or otherwise deter insertion of such tools. As will be understood, virtually nothing can be done to prevent a person from cutting open the rear end of the handle to gain unobstructed access to the needle within; short of such tactics, however, as will be seen a variety of abuse-frustrating configurations is within the scope of the invention.
Now with these preliminary observations in mind this discussion will proceed to a perhaps more-formal summary. The invention has several major aspects or facets.
In preferred embodiments of a first of these primary aspects, the present invention is a safety device for use in inserting a medical appliance such as a cannula into a patient and for thereafter protecting people from contact with portions of the device that have been within the patient--and from contact with the patient's blood. The device includes a hollow needle for piercing a patient and for guiding and carrying such an appliance into place within the patient; the needle has a shaft with at least one sharp end;
The device of the first aspect of the invention also includes a hollow handle adapted to enclose at least the sharp end of the needle beyond reach of such people's fingers; and some means for securing the shaft to the handle, with the sharp end projecting from the handle. These means, for purposes of breadth and generality in discussion of the invention, will be called the "securing means".
The device further includes some means for releasing the securing means and for substantially permanently retracting the sharp end of the needle into the handle and beyond the reach of such people's fingers. These means, again for generality and breadth, will be called the "releasing and retracting means"; they are manually actuable by a simple unitary motion, of amplitude that is substantially shorter than the shaft of the needle.
The device also includes some means for receiving blood from within the hollow needle and for reliably retaining that blood during and after retracting of the needle, notwithstanding forces developed by the retracting.
The foregoing may represent a description or definition of the first main facet of the invention in its broadest or most general form. (A considerable variety of different kinds of receiving and retaining means is introduced elsewhere in this document.)
Even in this form, however, this first aspect of the invention may be seen to provide the refinement needed to resolve concerns discussed earlier in this section of the present document. In particular, because the receiving and retaining means accept and hold the blood even in the face of retraction forces, they make possible avoidance of the flash expulsion sometimes observed upon fitting Kulli-type devices with a selective filter.
Nevertheless, for greatest enjoyment of the benefits of the invention, it is considered preferable to practice this first broad aspect of the invention in conjunction with certain other characteristics or features. It is particularly preferable to practice this first main facet of the invention in conjunction with the other principal aspects, to be introduced below; however, in addition to those major aspects there are several other preferable features or characteristics.
For example, the receiving and retaining means most preferably comprise a chamber fixed for motion with the needle; and some means for permitting viewing of received and retained blood by a user of the device. More specifically, it is preferred that the chamber be fixed to the needle, within the hollow handle.
It is also preferred that the receiving and retaining means further comprise some means for isolating the interior of the chamber from forces developed by said retracting. Several such isolating means are within the scope of the invention.
Among these are systems that include relatively high-impedance means for transmitting gas from the interior of the chamber. Such systems may for instance include means for permitting relatively slow escape of air from the interior of the chamber to enable entry of blood through the hollow needle; and means for deterring relatively rapid entry of air into the interior of the chamber to avoid expulsion of blood through the hollow needle by forces developed in retracting. Such high-impedance transmitting means may take the form of a selective filter, or a fine passage for venting air.
Alternatively, the receiving and retaining means preferably may include a chamber associated with the handle; and some means for transmitting blood from within the hollow needle into the chamber, substantially without transmitting into the chamber force developed during said retracting. For example blood-transmitting means may include a flexible tube communicating between the chamber and the interior of the hollow needle; or a frangible passage communicating between the interior of the chamber and the interior of the hollow needle (in which system the releasing and retracting means break the frangible passage); or a check valve disposed along a blood-flow path between the interior of the chamber and the interior of the hollow needle.
In preferred embodiments of a second major facet or aspect of the invention too, the invention is a safety device for use in inserting a medical appliance such as a cannula into a patient and for thereafter protecting people from contact with portions of the device that have been within the patient. This device too includes a hollow needle, hollow handle, securing means, and releasing and retracting means manually actuable by a simple unitary motion, of amplitude substantially shorter than the shaft of the needle--all substantially as set forth above.
In addition a device according to preferred embodiments of this second major facet of the invention also includes some means for absorbing some of the energy of the retracting--which will be denominated, for purposes mentioned earlier, "energy-absorbing means" or simply "absorbing means". (A variety of absorbing means may be employed, within the scope of the invention, as set forth elsewhere in this document.)
While the foregoing may represent a definition or discussion of the second aspect of the invention in its most general or broad form, once again this aspect too can be seen to resolve concerns discussed earlier in this section. In particular the energy-absorbing means enable the needle carriage to be amply powered for reliable retraction, since so powering the carriage no longer need produce objectionably loud, or startling retraction sounds--or objectionably forcible or jerky operation.
Nevertheless it is preferable, to maximize the benefits of the invention, that this second main facet of the invention too be practiced in conjunction with certain other features and characteristics that enhance its advantages. For example it is preferred that the device also include some biasing means for powering the retracting reliably, despite accumulated manufacturing tolerances tending against said retracting--or, in other words, that the possibility mentioned in the preceding paragraph be actualized by providing ample retraction force.
It is also preferred that the absorbing means include a viscous substance interposed between the needle and the hollow handle; and further that these means include a port defined in the hollow handle for placement of the viscous substance within the hollow handle.
Alternatively the absorbing means preferably include a surface that is fixed to one of (1) the needle and (2) an interior bore of the handle; and an element carried on the other of the needle and that interior bore, and bearing against said surface to develop friction during said retracting. Still further alternatively the absorbing means preferably include a dashpot element fixed for motion with the needle in said retracting.
In preferred embodiments of a third of its main facets or aspects, the invention is as before a safety device for use in inserting a medical appliance such as a cannula into a patient and thereafter protecting people from contact with portions that have been within the patient. This device includes as before a hollow needle, hollow handle, securing means, and manually actuable releasing and retracting means as characterized earlier.
In addition a device according to this third main facet of the invention includes some means--the "deterring means"--for deterring redeployment of the needle after said retracting. (A number of different forms of such means are described elsewhere herein.)
The foregoing may constitute a definition or description of this third aspect of the invention in its broadest or most general form. Even in this broad form, however, it may be seen to resolve needle-abuse concerns mentioned earlier in this section, as the deterring means will significantly reduce the risk of needle reuse by addicts and others, thereby correspondingly reducing the risk of disease propagation through such abuse.
Nevertheless this third facet of the invention, to optimize the benefits which it provides, is preferably practiced in conjunction with certain other features or characteristics. For example it is preferred that the deterring means deter access to the needle after said retracting. Also it is preferred that after the retracting the deterring means alternatively or additionally deter forward movement of the needle, or reengagement of the securing means, or both.
In preferred embodiments of a fourth major aspect of the invention, the invention is a catheter-insertion device with a retracting needle, and includes an elongated hollow needle having a piercing end and an interior end. The device also includes a handle defining an interior passage.
In addition this device includes a needle carriage, movably received within the interior passage, defining an interior chamber and supporting the needle so that the interior end of the needle communicates with the interior chamber and the piercing end of the needle extends outward. The device also includes some means for securing the needle and carriage with the piercing end of the needle outside the handle. In addition the device includes some means for releasing the securing means and retracting the needle and carriage inward with respect to the handle so that the piercing end of the needle is inside the handle.
The foregoing may represent a definition or description of the broadest or most general form of the fourth primary facet of the invention. Once again the invention in this form will be seen to resolve important concerns of abrupt leakage or squirting of blood, which arise upon fitting a Kulli device with a selective filter as described earlier in this section.
The invention as broadly couched in this fourth main aspect resolves such concerns by carrying the blood with the needle during retraction, rather than holding the blood in the handle--so that there is no relative motion between the blood and the needle. Under these conditions it remains only to deal with the compressive forces developed during retraction, to prevent application those forces to the blood that is carried with the needle; dealing with those forces can be accomplished by various means as indicated elsewhere in this document.
Nevertheless it remains preferable to practice this fourth major aspect of the invention in conjunction with other features or characteristics that lead to the most advantageous overall structure and function. For example it is preferred that the interior chamber include some means for making visible any contents of the interior chamber.
In addition preferably the interior chamber defines a first end sealingly attached to the interior end of the needle, and a second end. Preferably the needle carriage further includes means for permitting slow passage of air, and for deterring passage of blood, outward from the interior chamber into the interior passage of the handle; and for deterring rapid passage of air inward into the interior chamber from the interior passage of the handle.
These permitting-and-deterring means preferably comprise a filter covering the second end. Such a filter is preferably of a hydrophilic material.
Also preferably the handle defines an injection aperture for introducing a viscous substance into the interior passage of the handle; and the device further includes a viscous substance introduced through the injection aperture and disposed between the carriage and an interior surface of the handle. In addition preferably the device includes a grill secured across the interior passage of the handle.
As mentioned earlier it is preferred that all these major facets or aspects of the invention be practiced in conjunction with one another. They are all, however, to various extents capable of practice independently.
All of the foregoing operational principles and advantages of the present invention will be more fully appreciated upon consideration of the following detailed description, with reference to the appended drawings, of which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal section of a retracting-needle cannula-insertion device according to preferred embodiments of the invention--using for pressure isolation a flash chamber that moves with the needle, and for energy absorbing a viscous substance and a port for positioning the substance--shown together with a cannula that can be inserted using the device, and particularly showing the needle in its extended position; FIG. 1a is a partial like section, enlarged, showing an alternative, crushable energy absorber mounted to the chamber;
FIG. 2 is a like view of the FIG. 1 device but showing the needle retracted;
FIG. 3 is a cross-section of the same device taken along the lines 3--3 of FIG. 1 and so showing the needle extended;
FIG. 4 is a like view but taken along the lines 4--4 of FIG. 2 and so showing the needle retracted;
FIG. 5 is a cross-section of the same device taken along the lines 5--5 in either FIG. 1 or 2, and showing an embodiment of the invention that employs for abuse deterrence a grill supported across the interior of the hollow handle to render difficult any access to the needle for forward resetting;
FIG. 6 is a somewhat schematic partial longitudinal section of an alternative embodiment employing for pressure isolation a flexible interconnecting tube, and for abuse deterrence a generally complete obstruction of the interior of the hollow handle;
FIGS. 7 and 7a (taken along line 7a--7a in FIG. 7) represent a like schematic section of still another alternative embodiment--employing for pressure isolation an initially flattened, preferably transparent or translucent balloon fixed for liquid communication to the rear of the needle and for energy absorbing a separate laterally biased element, and for abuse deterrence a labyrinthine end cap that similarly provides essentially complete obstruction of the interior of the hollow handle;
FIG. 8 is a like schematic section of another alternative embodiment employing for pressure isolation a frangible passage and for abuse deterrence a laterally formed piston-pressure relief port that renders difficult any access to the needle for resetting; and
FIGS. 9 and 9a (greatly enlarged) are like schematic sections of yet another alternative embodiment--employing for pressure isolation a check valve, for energy absorbing a dashpot member that is integrated with the valve, and for abuse deterrence ratchet elements to prevent, respectively, forward motion of the needle and reengagement of the trigger to its locking position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 3 show a preferred embodiment 10 of the invention, having an elongated generally cylindrical handle housing 20 with a cylindrical wall 21 and a cylindrical interior passage 24. The housing 20 also defines an end portion 22 with an increased-diameter end recess 23.
A cylindrical end plug 85 defines an air passage 87 and a grill 86, which may by way of example be cruciform as shown. This plug 85 is secured within the end recess 23 using a force or interference fit, together with other appropriate attachment provision such as, for instance, adhesive or sonic welding.
Formed in an outer surface of the handle housing 20 is a radially extending (or upward-extending, with the device oriented as drawn in FIG. 1) trigger guard 25, and a plurality of ribs 26 to facilitate positive grasping of the device by a user. Also formed in the handle housing, through the cylindrical wall 21 for communication with the cylindrical interior passage 24, is a generally circular grease port 27.
A frontal housing 30 is secured to the forward end of the handle housing 20--again by any appropriate means such as adhesive, sonic welding etc., but preferably by a snap fit--and defines a generally tapered forward-extending nose portion 40, with a needle-passing aperture 42 formed at the forwardmost tip, and a tapered passage 41 generally coextensive with the nose portion 40 and communicating between the interior cavity 33 of the frontal housing and the needle aperture 42.
Formed transversely through either the frontal housing 30 or the front end of the handle housing 20--but preferably through the latter--is a pair of opposed slots 31, 32. A lock slider or trigger 50 (to some extent better seen in FIGS. 3 and 4) defines an elongated generally planar lock member 52--preferably formed of a strong material such as metal, and slidably received through the opposed slots 31 and 32. Formed through the planar lock member 52 is a keyhole-shaped aperture or slot 53.
Movably and preferably slidably received within the cylindrical interior passage 24 of the handle is a carriage or carrier block 60. This carriage 60 in turn defines an interior flash chamber 61, and a reduced-diameter portion 63.
Extending through and secured within this latter portion 63 of the carriage 60 in a sealed attachment is an elongated hollow needle 70. An internal end 71 of the needle 70 is positioned in communication with and preferably within the interior flash chamber 61.
The remainder of the hollow needle 70 extends forward from the carriage 60--through the tapered passage 41 and aperture 42 in the nose portion 40 of the frontal housing 30, and beyond. The needle terminates in a piercing point formed by a beveled facet 74.
Thus flash blood passing from a patient into the device through the hollow needle 70 is introduced into the interior flash chamber 61 for viewing. The device includes some means for permitting viewing of the flash blood by a user of the device; such means may include a separately defined transparent window, but preferably they include transparent materials used in fabrication of the entire chamber 61, indeed the entire carriage 60--as well as the handle housing 20.
The needle carriage 60 also defines a front end 65, a circumferential, preferably circular groove 64, and a rear end that is spanned by a hydrophilic filter 62. (Hydrophobic/hydrophilic composite units are also potentially useful.) This filter provides liquid sealing of the flash chamber 61 while permitting outward air diffusion into the passage 24 of the handle.
A coil spring 80 encircles and receives the reduced diameter portion 63 of the needle carriage 60, and is captured between the needle carriage 60 and, for convenience, the lock slider 50. As will be clear, the spring 80 can as well seat against an internal feature of the handle.
A conventional catheter or cannula 11 includes a catheter housing 90, with an interior cavity 94 that receives the nose portion 40 of the frontal housing 30 in a conventional attachment such as preferably a snap fit. (Description of the invention here in conjunction with a cannula is only for definiteness of description; as mentioned earlier the invention is for emplacement of other medical appliances as well.) The cannula 11 also includes an elongated hollow catheter tube 91 with an end portion 92--and a needle passage 93 formed through the tube 91 and end portion 92.
The interior end of the catheter tube 91 is sealingly secured, as is conventional, within the interior cavity 94 of the catheter housing 90. In the assembled position of FIG. 1, the piercing point 73 and bevel 74 of the needle 70 extend slightly beyond the end 92 of the catheter tube 91 to facilitate the piercing action of the needle unit 10.
FIG. 1 represents the needle-extended condition of the device, in which the carriage 60 and needle 70 have been drawn forward against the force of the compressing spring 80--so that the groove 64 in the front end 65 of the carriage 60 is aligned with the keyhole aperture 53 in the slider/trigger 50--and are held in that forward position by the slider 50.
This forward positioning of the needle 70 and carriage 60 is accomplished while the trigger 50 is initially moved downward (as drawn) within the slots 31, 32 of the frontal housing 30 or handle 20, thereby aligning the larger-transverse-dimension, circular part 55 (better seen in FIG. 4) of the keyhole aperture 53 with the end portion 65 of the needle carriage 60. The end portion 65 has then been passed through the larger-transverse-dimension circular part 55 of the keyhole, just enough to align the circumferential groove 64 in the carriage 60 with the planar trigger plate 50.
With the carriage 60 thus longitudinally aligned, the lock slider 50 has been raised (as drawn) to the position shown in FIGS. 1 and 3 so that the narrower portion 56 of its keyhole-shaped aperture 53 is fitted into the carriage groove 64, capturing and holding the carriage 60 and needle 70 in their forward positions--against the force of the spring 80. At this stage, the device 10 with associated cannula 11 is ready for use.
Now in proper use a medical professional manipulates the device 10, holding it by the handle housing 20, to pierce the patient's skin and target-vessel wall--and thereby insert the piercing point 73 and cannula tip 90 into the target vessel. Once this occurs, a small volume of the patient's blood, the flash blood, is forced through the passage of the hollow needle 70 by the patient's blood pressure and flows into the flash chamber 61--readily expelling before it from the chamber a like volume of air, through the filter 62.
The blood itself, however, is substantially obstructed by the filter and so is substantially completely confined within the chamber 61, where the blood may be readily observed to confirm proper insertion of the needle and catheter. Once the flash blood has been observed, the medical practitioner then withdraws the needle 70 from the patient's body while maintaining the cannula 11 in place.
At this juncture the device 10 contains a quantity of the patient's blood within the flash chamber 61, and the needle 70--both externally and within its hollow passage--is contaminated with a small quantity of the patient's blood. Thus in accordance with preferred safety practice the device 10 should be discarded with due care for the possibility of infecting people with that blood.
As in use of the Kulli device, the practitioner is able to retract the needle 70 to a safety or retracted position such as shown in FIGS. 2 and 4 by operating the trigger 50--that is to say, by forcing the lock slider/trigger 50 downward (as drawn) to bring the circular, larger-transverse-dimension portion 55 of the keyhole aperture 52 once again into alignment with the front end 65 of the needle carriage 60 as shown in FIG. 4. (The trigger guard 25 helps avoid inadvertent premature operation of the trigger.)
The larger-dimension portion 55 of the aperture 52, as noted earlier, is big enough for passage therethrough of the front end 65 of the carriage 60; therefore in this juxtaposition of the parts the locking action of the slider 50 upon the carriage 60 is released, no longer opposing the restoring force of the spring 80. In consequence the spring accelerates the needle carriage 60 rearward through the passage 24 of the handle housing 20--to the position shown in FIG. 2.
In that position the entirety of the needle 70, including the piercing point 73, is withdrawn into the interior of the frontal housing 30 and thus is no longer able to puncture the skin of the practitioner or anyone else. The end plug 85 blocks movement of the carriage 60 through the aperture at the rear end 22 of the handle housing 20 and so keeps the carriage 60 and needle 70 within the handle.
Importantly with respect to the present invention, the retracting rearward flight of the needle moves air quickly through the passage 24 of the hollow handle 20. By virtue of openings in the grill 86 and the air-leakage path forward around the needle carrier block, however, retraction develops relatively little air pressure increase within the passage 24.
To the extent that retraction may produce a brief pressure pulse in the passage 24, the filter acts essentially as an air-impermeable wall or piston tending to isolate the interior of the flash chamber 61 from such pressure. In consequence any piston-effect pressure developed during retraction is not applied to the blood in the flash chamber 61, and that blood is not expelled forward and outward through the hollow needle but rather is safely retained within the chamber.
The small lateral port 27 through the cylindrical wall 21 of the handle housing 20 facilitates introduction of a small quantity of viscous material, such as lubricant, into the interior of the passage 24. This viscous material provides the desired energy absorption mentioned earlier.
By virtue of this energy absorbing, a relatively strong spring 80 or other biasing element may be employed for reliable retraction--but without incurring undesirably loud or violent operation in some production units whose manufacturing tolerances aggregate toward maximum retraction speed. In this regard it has been found particularly satisfactory to use a spring that exercises a force in the range of 33 to 40 Newtons per meter (3 to 3.6 ounces per inch) of compression from its relaxed position.
A nominal or ideal value is roughly 37 N/m (3.3 oz/in)--amounting to a nominal 2.2N (8 oz) at 6.1 cm (2.4 inch) compression. The viscous material may be a lubricant such as "High Vacuum Grease" available from the Dow Corning Company.
Merely for purposes of placing these values within the environment of a practical device, and not to limit the scope of the invention as claimed, it is preferred to use these dimensions:
8.6 cm (3.4 inch) length from the rear end of the handle to forward surface of the frontal housing;
5.1 cm (2.0 inch) length from the forward surface of the frontal housing to the tip of the needle;
1.1 cm (0.42 inch) outside diameter of the frontal housing;
0.8 cm (0.30 inch) outside diameter of the handle grip surface;
0.46 cm (0.18 inch) inside diameter of the handle bore near the trigger, with fabrication tolerance of ±0.005 cm (±0.002 inch);
3.0 cm (1.18 inch) overall length of the carrier block;
0.94 cm (0.37 inch) effective length of the segment of the carrier block over which the spring is coiled;
0.33 cm (0.13 inch) outside diameter of that same segment of the carrier block, with fabrication tolerance of ±0.0025 cm (±0.001 inch);
1.8 cm (0.72 inch) length of the remainder of the carrier block--that is, the exterior length of the flash-chamber segment;
1.7 cm (0.67 inch) interior length of the flash chamber;
0.44 cm (0.175 inch) outside diameter of the flash chamber;
0.32 cm (0.125 inch) inside diameter of the flash chamber; and
0.22 cm (0.085 inch) inside diameter of the lubrication port.
For satisfactory operation it is also important to avoid underfilling, overfilling or misfilling the device. Underfilling tends to lead to inadequate energy-absorbing effect, and overfilling tends to make the effect excessive--or, in other words, to render retraction unreliable or possibly, in extreme cases, even to consistently prevent retraction.
To avoid such adverse phenomena the lubricant introduction techniques should be carefully developed to ensure that the lubricant is reasonably well distributed about the needle carrier block and in particular fills the region of the spring coils--but does not extend much rearward along the flash chamber 61. Grease must be kept away from the open rearward end of the needle lumen.
It has not been attempted to measure the speed of retraction or the jerk applied to the handle (and thereby to the hand of the operator) with vs. without the lubricant. Rather, the criteria used for success of the lubricant energy-absorbing technique of the invention have been the satisfaction with and acceptance of the operation by medical personnel.
By those criteria this energy-absorbing technique of the invention has been found to be a total success. In particular it has been found that the invention not only avoids startling or annoying operators, but goes further to convey an operational perception, sensation or so-called "feel" that is very solid, positive and professional--and accordingly enhances significantly the acceptance of the device in the field. Furthermore, no significant variation in at least these perceptions was noted as among different production units.
A grill 86 supported within the end plug 85 is provided to frustrate attempts to redeploy the needle 70 (as by inserting a screwdriver, paperclip or like tool to push the needle forward) for reuse. The grill 86 may be cruciform as illustrated, but other adequately strong grill patterns that significantly deter insertion of such tools will serve equally well.
Some prospective reusers may be so determined that they use cutting tools or breaking techniques for access to the needle; accordingly, complete prevention of discarded-device abuse may not be physically possible. Some device configurations, however, such as the grill 86 illustrated, do protect at least against more ordinary efforts such as insertion of pushing tools.
Although it is preferable to use as the receiving and retaining means a movable interior chamber 61 and associated filter 62 as in FIG. 1, alternative means as mentioned earlier may be employed instead. For example, flash blood may be received from within the hollow needle 170 (FIG. 6) and reliably retained, during and after retracting of the needle, in a chamber 161 that is associated with, fixed to, or even integral with the handle housing 120.
In such a configuration it is appropriate to provide some means for transmitting blood from within the hollow needle into the chamber, substantially without transmitting into the chamber the compressive force that is developed in the course of retraction. Such a transmitting means may take the form of a flexible tube 163 that interconnects for fluid communication the interior of the flash chamber 161 with the needle lumen.
During retraction the forward end 163f of the flexible tube 163 moves with the needle while the rearward end 163r of the same tube 163 remains fixed to a tubular extension 161f at the front end of the chamber 161 and thus to the handle housing 120. The intervening long segment 163i of the tube 163 takes up the differential motion by bodily deformation.
To facilitate this operation the intervening portion 163i of the tube may if desired be coiled slightly as shown, to facilitate an orderly arrangement of that portion 163i during retraction. This may help avoid its obstructing the advancing needle carriage 160--as for example by tangling, or catching between the advancing needle carriage 160 and the interior bore of the cylindrical handle wall 121. A slightly longer handle 121 is preferred to accommodate the coiled tube 163 after retraction. During flash acquisition, air is exhausted at the rear of the assembly through, for example, a lateral port 162 as in other fixed-flash-chamber devices.
Conceptually somewhat related to the receiving and retaining system of FIG. 6 is a likewise flexible element 262 (FIG. 7) that operates by resilient deformation to take up dimensional differences--but here these are differences between pre- and postflash dimensions, rather than pre- and postretraction dimensions. In this case the flexible element is a translucent or transparent balloon 262 that serves as the flash chamber.
The balloon chamber 262 is initially flattened, thus enclosing very little air, and expands with introduction of flash blood through the needle 270--thereby eliminating the need for a selective filter, vent system or the like for exhaust of displaced air and retention of blood. Upon retraction the balloon chamber 262 is protected against potentially compressive forces within the handle 220 by a relatively stiffer plastic sleeve 261.
As can be seen, this FIG. 7 embodiment is also to an extent conceptually related to that of FIGS. 1 through 5, in that the balloon chamber 262 and sleeve 261 during retraction move with the needle. Other forms of receiving and retaining means within the scope of our invention may be seen as related instead to the system of FIG. 6 in that a chamber is associated with the handle housing rather than with the needle--and a filter or vent system accommodates air exhaust ahead of the flash--but no flexible member is used to accommodate dimensional changes.
For example, one of such other forms employs instead a frangible duct 363 (FIG. 8) for directing flash blood from the needle 370 lumen to a flash chamber 361 fixed to or integral with the handle 320--as for example an annularly arranged chamber 361. In retraction the breakaway duct 363 is left loose within the handle 320.
Another of such forms employs a pivoted flapper-style valve 463 connected to the needle-carriage 460 (FIG. 9) for admitting flash blood from the needle 470 lumen directly to the interior of the passage 424 within the hollow handle 420--and for blocking return passage of that blood from the passage 424 into the lumen in retraction.
Other forms of energy-absorbing means too are, analogously, within the scope of the invention. For instance a crushable element--such as a crushable type of filter 62' (FIG. 1a)--at the rear of the flash chamber may be substituted for the hydrophilic or like filter discussed earlier. The crushable filter may be for instance a sintered plastic unit commercially available from the Porex Company. Alternatively a crushable element in the form of fine molded vanes or the like may be used instead.
Another usable energy absorber is a separate bearing element 227 (FIGS. 7, 7a) may be fixed to the needle--preferably carried in the needle carriage 260--and biased laterally (e.g., radially outward) as by a crescent spring 227s against the interior cylindrical surface 221 of the hollow handle housing 220.
Also available is the converse system--that is to say, a separate bearing element (not illustrated) carried in the inner cylindrical surface 221 of the housing 220 and bearing against a surface fixed to the needle--preferably carried on the carriage 260. Either of these biased-element systems is believed to provide drag or damping as desired.
Yet another form of energy-absorbing means is a dashpot piston 427 (FIG. 9) fixed at the end of the needle for developing damping, during retraction, through friction with liquid--and more specifically the flash blood--inside the hollow handle 420. For manufacturing convenience this dashpot element 427 is advantageously integrated with the check valve 463 discussed earlier.
Other forms of redeployment-deterring means too are within the scope of the invention. For example the two end walls of a flash chamber 161 (FIG. 6) that is firmly fixed to the rear of the hollow handle 120 also form a complete obstruction of the hollow handle 120--thus deterring insertion of a tool through that rear portion of the handle to redeploy the needle 170. This would remain essentially true even if a puncturable filter, forming the rear of the chamber, were provided in place of the lateral port 162--as the forward wall of the chamber would still provide a near-complete barrier.
As another example, a labyrinthine end plug 286 (FIG. 7) can serve to exhaust air from the internal passage 221 of the handle housing 220, while entirely blocking insertion of a tool into the housing 220 to redeploy the needle. Alternatively air exhaust can be effected through relief ports 362 (FIG. 8) formed laterally, e.g., radially, through the cylindrical wall 321 of the handle housing 320--rather than longitudinally at the end of the housing 320--thereby permitting use of an entirely solid endcap 285 to obstruct tool insertion.
Still further, abuse-deterring means may take the form of a ratchet element 486a (FIG. 9), cooperating with the narrow portion 56 (FIG. 4) of the keyhole aperture in the lock slider/trigger 450, to prevent resetting of the trigger 450 after the assembly has been first made ready for use. As will be understood the mechanism must permit resetting of the trigger 450 one initial time, since this is the procedure by which the needle is deployed initially for its intended use.
Analogously, further abuse-deterring means may take the form of a ratchet-like element 486c which upon retraction falls in front of the needle 470 piercing end, to block subsequent forward movement of the needle.
It will be understood that the foregoing disclosure is intended to be merely exemplary, and not to limit the scope of the invention--which is to be determined by reference to the appended claims.
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Leakage of blood from the insertion set, during and after safety-needle retraction, is suppressed by components that receive and retain flash blood for viewing--notwithstanding forces developed within the device in retraction. One preferred such system includes a flash chamber that moves with the retracting needle, within a hollow handle, carrying a relatively high flow-impedance element which allows air exhaust from the chamber into the handle to admit flash blood--but isolates blood in the chamber from retraction-generated increase in air pressure in the handle. Energy-absorbing components control or compensate for retraction speed, to provide quiet smooth retraction--while yet enabling use of ample retraction force to make retraction reliable. Among several energy absorbing systems disclosed is a preferred one that includes a viscous material introduced within the hollow handle to damp the retracting motion; and an injection port to facilitate introduction of the viscous material. Needle reuse, and concomitant risk of spreading disease, are avoided through components that deter needle redeployment--by deterring access to or forward motion of the needle, or trigger reengagement.
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BACKGROUND OF THE INVENTION
This invention relates to a fan assembly, particularly to a fan assembly of the type which has a housing having side walls, a fan having rotating blades mounted within the housing and a slidable fan screen mounted relative to the housing and spaced from the rotating blades.
In the fan industry, there is a need for a fan housing which allows ready access to the fan unit within the housing for cleaning and maintenance purposes. While being readily accessible for cleaning and maintenance purposes, the fan housing must allow a maximum amount of the air flow through the fan while still providing a safety guard which prevents objects from getting into the path of the fan blades.
A primary concern of the fan industry is safety. During typical fan operation, fan blades am rotated at high RPM's. These rotating fan blades are often enclosed within a fan housing which contains front and rear guards (typically made of wire) in order to limit access to the fan blades during fan operation. Circulating fans are often installed in industrial or agricultural applications, which are notoriously unclean environments. In these types of applications, fans are wall mounted to exhaust air or ceiling hung for providing ventilation to livestock. In these harsh environments, hay, straw, dust, chicken feathers, or other airborne material typically become lodged within the fan housing. Therefor, the fan housing must allow easy access to the fan unit for cleaning and maintenance.
In the past, fans for these applications have had fan housings which include rear and front shielded fan guard faces, with totally or partially shielded side walls. The shielded rear and front fan guard faces will permit some objects to pass partially therethrough. A totally or partially enclosed circumferential side wall connects the rear and front guard faces to enclose the fan blades. The fan blades may be located approximately equal distances from the front and back guard faces, with the guard faces being far enough away from the fan blades to prohibit a human hand from reaching the blade path.
The front and rear fan guards of these devices have been limited to guards that are secured to the fan housing side wall by methods which require the use of tools for removing the guards for access to the fan units for cleaning and maintenance purposes. The methods of securing the front or rear fan guard to the fan housing side wall typically consists of a bolted or screw connection, or even a permanent welded connection of the fan guard to the fan housing side wall.
Since the fan guards are fixedly secured to the fan housing, tools such as screwdrivers and wrenches: and excessive handling is required to open the fan for cleaning and maintenance purposes. As mentioned, these fans are often located in harsh environments, where hay, straw, dust, chicken feathers, or other airborne material typically become lodged within the fan housing. Regular maintenance and cleaning or these fans to remove such material is required to keep these fans operating at maximum efficiency. Since several fans are usually located within a single barn or shed, the removal of the fan guards for cleaning or maintenance purposes becomes labor intensive and time consuming.
SUMMARY OF THE INVENTION
The present invention is directed to a fan assembly of the type which has a housing having side walls, a fan having rotation blades mounted within the housing, and a fan screen. The fan screen is mounted relative to the housing and spaced from the rotating blades. The inventive fan assembly includes the housing having two parallel spaced tracks for slidable reception of a pair of parallel edges of the fan screen. The fan screen is slidably movable between an operable position in front of the rotating blades and a fan clean-out position disengaged or partially disengaged from the tracks of the housing. This allows easy removal of the fan screen for access to the fan unit for cleaning and maintenance purposes. In one preferred embodiment, the fan screen assembly may include at least one manually operable side clip mounted to the fan housing for securing the fan screen to the fan assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further described with reference to the accompanying drawings, where like numbers refer to like parts in several views.
FIG. 1 is a perspective view of a fan showing the present fan screen assembly invention.
FIG. 2 is a sectional view as taken along line 2--2 of FIG. 1.
FIG. 3 is an enlarged sectional view as taken along line 3--3 of FIG. 1.
FIG. 4 is a perspective view of a fan showing the present fan screen assembly invention in a clean-out position.
These drawing figures are provided for illustrative purposes only and are not drawn to scale, nor should they be construed to limit the intended scope and purpose of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a fan assembly is shown generally at 10 with the fan screen assembly of this invention being shown generally at 12. As seen in FIG. 2, a fan motor 14, a motor shaft 16, and fan blades 20 are mounted within a fan housing 22. A starting capacitor 24, fan motor mounting plate 26, an electric power source connector 28 are attached to the fan motor 14 within the fan housing 22.
Two fan motor supports 30 extend from the bottom of the fan housing 22 to the top of the fan housing 22. The fan motor mounting plate 26 is bolted to the fan motor supports 30 for supporting the fan motor 14 within the fan housing 22. Typical mounting applications for the fan assembly 10 include wall mounting the fan assembly 10 for air exhaust or hanging the fan assembly 10 from a ceiling or rafter for ventilation.
The fan motor 14 is connected to the motor shaft 16 which in turn is connected to the fan blades 20. The fan assembly 10 is powered through the electric power source connector 28 which supplies power to the fan motor 14. In one embodiment, a starting capacitor 24 is used to start the fan motor 14. The fan motor 14 converts electrical energy to mechanical energy which rotates the motor shaft 16 and fan blades 20 which are attached to the motor shaft 16. This system results in typical fan operation, whereby the fan blades 20 are rotated at higher RPM's.
The rotating fan blades 20 are encased within the fan housing 22. The fan housing 22 of the invention generally includes an outer wall 32, a front fan screen assembly 34, and rear fan screen assembly 36. The outer wall 32 is located adjacent the fan blade 20 path and may take on any structural shape or form (e.g., round, rectangular, etc.). The outer wall 32 includes a top wall 33, bottom wall 35, and side walls 37. Typically, the outer wall 32 is formed in a rectangular or circular shape. The outer wall 32 may consist of sheet metal, plastic, wood, or any other solid material typically used for fan applications. The outer wall 32 also may consist of parallel circumferential or rectangular wires which when secured together form the outer wall 32. In one embodiment, the outer wall 32 consists of plywood, which is nailed or screwed together in a rectangular form. This embodiment includes an inner sleeve 38 which consists of a rectangular piece of sheet metal fitted inside the rectangular shaped outer wall 32, and which includes a circular opening 40 in which the diameter of the circular opening 40 is greater than the diameter of the fan blade 20 path. Secured to the outer wall 32 is a front fan screen assembly 34 and a rear fan screen assembly 36.
The front fan screen assembly 34 includes a fan screen 42, an upper track 44, a lower track 46 and a side clip 48. The fan screen 42 includes an outer support wire 50, vertical support wire 52, horizontal wires 54, and vertical wires 56. In one embodiment as shown in FIG. 1, the outer support wire 50 is the same general rectangular shape as the rectangular outer wall 32. A vertical support wire 52 runs from the center of the bottom of the outer support wire 50 (shown in FIG. 1 located along the bottom wall 35) to the center of the top of the outer support wire 50 (shown in FIG. 1 located along the top wall 33). It is securely attached to the outer support wire 50 with spot-welds. Horizontal wires 54 are spaced parallel horizontally from the bottom of the outer support wire 50 to the top of the outer support wire 50. Vertical wires 56 are spaced parallel from one side of the outer support wire 50 to the other side of the outer support wire 50. Together, the horizontal wires 54 and vertical wires 56 form a cross-hatched fan screen 42 and are securely attached with a spot weld to the outer support wire 50, vertical support wire 52, and to each other at each point where they cross, intersect, or meet each other.
The fan screen 42 is slidably receivable between the upper track 44 and lower track 46, both of which are U-shaped. The upper track 44 is mounted to the underside of the fan top wall 33 where it extends beyond the front of the side wall 37. The lower track 46 is mounted to a top side of the bottom wall 35 where the fan housing bottom wall 35 extends beyond the front of the side wall 37 (and in alignment with the upper track 44). FIG. 3 shows how the fan screen 42 fits within the upper track 44. The front fan screen assembly 34 allows the fan screen 42 to slide between an operable position shown in FIG. 1 and a clean-out position shown in FIG. 4. The clean-out position allows access to the interior of the fan assembly 10 for maintenance and cleaning purposes. In its clean-out position, the fan screen 42 may be completely disengaged and removed from the fan 10. The fan screen 42 may also be slid to either side to allow access to fan screen assembly 34, while still engaged between the upper track 44 and lower track 46.
When the fan screen 42 is in the operable position, the fan screen 42 is secured to the outer wall 32 using one or more side clips 48. Each side clip 48 is mounted on one of the side walls 37 of the outer wall 32, and is manually manipulated to engage and disengage the fan screen 42 from sliding movement with respect to the fan housing 22 so that the movement of the fan screen 42 between its operable position and its clean-out position is accomplished without the use of tools. The side clip may take the form of any suitable and simple latching mechanism to secure the fan screen 42 from sliding movement relative to the fan housing 22 (such as, for example, a pivotally mounted finger secured on the side wall 37 (as shown) or a retractable sliding mechanism) which, in its locking position, protrudes though one of the openings in the fan screen 42 adjacent the side wall 37.
The rear fan screen assembly 36 is located as shown in FIG. 2, and includes a fan screen 62, an upper track 64, a lower track 66, and a side clip 68. Like the front fan screen assembly, the rear fan screen assembly allows the fan screen 62 to slide within the upper track and lower track between an operable position and a clean-out position. One or more side clips are used to manually secure the fan screen 62 to the outer wall 32.
In a fan assembly which has front and rear axially spaced safety screens, one on each side of the fan blades, only the front (or only the rear) safety screen may be slidably movable.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. For example, the fan housing may be any given shape to fit different applications, such as a circular shape, as long as it has two parallel edges. In a circular application, the fan may be wall mounted with the fan screen assembly (including an upper and lower track) mounted to the wall. In an alternative embodiment, the diameter of the front of the fan assembly 10 may be greater than the diameter of the rear of the fan assembly 10. Also, the diameter of the fan blade 20 path may vary, for example, typical fan assembly 10 sizes include 12 inches, 20 inches, 24 inches, and 36 inches. The type of fan screen may also vary, including being totally open or louvered.
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A fan assembly having a housing having side walls, a fan having rotating blades mounted within the housing and a fan screen mounted relative to the housing and spaced from the rotating blades. The fan assembly includes a housing having two parallel spaced tracks for slidable reception of a pair of opposed parallel edges of the fan screen. The fan screen is slidably moveably between an operable position in front of the rotating blades and a fan clean-out position where the fan screen is at least partially disengaged from the tracks of the housing.
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CROSS REFERENCE TO RELATED APPLICATION
The present application is a continuation-in-part application of the application of Mark Welker, U.S. Ser. No. 11/031,928, filed Jan. 8, 2005, entitled FIXTURE AND METHODS.
FIELD OF THE INVENTION
The present invention relates generally to the field of lighting. More particularly, the present invention relates to decorative, reconfigurable or energy and maintenance efficient fluorescent light fixtures, and to an apparatus for new fluorescent light fixtures and for replacing an existing fluorescent light fixture for energy efficient use. Further, the present invention relates to a system that integrates light fixtures with a suspended grid ceiling or a solid ceiling.
BACKGROUND OF THE INVENTION
Typically in buildings, suspended ceilings having a metallic grid that supports panels in grid openings are common. Generally, in such ceilings, direct lighting fixtures replace panels in selected grid openings to provide room illumination. Such light fixtures are usually open bottom boxes that have a number of fluorescent lamps mounted in the box, in parallel, with a translucent or parabolic cover on the bottom of the box. The box is supported on the grid. In direct lighting, light from the lamps shines directly downward through a translucent or parabolic cover into the room. Generally, the lamps are visible from below. Such direct form of fluorescent lighting is relatively inexpensive, but very plain and utilitarian, without much decorative effect or the ability to upgrade to future lamp technologies of various lengths or quantities and without consideration for simplifying the related maintenance issues associated with the normal operations of a florescent lighting fixture.
Also an indirect or reflected type of fluorescent lighting is used with suspended grid ceilings as well as fixed ceilings. In such indirect lighting, the fluorescent lamps are less visible or cannot be seen, but the lighting yields a glow over the room, which can be used to achieve desirable decorative effects. Translucent to opaque covers, panes or lenses are normally used with this type of lighting. The light shines through open space into the room after being reflected. In one form of indirect lighting, the lamps are positioned below the ceiling panels of the suspended ceiling, and reflect against the ceiling into the room. An opaque shield conceals viewing the lamps from the room below. Such installations are generally custom designed and installed, with attendant, generally extensive, expense.
To avoid the expense of custom designing and installing indirect lighting which reflects against the ceiling, indirect lighting fixtures can be supported in grid openings as in direct lighting fixtures. In this form of indirect lighting in suspended grid ceilings, the fixture reflects light through a grid opening itself, as in U.S. Pat. No. 5,709,460. In the referenced patent, the lamps are positioned above and behind panels adjacent the openings. The lamps are concealed from view. The light is reflected from a dome over the opening and lamps, into the room below, through the grid opening. A mask or trim is optionally secured to the fixture to reduce the area of the opening through which the reflected light travels, and to further conceal the lamps from view from below. The fixture, including the reflector dome, rests on the grid beam flanges.
The light produced by a fluorescent lamp is generated by an electric current being conducted through mercury and inert gases. Fluorescent lighting is generally used, but not always, in indoor applications for both ambient and task lighting. The most commonly used types of fluorescent lamps are 2 foot by 2 foot (2′×2′), 2 foot by 4 foot (2′×4′) and 1 foot by 4 foot (1′×4′) lamps, and others exist of different dimensions, but the others are not as common when associated with applications for ambient or task lighting indoors. Fluorescent fixtures and lamps are preferred for ambient and task lighting in large areas because their visual efficiency creates less direct glare than do incandescent bulbs, and because fluorescent lighting is several times as energy efficient as incandescent lighting.
Although fluorescent lamps are generally energy efficient, there are more efficient lamps that use improved electrodes and coatings when compared to older fluorescent lamp types. These lamps produce increased lumen output with improved and substantially lower power consumption. The current lamps can be replaced with energy-saving lamps of lesser wattage and improved visual aspects, but the current fixtures are currently restricted by the necessity of having to use the same length and configuration of lamps as originally designed by the manufacturer, even when lamps of shorter lengths exist and the shorter lamps would allow an even greater improvement in energy savings or more practical to an application task. Also, more energy efficient ballasts are available. These improved ballasts can measurably increase the energy efficiency of the fixture.
A large market exists for new light fixtures as well as for the upgrading of existing fluorescent lighting in any appropriate applications, including but not limited to office buildings, residential buildings, warehouses, retail centers, hospitals, airports, schools, colleges, municipal buildings and factories, to install modern energy efficient lamps and ballasts. In addition, many older fluorescent light fixtures were installed because at that time they were the most efficient. With today's concern for energy efficiency and cost reduction, it is desirable to upgrade a current fluorescent fixture to one having a more energy efficient design related to the application task. When upgrading a fixture, it is important to use a fixture that is flexible and expandable to provide options for future lamp trends and standards. As used herein, expandability refers to the length of the lamps and the flexibility refers to the number of lamps in each fixture.
Often times, a single building will have a plurality of fixture sizes. At present, a separate different light fixture is required for each fixture configuration holding one or more fluorescent lamps. In a given structure, this may vary from one or two different fixture configurations to a multiple number of configurations, but is typically not restricted. Manufacturers must therefore make and stock a commensurate number of individual, different fixture configurations for fluorescent lamps.
There exists, therefore, a need for a fixture apparatus having enhanced expandability and flexibility with respect to existing structures and the fixtures therein.
It would therefore be useful to provide a single light fixture that can hold a multiple number of lamp configurations of various fluorescent lamp lengths and lamp types, and thus the fixture is interchangeable.
A feature of the present invention is to provide a light fixture system with the capacity to be converted from a direct lighting fixture to an indirect lighting fixture and capable of providing the various aesthetic, maintenance, and improved efficiencies and options as requested or required to improve or meet desired task lighting.
A feature of the present invention is to provide a light fixture system having a fixture housing equipped with various removable perforated slots allowing the fixture the ability to use various lamp lengths, lamp types and lamp configurations without having to purchase or use a new fixture housing.
A feature of the present invention is to provide a light fixture system having all the necessary parts being removable and re-configurable in the field or at manufacturing facility to accommodate various lamp configurations reducing the need for an electrician or other skilled technician, or only requiring a non-skilled technician as allowed by the relevant laws or ordnances.
Another feature of the present invention is to provide a light fixture system having all the necessary parts being removable and re-configurable in the field or at manufacturing facility to accommodate various lamp types, lengths, wattage, sizes and parts while reducing the need for an electrician or other skilled technician as allowed by the relevant laws or ordnances.
Yet another feature of the present invention is to provide a light fixture system having all the necessary parts being removable and re-configurable in the field or manufacturing facility to accommodate various lamp quantities reducing the need for an electrician or other skilled technician as allowed by the relevant laws or ordnances.
Another feature of the present invention is to provide a light fixture system that can be easily reconfigured without disengaging the fixture from the ceiling or, in many cases from, its power source.
Yet another feature of the present invention is to provide a light fixture system that can be easily serviced without disengaging the fixture from the ceiling or, in many situations from, its power source and typically without the need for an electrician, skilled laborer or other qualified technician as allowed by the relevant laws or ordnances.
Another feature of the present invention is to provide a light fixture system such that the fixture is easily accessed for replacement of electronic parts or other possible maintenance considerations without the need of specialty tools or an electrician, skilled laborer or other qualified technician as allowed by the relevant laws or ordnances.
Another feature of the present invention is to provide a light fixture system that provides for the installation of the fixture of the present invention without the removal of the existing fixture housing.
A feature of the present invention is to provide a light fixture system that has Shadow Box™ trim that is functional with respect to providing proportionality between the fixture configuration and the lamp characteristics of type and length.
Another feature of the present invention is to provide a light fixture system that has trim that is decorative.
Yet another feature of the present invention is to provide a light fixture system that has trim, which trim can be made of various materials, colors, textures, cuts, logos and designs.
Yet another feature of the present invention is to provide a light fixture system that has trim, which trim can be functional for illuminating a logo, image or slogan for advertising, branding or personalizing the fixture and the like.
Another feature of the present invention is to provide a light fixture system that has trim, which trim can be removed and replaced without the use of tools, special equipment or a qualified technician.
Another feature of the present invention is to provide a light fixture system that has trim, which trim is illuminated by light from the lamps in the fixture or from an auxiliary light source associated with the fixture.
Another feature of the present invention is to provide a light fixture system that provides lamp holders for various lamp configurations for several different types of lamps with no restriction as to the length of the lamp.
Another feature of the present invention is to provide a light fixture system for converting a fixture to a different configuration.
Yet another feature of the present invention is to provide a light fixture system that has trim, which trim is designed for the functionality of maximizing the performance parameters of the fixture in regards to but not limited to shorter lamp lengths, lamp positioning, lamp quantities, lens attachment, and other related features necessary to perform a preferred lighting task such as by way of example indirect lighting.
Yet another feature of the present invention is to provide a light fixture system that has trim, in regards to but not limited to, advertising a logo, image or slogan, or illuminating or projecting an image for the purpose of personalizing the fixture to custom specifications.
Yet another feature of the present invention is to provide a light fixture system that has trim for advertising, illuminating or projecting an image for the purpose of personalizing the fixture to custom specifications that uses the lamps incorporated in the fixture specifications designed for the task.
Yet another feature of the present invention is to provide a light fixture system that has trim for advertising, illuminating or projecting an image for the purpose of personalizing the fixture to custom specifications that uses an alternate illumination source for the purpose of illuminating or projecting the image, where such alternate illumination sources are, without limitation, LED lighting, cold cathode devices, CFLs, fluorescent, and the like.
Yet another feature of the invention is to provide a light fixture system where the ballast is mounted to the outside of the fixture so as to be away from the lamps and the associated heat generated thereby for providing a cooler running temperature for the ballast and lamps so as to optimize energy use, ballast life and lamp life.
Another feature of the present invention is to provide a light fixture system that can use various ballast lengths as deemed necessary by the lamp and power requirements.
Yet another feature of the present invention is to provide a light fixture system wherein the ballast can be changed without the need of tools, special equipment or a skilled technician, i.e., plug and play characteristics.
Yet another feature of the present invention is to provide a light fixture system having a ballast that is mounted on the outside of the fixture which ballast is easily accessed for replacement or maintenance.
Another feature of the present invention is to provide a light fixture system that provides a ballast cover that may be mounted on the back of the fixture which cover is perforated to allow excess heat to escape in models used in a non-insulated area of operation in which the ceiling insulation does not engage the ballast cover.
Yet another feature of the invention is to provide a light fixture system that provides a ballast cover with no openings for use when the fixture is used in an operation where ceiling insulation may contact the ballast cover or wiring surfaces of the fixture.
Yet another feature of the present invention is to provide a light fixture system having a ballast having a heat sink engaged therewith to optimize energy use, ballast life and lamp life.
Still another feature of the present invention is to provide a light fixture system adaptable for use with multiple ballasts as well as multiple ballast lengths and sizes.
Yet still another feature of the present invention is to provide a light fixture system having an install apparatus that engages the perimeter of an opening into which a fluorescent fixture will fit for removably accepting the fixture.
A feature of the present invention is to provide a light fixture system having an install apparatus upon which an old fixture rests such that a new fixture can be engaged to the install apparatus without removing the old fixture.
Another feature of the present invention is to provide a light fixture system having an install apparatus for accepting a fixture which fixture can be opened by pivoting or disengaging from the install apparatus.
Another feature of the present invention is to provide a light fixture system having an install apparatus for associating with the perimeter in which the install apparatus is engaged for providing an air return path.
Another feature of the present invention is to provide a light fixture system having an install apparatus for accepting a fixture which fixture can be disengaged and dropped for removal from the install apparatus with or without pivoting with respect to the install apparatus.
Yet still another feature of the present invention is to provide a light fixture system having an install extension apparatus that engages the perimeter of an opening into which a fluorescent fixture will fit for removably accepting the fixture and for lifting a low-profile fixture so that a deeper, new fixture can be used under the low-profile fixture.
Yet another feature of the present invention is to provide a light fixture that does not directly engage the ceiling, wall or T-grid into which it fits.
Yet another feature of the present invention is to provide a light fixture that is adapted for use with a surface mount box, which surface mount box accepts the install apparatus of the present invention.
Yet still another feature of the present invention is to provide a light fixture that has light guides for directing light through the opening of a trim member or any desired angle with respect to the Shadow Box™ trim.
Additional features and advantages of the invention will be set forth in part in the description which follows, and in part will become apparent from the description, or may be learned by practice of the invention. The features and advantages of the invention may be realized by means of the combinations and steps particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
To achieve the foregoing objects, features, and advantages and in accordance with the purpose of the invention as embodied and broadly described herein, a light fixture system is provided.
Fixture Housing
The housing is equipped with various removable perforated slots allowing the fixture the ability to use various lamp lengths, lamp types and lamp quantities without having to purchase or use a new housing. All the necessary/required parts, such as end plates and lamp holders, are removable and reconfigurable in the field or in the manufacturing facility to allow various lamp and other necessary light needs to be preformed. The housing is an apparatus that assembles without the use of specialty tools. In addition to providing light reflectivity, the additional functions of the housing apparatus is to provide the flexibility to configure the light fixture in any desired configuration with respect to the number of lamps, the length of lamps, the wattage of lamps and any other relevant parameter associated with the configuration of the light fixture.
In one embodiment of the present invention, the fixture rotates out of the T-grid with the ballast on the outside of the lamp cavity away from the heat associated with the lamps.
Method of assembly: (1) housing, (2) end plates, (3) lock bar, (4) axles, (5) pins with springs, (6) electronics, (7) Shadow Box™ trim, (8) ballast cover, (9) tombstone covers, and (10) lens cover.
A preferred embodiment of the present invention is to rotate out of the ceiling to (1) get to the electronics and the lamps, (2) install and remove the fixture, (3) easy maintenance, (4) easily move the entire fixture to another T-grid.
A tombstone/lamp holder is provided. The tombstone/lamp holder is adaptable for use with various lamp configurations and for various different types of lamps (e.g., T8-T5) but not restricted to any known lamp.
Ballast Configurations
The ability to use any ballast length and size as deemed necessary by the lamp and power requirements, and is not restricted to any such ballast.
The ballast can be changed without the need of tools, special equipment or hard wiring through the use of electrical connectors, and can be described as “plug and play.”
The ballast is preferably mounted on the outside of the fixture, but not limited to that location, which is easily accessed for replacement or maintenance, and can be described as “snap-in and snap-out.”
The ballast is mounted to the outside of the fixture away from the lamps and the heat generated which results in a cooler running temperature for the ballast to optimize energy use, ballast life and lamp life.
Ballast Cover
The ballast cover is mounted on the back of the fixture, but is not limited to that location, and may be perforated to allow excess heat to escape in models used in a noninsulated area of operation in which the ceiling insulation does not cover the ballast cover.
An alternate ballast cover with no openings can be used when the fixture is used in an operation where ceiling insulation will contact the ballast cover or wiring surfaces of the fixture.
Install Apparatus:
The function of the install apparatus is to provide the removable engagement of the light fixture with any ceiling, wall, T-grid or the like.
The method in which the install apparatus is installed varies with the required situation. Preferably, the install apparatus can be installed by placing the individual pieces into the aperture associated with the ceiling, wall, T-grid or the like.
Alternately, the install apparatus is easily assembled and then installed as a complete unit in the aperture associated with the ceiling, wall, T-grid or the like utilizing the interlocking panels.
The install apparatus allows the fixture to be easily accessed for replacement of electronic parts or other possible maintenance needs because the light fixture pivots from the install apparatus for providing easy access to the fixture. In one embodiment, the light fixture pivots from the channel lock groves of the install apparatus for providing easy access to the fixture.
Further, the install apparatus provides for the installation of the light fixture without the removal of the existing fixture, if desired.
The method of using an install apparatus with a light fixture for removeably affixing the light fixture in a ceiling/wall structure having an opening therein comprises (1) engaging the perimeter of the opening with the install apparatus, (2) engaging the light fixture with the install apparatus such that the light fixture is removeably engaged with respect to the ceiling/wall structure, (3) pivoting or disengaging the fixture from the install apparatus for providing easy access to all parts of the fixture for easy operation and maintenance of the fixture and (4) returning of the fixture to a mounted position during operation.
The method of using a install apparatus with a light fixture for removeably affixing the light fixture in a ceiling/wall structure having another existing light fixture in an opening therein, the method comprises (1) disengaging the existing light fixture from the opening in a direction away from the direction the existing fixture casts light, (2) engaging the perimeter of the opening with the install apparatus, and (3) engaging the light fixture with the install apparatus such that the light fixture is removeably engaged with the install apparatus and the existing light fixture is resting on the light fixture which is thus removeably engaged with respect to the ceiling/wall structure. Further, the fixture by itself can be used with its own “jack-up” kit device. This allows the fixture to be made deeper without changing or installing a “jack up kit” to the install apparatus.
The method of converting an existing light fixture for removeably affixing the light fixture in a ceiling/wall structure having an opening therein, the method comprises (1) removing the back of the fixture, (2) adapting a pivot/hinge/latch mechanism between the fixture and the removed back and (3) pivoting the back about the mechanism such that the back drops from the opening and can be accessed for maintenance. The pivoting back could also incorporate the use of tear out tabs for various lamp lengths.
The method of converting an existing light fixture for removeably affixing the light fixture in a ceiling/wall structure having an opening therein, the method comprises (1) using the housing of an existing fixture, (2) adapting a pivot/hinge/latch mechanism between the existing housing and a smaller fixture that fits into the housing and (3) pivoting the smaller fixture about the mechanism such that the smaller fixture pivots or drops from the housing of the existing fixture and can be accessed for maintenance. Alternately, the present invention provides a method of manufacturing a new light fixture for removeably affixing the light fixture in a ceiling/wall structure having an opening therein, the method comprises (1) using the housing of a fixture, (2) adapting a pivot/hinge/latch mechanism between the housing and a smaller fixture such that the smaller fixture fits into the housing and (3) pivoting the smaller fixture about the mechanism such that the smaller fixture pivots or drops from the housing and can be accessed for maintenance.
It can be appreciated by those skilled in the art that many configurations are possible and are not limited and many different configurations are available in practicing the present invention. Examples of configurations, without limitation, are: (1) install apparatus, (2) cover plate for ballast cover hole, optional, (3) ballast, optional, (4) lamps; (1) lamps, (2) ballast, (3) install apparatus, (4) wiring harness, optional; and (1) lamps, (2) ballast, (3) install apparatus, (4) wiring harness, optional, (5) plug & play connectors, optional, (6) blanks for ballast cover and lamp holders.
Shadow Box™ Trim
The Shadow Box™ trim can be removed and attached to the light fixture without tools or attachment mechanisms. One Shadow Box™ trim is easily interchanged with another Shadow Box™ trim. The Shadow Box™ trim provides decorative trim which can be made of various materials, colors, textures, designs and other characteristics. The Shadow Box™ trim can be manufactured with corporate logos or other branding or advertising designs and is not limited to corporate designs. For example, graphic designs, images of animals, equipment, directions, and the like can be adapted for use with the Shadow Box™ trim. The Shadow Box™ trim can be rotated and laid into place so as to be removed and replaced without being lifted above the T-grid.
The Shadow Box™ trim can also provide a means for an indirect lighting apparatus. Further, the Shadow Box™ trim can be used with a ceiling mount apparatus to place a light fixture on a solid ceiling or wall.
Thus, the Shadow Box™ trim can be of any color, texture, material or other characteristic. More particularly, but without limitation, the Shadow Box™ trim can be plain, bear a design, bear a picture of an animal, person, figure, or any other item, bear a logo, bear a particular branding, or convey advertising, all referred to simply as the design. The Shadow Box™ trim provides that the design therein can be illuminated. The illumination of the design in the Shadow Box™ trim can be provided by the lamps associated with the light fixture. Also, the design in the Shadow Box™ trim can be illuminated by an alternate light source. Examples of such alternate light sources are, without limitation, LEDs, lasers, cold cathode devices, CFLs and the like. The design in the Shadow Box™ trim can be displayed in different colors. The coloring of the design can be achieved by using colored mylar film, colored LEDs, prisms, or the like. The Shadow Box™ trim has quick release hinge tabs to easily pivot, remove and replace the trim.
Methods:
One embodiment of the present invention is a method of installing a light fixture. The method of installing a light fixture as practiced by the present invention into an aperture in a ceiling, wall or box where the aperture is defined by a perimeter comprises the steps of engaging an install apparatus with the perimeter of the aperture, engaging a fixture in a hanging relationship with the install apparatus, connecting a power source to the fixture, rotating the hanging fixture until the fixture is operational or functional with the perimeter of the aperture, securing the fixture in a flush or operational relationship with the perimeter of the aperture, and providing power to the fixture for lighting the fixture.
Another embodiment of the present invention is a method of changing a lamp in a light fixture. The method of changing a lamp in a light fixture as practiced by the present invention wherein the light fixture is engaged in a pivotal relationship by a trim member comprises the steps of disengaging a latch mechanism between the fixture and the trim member which latch mechanism removably secures the trim member to the fixture, pivoting the trim member away from the fixture such that the lamp in a cavity in the fixture is exposed and the trim member is hanging from a portion of the fixture, removing the old lamp from the cavity, and engaging a new lamp in the cavity of the fixture without displacing any other lamps or components, pivoting the trim member for securing the lamp in the cavity, and engaging the latch mechanism for securing the trim member to the fixture.
Yet another embodiment of the present invention is a method of changing a ballast. The method of changing a ballast in a light fixture as practiced by the present invention wherein the light fixture is engaged in a pivotal relationship with an install apparatus comprising the steps of disengaging a latch mechanism between the fixture and the install apparatus which latch mechanism removably secures the fixture to the install apparatus, pivoting the fixture away from the install apparatus such that the ballast cover is exposed and the fixture is hanging from a portion of the install apparatus, removing the ballast cover and the old ballast from the fixture, engaging a new ballast and the ballast cover on the fixture, pivoting the fixture for engagement with the install apparatus, and engaging the latch mechanism for securing the fixture to the install apparatus.
Yet still another embodiment of the present invention is a method of changing the location of a tombstone holder with respect to a fixture. The method of changing the location of a tombstone holder with respect to a fixture as practiced by the present invention comprises the steps of accessing the tombstone holder, releasing the tombstone holder from the fixture housing, relocating the tombstone holder to another location, securing the tombstone holder to the fixture housing at the new location.
Still another embodiment of the present invention is a method of using a Shadow Box™ trim or trim member with a light fixture. The method of using a Shadow Box™ trim or trim member with a light fixture as practiced by the present invention wherein the light fixture is engaged in a pivotal relationship by a trim member comprising the steps of disengaging a latch mechanism between the fixture and the trim member which latch mechanism removably secures the trim member to the fixture, pivoting the trim member away from the fixture such that the trim member is hanging from a portion of the fixture, removing the trim member from the fixture, engaging a new trim member with the fixture, pivoting the trim member for removably engaging the fixture, engaging the latch mechanism for securing the trim member to the fixture.
Yet another embodiment of the present invention is a method of installing an install apparatus in a T-grid. The method of installing an install apparatus in a T-grid as practiced by the present invention comprises the steps of engaging a first lateral member in congruence with a first lateral side of the T-grid, engaging a second lateral member in congruence with a second lateral side of the T-grid, engaging a first longitudinal member in congruence with a first longitudinal side of the T-grid, interlocking the first lateral member and the first longitudinal, interlocking the second lateral member and the first longitudinal, engaging a second longitudinal member in congruence with a second longitudinal side of the T-grid, interlocking the first lateral member and the second longitudinal member, interlocking the second lateral member and the second longitudinal member such that the lateral members and the longitudinal members define the install apparatus.
Another embodiment of the present invention is a method of changing the lamp configurations or the lamp quantities comprising the steps of accessing the tombstone holder, releasing the tombstone holder from the fixture housing, engaging a new tombstone holder with the desired number of tombstones, and securing the new tombstone holder to the fixture housing.
Yet another embodiment of the present invention is a method of using a light fixture extension as practiced by the present invention for placement into an aperture in a ceiling, wall or box where the aperture is defined by a perimeter comprises the steps of removing trim member from the fixture, disengaging the fixture from the install apparatus via a latch mechanism between the fixture and the install apparatus, removing the existing hardware, replacing the hardware onto an extension, attaching the extension to the fixture to the correct corresponding positions, adding an end extension to the end plates, replacing the fixture for engagement into the install apparatus via a latch mechanism between the fixture and the install apparatus, and replacing the trim member and locking into position.
Yet still another embodiment of the present invention is a method of using an install apparatus extension as practiced by the present invention for placement into an aperture in a ceiling, wall or box where the aperture is defined by a perimeter comprises the steps of removing the fixture from the install apparatus, removing the install apparatus from the opening and attaching extension elements to the install apparatus, replacing the install apparatus into the ceiling or wall cavity, and replacing the fixture and engaging into the install apparatus via a latch mechanism between the fixture and the install apparatus.
Still another embodiment of the present invention is a method of adapting a light fixture as practiced by the present invention for casting indirect light comprises the steps of removing the trim member, removing the lamps, lowering the fixture from the install apparatus, removing the electronics, adding the new electronics, rotating the fixture back into the install apparatus, securing the fixture into the install apparatus, installing the indirect reflective shield, adding the lamps, attaching the indirect apparatus to trim member, attaching the trim member to the fixture, and rotating the trim member into the fixture and securing it in place.
Yet still another embodiment of the present invention is a method of using an install apparatus with a light fixture as practiced by the present invention. The method of using an install apparatus with a light fixture as practiced by the present invention for placement into an aperture in a ceiling, wall or box where the aperture is defined by a perimeter comprises the steps of pushing the existing fixture up, engaging an install apparatus with the perimeter of the aperture, engaging a fixture in a pivotally hanging relationship with the install apparatus such that the existing fixture is resting above the fixture and the install apparatus, connecting a power source to the fixture, rotating the hanging fixture until the fixture is operational with the perimeter of the aperture, securing the fixture in a flush or operational relationship with the perimeter of the aperture, and providing power to the fixture for lighting the fixture.
Yet another feature of the present invention is to provide a light fixture system for providing indirect light having an installation apparatus that engages the perimeter of an opening into a trim member where an indirect lighting cover/mechanism can be attached without the aid of specialty tools or skilled labor for converting the direct lighting configuration into an indirect light configuration.
Yet still another feature of the present invention is to provide a light fixture system having an installation apparatus that converts the electrical components from a direct lighting system into an indirect lighting system without the aid of specialty tools or skilled labor.
Additional advantages and modification will readily occur to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus, and the illustrative examples shown and described herein. Accordingly, the departures may be made from the details without departing from the spirit or scope of the disclosed general inventive concept.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention and together with the general description of the invention given above and the detailed description of the preferred embodiment given below, serve to explain the principles of the invention.
FIG. 1 is a perspective view of a preferred embodiment of the light fixture apparatus of the present invention with the Shadow Box™ trim pivoted from and disposed at a 90 degree angle to the fixture/troffer.
FIG. 2 is a perspective view of a preferred embodiment of the light fixture apparatus of the present invention with the fixture/troffer pivoted from and disposed at a 90 degree angle to the install apparatus which is engaged with a T grid.
FIG. 3 is a perspective view of a preferred embodiment of the light fixture apparatus of the present invention showing the fixture/troffer, the Shadow Box™ trim and the install apparatus.
FIG. 4 is a perspective view of a preferred embodiment of the housing associated with the light fixture apparatus of the present invention.
FIG. 5 is a plan view of the back side a preferred embodiment of the housing associated with the light fixture apparatus of the present invention.
FIG. 5A is a plan view of the back side another preferred embodiment of the housing associated with the light fixture apparatus of the present invention.
FIG. 6 is an end view of a preferred embodiment of the housing associated with the light fixture apparatus of the present invention.
FIG. 6A is an end view of another preferred embodiment of the housing associated with the light fixture apparatus of the present invention.
FIG. 7 is a plan view of a preferred embodiment of the Shadow Box™ trim associated with the light fixture apparatus of the present invention.
FIG. 8 is a perspective view of a preferred embodiment of latch mechanism associated with the light fixture apparatus of the present invention.
FIG. 9 is a perspective view of another preferred embodiment of latch mechanism associated with the light fixture apparatus of the present invention.
FIG. 10 is a perspective view of a preferred embodiment of ballast cover associated with the light fixture apparatus of the present invention.
FIG. 11 is a perspective view of a preferred embodiment of ballast cover associated with the light fixture apparatus of the present invention that provides for the venting of heat from the ballast cover.
FIG. 12 is a perspective view of a preferred embodiment of the light fixture apparatus of the present invention engaged with a T-grid as seen from below illustrating the promotional use of a logo with the Shadow Box™ trim.
FIG. 13 is a perspective view of a preferred embodiment of the light fixture apparatus of the present invention engaged with a T-grid as seen from below illustrating the promotional use of a design with the Shadow Box™ trim.
FIG. 14 is a flow chart illustrating a preferred embodiment of the method of installing a light fixture as practiced by the present invention.
FIG. 15 is a flow chart illustrating a preferred embodiment of the method of changing a lamp as practiced by the present invention.
FIG. 16 is a flow chart illustrating a preferred embodiment of the method of changing a ballast as practiced by the present invention.
FIG. 17 is a flow chart illustrating a preferred embodiment of the method of changing the location of a tombstone holder with respect to a fixture as practiced by the present invention.
FIG. 18 is a flow chart illustrating a preferred embodiment of the method of using a shadow box with a light fixture as practiced by the present invention.
FIG. 19 is a flow chart illustrating a preferred embodiment of the method of installing an install apparatus as practiced by the present invention.
FIG. 20 is a flow chart illustrating a preferred embodiment of the method of changing the lamp configurations or the lamp quantities as practiced by the present invention.
FIG. 21 is a flow chart illustrating a preferred embodiment of the method of changing the lamp types as practiced by the present invention.
FIG. 22 is a flow chart illustrating a preferred embodiment of the method of using a light fixture extension as practiced by the present invention.
FIG. 23 is a flow chart illustrating a preferred embodiment of the method of using an install apparatus extension as practiced by the present invention.
FIG. 24 is a flow chart illustrating a preferred embodiment of the method of adapting a light fixture as practiced by the present invention for casting indirect light.
FIGS. 25A , 25 B, 25 C, 25 D are perspective views of a preferred embodiment of an indirect lighting trim for use with the light fixture apparatus of the present invention.
FIG. 26 is a perspective view of a preferred embodiment of a ballast rail of the present invention.
FIG. 27 is an end view of the preferred embodiment of a ballast rail of the present invention as illustrated in FIG. 26 .
FIG. 28 is a longitudinal view of the preferred embodiment of a ballast rail of the present invention as illustrated in FIG. 26 .
FIG. 29 is a plan view of the preferred embodiment of a ballast rail of the present invention as illustrated in FIG. 26 engaged with a collet.
FIG. 30 is a plan view of the preferred embodiment of the collet of the present invention as illustrated in FIG. 29 .
FIG. 31 is a perspective view of a preferred embodiment of a latch bar of the present invention.
FIG. 31A is a longitudinal view of the preferred embodiment of the latch bar of the present invention as illustrated in FIG. 31 .
FIG. 31B is a detail view of the preferred embodiment of the latch bar of the present invention as illustrated in FIG. 31A .
FIG. 31C is a longitudinal, break-away view of the preferred embodiment of the latch bar of the present invention as illustrated in FIG. 31 .
FIG. 31D is a detail view of the preferred embodiment of the latch of the latch bar of the present invention as illustrated in FIG. 31A .
FIG. 32A is a perspective view of the preferred embodiment of the lens receiver guide of the present invention.
FIG. 32B is an elevation view of the preferred embodiment of the lens receiver guide of the present invention as illustrated in FIG. 32A .
FIG. 32C is a plan view of the preferred embodiment of the lens receiver guide of the present invention as illustrated in FIG. 32A .
FIG. 33A is a perspective view of a preferred embodiment of the lens clip of the present invention.
FIG. 33B is an elevation view of the preferred embodiment of the lens clip of the present invention as illustrated in FIG. 33A .
Additional advantages and modification will readily occur to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus, and the illustrative examples shown and described herein. Accordingly, the departures may be made from the details without departing from the spirit or scope of the disclosed general inventive concept.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The above general description and the following detailed description are merely illustrative of the generic invention, and additional modes, advantages, and particulars of this invention will be readily suggested to those skilled in the art without departing from the spirit and scope of the invention.
FIG. 1 is a perspective view of a preferred embodiment of the light fixture apparatus 100 of the present invention with the Shadow Box™ trim 300 pivoted from and disposed at a 90 degree angle to the fixture/troffer 200 . The fixture/troffer 200 and the Shadow Box™ trim 300 have a detachable relationship as well as a pivoting relationship. Thus, the Shadow Box™ trim 300 can either be removed completely from the fixture/troffer 200 , or the Shadow Box™ trim 300 can be in a pivoting relationship with the fixture/troffer 200 .
The fixture/troffer 200 comprises a base 202 , end plates 204 , lamp holder covers 206 , a ballast cover 208 , a fixture release mechanism 210 and a pivot member 212 for the fixture/troffer 200 . The base 202 has a convexed surface 202 A and a concaved surface 202 B. The end plates 204 have an outer surface 204 A and an inner surface 204 B. The concaved surface 202 B of the base 202 and the inner surfaces 204 B of the end plates 204 form a cavity 203 . The cavity 203 accepts one or more lamps 12 . The lamps are held in place by a plurality of lamp holders or tombstones 205 .
The Shadow Box™ trim 300 comprises a perimeter structure 310 , a pivot member 312 , a display surface 314 , an engaging mechanism 320 and a lens 330 . The pivot member 312 of the Shadow Box™ trim 300 removeably engages the perimeter of the base 202 of the fixture/troffer 200 such that the Shadow Box™ trim 300 pivots about a perimeter of the fixture/troffer 200 . In FIG. 1 , the Shadow Box™ trim 300 is illustrated to be in an open-pivoted relationship with and disposed at a 90 degree angle to the fixture/troffer 200 . It can be readily appreciated that the Shadow Box™ trim 300 can be moved about the pivot member 312 to be in a closed-pivoted relationship with the fixture/troffer 200 . The Shadow Box™ trim 300 is held in a closed-pivoted relationship with the fixture/troffer 200 by the engaging mechanism 320 interacting with the release mechanism 220 .
FIG. 2 is a perspective view of a preferred embodiment of the light fixture apparatus 100 of the present invention with the fixture/troffer 200 pivoted from and disposed at a 90 degree angle to the install apparatus 400 which is engaged with a T grid 10 . The fixture/troffer 200 and the install apparatus 400 have a detachable relationship as well as a pivoting relationship. Thus, the fixture/troffer 200 can either be removed completely from the install apparatus 400 , or the fixture/troffer 200 can be in a pivoting relationship with the install apparatus 400 .
The fixture/troffer 200 illustrated in FIG. 2 shows the concaved side 202 A. The fixture/troffer 200 is illustrated with the lamp holder covers 206 , the tombstone holders 207 , the ballast 20 , the power source-to-ballast connectors 260 , the ballast-to-tombstone connectors 270 , the convexed surface 202 A of the base 202 , the ballast cover 208 and the ventilation grid 209 in the ballast cover 208 .
The install apparatus 400 is shown engaged with the T-grid 10 . The install apparatus 400 includes the lateral members 410 A, 410 B and the longitudinal members 430 A, 430 B [latter not shown]. The longitudinal members 430 A, 430 B of the install apparatus 400 are illustrated engaging longitudinal portions of the T-grid 10 . The longitudinal members 430 A, 430 B are preferably made of angled material such as for example U-shaped metal. Particularly, the longitudinal member 430 A shown in FIG. 2 illustrates the concaved side thereof with a smaller side engaging the T-grid 10 and the other smaller side remote from the T-grid 10 . The longitudinal members 430 A, 430 B may have one or more extensions from a remote end for removeably engaging the lateral members 410 A, 410 B, such as one or more extensions [not shown]. The extensions protruding from the longitudinal members 430 A, 430 B can be configured to be accepted in the respective lateral members 410 A, 410 B to form a detent [not shown] at an end location 422 for locking the movement of the lateral members 410 A, 410 B and the longitudinal members 430 A, 430 B. Also, the end remote from the detent may be secured to the T-grid 10 by use of a screw in the holes 412 illustrated in the lateral members 410 A, 410 B and the longitudinal members 430 A, 430 B or by any other conventional securing mechanism.
Of importance is the channel-lock feature of the fixture/troffer 200 relative to the install apparatus 400 . The fixture/troffer 200 has the pivot member 212 extending from one side of its perimeter. The pivot member 212 has at both its extremities an expanded portion that has a larger radial dimension than the main portion of the pivot member 212 . The install apparatus 400 has one or more slots 414 in each lateral member 410 A, 410 B. The slot 414 has a larger portion 414 A and a smaller portion 414 B. The larger portion 414 A is for receiving there through the expanded portion of the pivot member 212 . As the pivot member 212 is pushed from the larger portion 414 A into the smaller portion 414 B of the lateral member 410 A, 410 B, the pivot member 212 is secured in the smaller portion 414 B of the lateral members 410 A, 410 B such that the expanded portion of the pivot member 212 is on one side of the lateral members 410 A, 410 B and the main portion of the pivot member 212 along with the fixture/troffer 200 are on the other side of the lateral members 410 A, 410 B such that the fixture/troffer 200 is encompassed by the pivot member 212 . Also illustrated is alternate slot 415 which can be used in place of the slot 414 . It can be appreciated by those skilled in the art that alternate means are or could be available to perform the same function as the channel-lock feature of the present invention and such alternate means are encompassed by the present invention.
Also of importance is the pivoting of the fixture/troffer 200 about the pivot member 212 such that the fixture release mechanism 210 [see FIG. 1 ] is removably engaged with the install apparatus 400 such that the fixture/troffer 200 is held in place within the T-grid 10 on the surface 420 .
FIG. 3 is a perspective view of a preferred embodiment of the light fixture apparatus 100 of the present invention showing the fixture/troffer 200 , the Shadow Box™ trim 300 and the install apparatus 400 . The install apparatus 400 is illustrated with the lateral members 410 and the longitudinal members 430 . The Shadow Box™ trim 300 is illustrated with the perimeter structure 310 and the display surface 314 . The fixture/troffer 200 includes the base 202 , the end plates 204 , the lamp holder covers 206 , the ballast cover 208 and the lock bar assembly 220 . The base 202 has a plurality of tombstone adjustment slots 232 and one or more ballast slots 234 . The tombstone adjustment slots 232 are provided in the form of knock-outs so that, depending on the length of the lamp to be used with the light fixture apparatus 100 , the tombstone adjustment slots 232 corresponding to the lamp length used can be knocked out. Thus, it is appreciated by those skilled in the art that any lamp length or combination there of can be used with the light fixture apparatus 100 of the present invention. Similarly, the ballast adjustment slot 234 is provided for use with a ballast retainer [see FIG. 5 ] and ballast clip [not shown]. The ballast retainer provides that a conventional ballast having a projected portion can be slid under the ballast retainer for securing one end of the ballast. The ballast clip slideably engages the ballast adjustment slot 234 and the ballast for securing the ballast, regardless of size and shape, between the ballast retainer, the base 202 and the ballast clip. The ballast cover 208 has a ventilation grid 209 .
FIG. 4 is a perspective view of a preferred embodiment of the housing or base 202 associated with the light fixture apparatus 100 of the present invention. FIG. 4 illustrates the ability of the light fixture apparatus 100 of the present invention to be adapted for use with any lamp and any ballast. The ability to adapt to any lamp is derived from the ability to locate the tombstones 205 [see FIG. 1 ] that hold the lamps at any location, and thus, for accepting a lamp of any dimension, regardless of length or radius. The tombstone adjustment slots 232 A, 232 AA are provided for holding tombstones at the greatest distance apart, and thus, for accepting a lamp of maximum length for the base 202 shown. The intermediate tombstone adjustment slots 232 B, 232 BB are provided for holding tombstones at an intermediate distance apart, and thus, for accepting a lamp of intermediate length for the base 202 shown. The tombstone adjustment slots 232 C, 232 CC are provided for holding tombstones at the shortest distance apart, and thus, for accepting a lamp of a minimum length for the base 202 shown. Since the tombstone adjustment slots 232 span the width of the base 202 , tombstones 205 can be placed in any number across the base 202 with a lamp associated with each remote pair of tombstones 205 . The limiting factor with respect to the number of lamps that can be adapted for use in the light fixture apparatus 100 of the present invention is that the sum of the diameters of all the lamps is less that the length of the respective tombstone adjustment slots 232 . A ballast adjustment slot 234 is illustrated in the convexed surface 202 A to operate in a similar manner as do the tombstone adjustment slots 232 .
FIG. 5 is a plan view of the preferred embodiment of the concaved surface 202 B of the housing 202 associated with the light fixture apparatus 100 of the present invention as illustrated in FIG. 4 . The tombstone adjustment slots 232 A, 232 AA, 232 C, 232 CC for the maximum length lamp and the minimum length lamps are illustrated as knock-outs. The tombstone adjustment slots 232 B, 232 BB for the intermediate length lamps are illustrated as slots ready to accept the tombstones 205 which are secured by the tombstone holders 207 as illustrated in FIG. 2 . The ballast adjustment slot 234 is provided for use with a ballast retainer [in line with the ballast adjustment slot 234 ] and the ballast clip [not shown]. The ballast retainer provides that a conventional ballast having a projected portion can be slid under the ballast retainer for securing one end of the ballast. The ballast clip slideably engages the ballast adjustment slot 234 and the ballast for securing the ballast, regardless of size and shape, between the ballast retainer, the base 202 and the ballast clip. As is appreciated by those skilled in the art, the ballast clip can be any configuration which effects the removable engagement of the ballast with the ballast retainer, the base 202 and the ballast clip.
FIG. 6 is an end view of a preferred embodiment of the housing 202 associated with the light fixture apparatus 100 of the present invention. The housing 202 is illustrated to view the convexed portion 202 A of the housing 202 with the cancaved portion 202 B of the housing 202 . The extremities illustrated in FIG.6 are illustrated in FIGS. 8 and 9 to better illustrate possible release mechanisms.
FIG. 5A is a plan view of the back side another preferred embodiment of the housing 1202 associated with the light fixture apparatus of the present invention. The housing 1202 comprises a concaved portion 1202 B, a first angled portion 1203 , a second angled portion 1205 , a third angled portion 1207 , a planer portion 1209 and a flat portion 1211 . The concaved portion 1202 B has therein a plurality of tombstone adjustment slots 1232 A, 1232 AA, 1232 B, 1232 BB, 1232 C, 1232 CC. The planer portion 1209 comprises one or more knock-outs 1241 . Also, the planer portion 1209 comprises one or more T-shaped apertures 1243 that are engaging and/or pivoting points for engaging elements. Further, the planer portion 1209 comprises one or more apertures 1245 .
FIG. 6A is an end view of another preferred embodiment of the housing 1202 associated with the light fixture apparatus of the present invention. The housing 1202 comprises a concaved portion 1202 B, a convexed portion 1202 A, a first angled portion 1203 , a second angled portion 1205 , a third angled portion 1207 , a planer portion 1209 and a flat portion 1211 .
FIG. 7 is a plan view of a preferred embodiment of the Shadow Box™ trim 300 associated with the light fixture apparatus 100 of the present invention. The Shadow Box™ trim 300 comprises a perimeter structure 310 , a display surface 314 , a light opening 330 A, a pivot member 312 A and an engaging mechanism 320 .
The Shadow Box™ trim 300 can be removed and attached to the light fixture 100 without tools or attachment mechanisms. Any Shadow Box™ trim 300 is easily interchanged with another Shadow Box™ trim 300 . The Shadow Box™ trim 300 provides decorative trim which can be made of various materials, colors, textures and designs to depict corporate logos or other branding or advertising designs. The Shadow Box™ trim 300 may be, but not required to be, rotated and laid into place so as to be removed and replaced without being lifted above the T-grid. The Shadow Box™ trim 300 can also provide a means for an indirect lighting apparatus. Further, the Shadow Box™ trim 300 can be adapted for use with any fixture.
More particularly, but without limitation, the Shadow Box™ trim 300 can be plain, bear a design, bear a picture, bear a logo, bear a particular branding, or convey advertising, all referred to simply as the design. The Shadow Box™ trim 300 provides that the design therein can be illuminated. The illumination of the design in the Shadow Box™ trim 300 can be provided by the lamps associated with the light fixture. Also, the design in the Shadow Box™ trim 300 can be illuminated by an alternate light source. Examples of such alternate light sources are, without limitation, LEDs, lasers, cold cathode devices, CFLs and the like. The design in the Shadow Box™ trim 300 can be displayed in different colors. The coloring of the design can be achieved by using colored mylar film, colored LEDs, prisms, or the like. The Shadow Box™ trim 300 has quick release-engaging mechanism 320 to easily pivot, remove and replace the Shadow Box™ trim 300 .
FIG. 8 is a perspective view of a preferred embodiment of latch mechanism 225 associated with the light fixture apparatus 100 of the present invention.
FIG. 9 is a perspective view of another preferred embodiment of latch mechanism 226 associated with the light fixture apparatus 100 of the present invention.
FIG. 10 is a perspective view of a preferred embodiment of the ballast cover 208 associated with the light fixture apparatus 100 of the present invention. The ballast cover 208 is an elongate member such that any size ballast can be covered. The ballast cover 208 has open knock-outs 208 A for accepting the tombstone holder cover for the lamp holders 206 . Further, the ballast cover 208 has closed knock-outs 208 B which are available for knocking out and thereafter for accepting the tombstone holder cover for the lamp holders 206 . Typically, the ends of the ballast cover 208 are closed. Also, the ballast cover 208 has an opening between the open knock-outs 208 A for accepting power from a remote power source.
FIG. 11 is a perspective view of a preferred embodiment of ballast cover 208 associated with the light fixture apparatus 100 of the present invention that provides for the venting of heat from the ballast cover 208 by a ventilation grid 209 . The ballast cover 208 has open knock-outs 208 A for accepting the tombstone holder cover for the lamp holders 206 . Further, the ballast cover 208 has closed knock-outs 208 B which are available for knocking out and thereafter for accepting the tombstone holder cover for the lamp holders 206 .
FIG. 12 is a perspective view of a preferred embodiment of the light fixture apparatus 100 of the present invention engaged with a T-grid 10 as seen from below illustrating the promotional use of a logo 340 with the Shadow Box™ trim 300 . The logo 340 is in the display surface 314 of the Shadow Box™ trim 300 . The logo 340 can be lighted by the lamps in the fixture/troffer 200 , or alternately, can be lighted by auxiliary means so the logo 340 remains illuminated when the lamps in the light fixture apparatus 100 are off.
FIG. 13 is a perspective view of a preferred embodiment of the light fixture apparatus 100 of the present invention engaged with a T-grid 10 as seen from below illustrating the promotional use of a design 350 with the Shadow Box™ trim 300 . The design 350 is in the display surface 314 of the Shadow Box™ trim 300 . The design 350 can be lighted by the lamps in the fixture/troffer 200 , or alternately, can be lighted by auxiliary means so the design 350 remains illuminated when the lamps in the light fixture apparatus 100 are off.
FIG. 14 is a flow chart illustrating a preferred embodiment of the method of installing a light fixture as practiced by the present invention. The method of installing a light fixture as practiced by the present invention into an aperture in a ceiling, wall or box where the aperture is defined by a perimeter comprises the steps of engaging an install apparatus with the perimeter of the aperture, engaging a fixture in a hanging relationship with the install apparatus, connecting a power source to the fixture, rotating the hanging fixture until the fixture is operational with the perimeter of the aperture, securing the fixture in a operational relationship with the perimeter of the aperture, and providing power to the fixture for lighting the fixture.
FIG. 15 is a flow chart illustrating a preferred embodiment of the method of changing a lamp in a light fixture as practiced by the present invention. The method of changing a lamp in a light fixture as practiced by the present invention wherein the light fixture is engaged in a pivotal relationship by a trim member comprising the steps of disengaging the trim member from the fixture to expose a lamp cavity, pivoting the trim member away from the fixture such that the lamp in a cavity in the fixture is exposed and the trim member is hanging from a portion of the fixture, removing the old lamp from the cavity, and engaging a new lamp in the cavity without displacing any other lamp or component, pivoting the trim member for securing the lamp in the cavity, and engaging the latch mechanism for securing the trim member to the fixture.
FIG. 16 is a flow chart illustrating a preferred embodiment of the method of changing a ballast as practiced by the present invention. The method of changing a ballast in a light fixture as practiced by the present invention wherein the light fixture is engaged in a pivotal relationship with an install apparatus comprising the steps of disengaging a latch mechanism between the fixture and the install apparatus, pivoting the fixture away from the install apparatus to expose the ballast area, removing the old ballast from the fixture, engaging a new ballast on the fixture, pivoting the fixture for engagement with the install apparatus, and securing the fixture to the install apparatus.
FIG. 17 is a flow chart illustrating a preferred embodiment of the method of changing the location of a tombstone holder with respect to a fixture for changing lamps having different lengths as practiced by the present invention. The method of changing the location of a tombstone holder with respect to a fixture for changing lamps having different lengths comprising the steps of accessing the tombstone holder, releasing the tombstone holder from the fixture housing, relocating the tombstone holder to another location, and securing the tombstone holder to the fixture housing at the new location.
FIG. 18 is a flow chart illustrating a preferred embodiment of the method of using a Shadow Box™ trim or trim member with a light fixture as practiced by the present invention. The method of using a Shadow Box™ trim or trim member with a light fixture as practiced by the present invention wherein the light fixture is engaged in a pivotal relationship by a trim member comprising the steps of disengaging a latch mechanism between the fixture and the trim member which latch mechanism removably secures the trim member to the fixture, pivoting the trim member away from the fixture such that the trim member is hanging from a portion of the fixture, removing the trim member from the fixture, engaging a new trim member with the fixture, pivoting the trim member for removably engaging the fixture, and engaging the latch mechanism for securing the trim member to the fixture.
FIG. 19 is a flow chart illustrating a preferred embodiment of the method of installing an install apparatus in a T-grid as practiced by the present invention. The method of installing an install apparatus in a T-grid as practiced by the present invention comprising the steps of engaging a first lateral member in congruence with a first lateral side of the T-grid, engaging a second lateral member in congruence with a second lateral side of the T-grid, engaging a first longitudinal member in congruence with a first longitudinal side of the T-grid, interlocking the first lateral member and the first longitudinal, interlocking the second lateral member and the first longitudinal, engaging a second longitudinal member in congruence with a second longitudinal side of the T-grid, interlocking the first lateral member and the second longitudinal member, interlocking the second lateral member and the second longitudinal member such that the lateral members and the longitudinal members define the install apparatus.
FIG. 20 is a flow chart illustrating a preferred embodiment of the method of changing the lamp configurations or the lamp quantities as practiced by the present invention. The method of changing the lamp configurations or the lamp quantities comprises the steps of accessing the tombstone holder, releasing the tombstone holder from the fixture housing, engaging a new tombstone holder with the desired number of tombstones and securing the new tombstone holder to the fixture housing.
FIG. 21 is a flow chart illustrating a preferred embodiment of the method of changing the lamp types as practiced by the present invention. The method of changing the lamp types comprises the steps of accessing the tombstone holder, releasing the tombstone holder from the fixture housing, removing the existing tombstone, engaging in the tombstone holder a new tombstone for use with the new lamp type and securing the tombstone holder to the fixture housing.
FIG. 22 is a flow chart illustrating a preferred embodiment of the method of using a light fixture extension as practiced by the present invention. The method of using a light fixture extension as practiced by the present invention for placement into an aperture in a ceiling, wall or box where the aperture is defined by a perimeter comprising the steps of removing a trim member from the fixture, disengaging the fixture from the install apparatus via a latch mechanism between the fixture and the install apparatus, removing the existing hardware, replacing the hardware onto the fixture extensions, attaching the fixture to the fixture extensions to the correct corresponding positions, adding an end plate extension to the end plates, replacing the fixture for engagement into the install apparatus via a latch mechanism between the fixture and the install apparatus, and replacing the trim member and locking into position.
FIG. 23 is a flow chart illustrating a preferred embodiment of the method of using an install apparatus extension as practiced by the present invention. The method of using an install apparatus extension as practiced by the present invention for placement into an aperture in a ceiling, wall or box where the aperture is defined by a perimeter comprises the steps of removing the fixture from the install apparatus, removing the install apparatus from the opening and attaching extensions to the install apparatus, replacing the install apparatus into the ceiling or wall cavity, and replacing the fixture and engaging into the install apparatus via a latch mechanism between the fixture and the install apparatus.
FIG. 24 is a flow chart illustrating a preferred embodiment of the method of adapting a light fixture as practiced by the present invention for casting indirect light. The method of adapting a light fixture as practiced by the present invention for casting indirect light comprising the steps of, removing the trim member, removing the lamps, lowering the fixture from the install apparatus, removing the electronics, adding the new electronics, rotating the fixture back into the install apparatus, securing the fixture into the install apparatus, installing the indirect reflective shield, adding the lamps, attaching the indirect apparatus to trim member, attaching the trim member to the fixture, and rotating the trim member into the fixture and securing it in place.
FIGS. 25A , 25 B, 25 C, 25 D are perspective views of a preferred embodiment of an indirect lighting trim 500 for use with the light fixture apparatus 100 of the present invention. FIGS. 25A , 25 B, 25 C, 25 D illustrate the indirect lighting trim 500 for converting the light fixture apparatus 100 of the present invention into an indirect lighting fixture. The tombstone holder extension 516 A is inserted into the desired lamp length slot 232 B, 232 BB [see FIG. 4 ] allowing the lamps 12 to be positioned to the desired heights within the fixture/troffer 200 [see FIG. 1 ]. The lamp holders 205 are inserted into the tombstone holder extension 516 A before the tombstone holder extension cover 516 is attached. The indirect lighting trim 500 is placed onto the Shadow Box™ trim 300 and secured into place with a clip device 352 . The indirect reflective shield 580 is inserted into the fixture/troffer 200 and secured into place before closing the Shadow Box™ trim 300 with the indirect lighting trim 500 attached.
FIG. 26 is a perspective view of a preferred embodiment of a ballast rail 2200 of the present invention. The ballast rail 2200 comprises a planar portion 2202 , an offset portion 2204 , a lip portion 2206 and a beveled portion 2208 . The planar portion 2202 has one or more ballast adjustment slots 2234 A, 2234 B for removeably securing a ballast to the ballast rail 2200 . The offset portion 2204 provides that there is minimal engagement with respect to the planar portion 2202 of the ballast rail 2200 and the housing or base 202 as illustrated in FIG. 4 .
FIG. 27 is an end view of the preferred embodiment of the ballast rail 2200 of the present invention as illustrated in FIG. 26 . The ballast rail 2200 has a planar portion 2202 , an offset portion 2204 and a lip portion 2206 and a beveled portion 2208 .
FIG. 28 is a longitudinal view of the preferred embodiment of the ballast rail 2200 of the present invention as illustrated in FIG. 26 .
FIG. 29 is a plan view of the preferred embodiment of the ballast rail 2200 of the present invention as illustrated in FIG. 26 engaged with a collet. The ballast rail 2200 comprises a planar portion 2202 , an offset portion 2204 , a lip portion 2206 and a beveled portion 2208 . The planar portion 2202 has one or more ballast adjustment slots 2234 A, 2234 B for removeably securing a ballast to the ballast rail 2200 . Also, a collet 2240 secures the ballast rail 2200 to the housing. The configurations illustrated in FIGS. 26 , 27 , 28 , 29 , 30 provide special and enhanced heat sink effects for the ballasts attached to the ballast rail 2200 .
FIG. 30 is a plan view of the preferred embodiment of the collet 2240 of the present invention as illustrated in FIG. 29 . The collet 2240 comprises a planar member 2242 , a lip portion 2246 , a beveled portion 2248 and one or more apertures 2249 .
FIG. 31 is a perspective view of a preferred embodiment of a latch bar 3100 of the present invention. The latch bar 3100 comprises a longitudinal member 3102 , a latch 3104 , an aperture 3106 and an angled portion 3108 .
FIG. 31A is a longitudinal view of the preferred embodiment of the latch bar 3100 of the present invention as illustrated in FIG. 31 . The latch bar 3100 is illustrated with the angled portion 3108 .
FIG. 31B is a detail view of the preferred embodiment of the angled portion 3108 of the latch bar 3100 of the present invention as illustrated in FIG. 31A .
FIG. 31C is a longitudinal, break-away view of the preferred embodiment of the latch bar 3100 of the present invention as illustrated in FIG. 31 . The latch bar 3100 is illustrated with the longitudinal member 3102 , the latch 3104 , the aperture 3106 and the angled portion 3108 .
FIG. 31D is a detail view of the preferred embodiment of the latch of the latch bar 3100 of the present invention as illustrated in FIG. 31A . The latch bar 3100 is illustrated with the longitudinal member 3102 , the latch 3104 , the aperture 3106 and the angled portion 3108 .
FIG. 32A is a perspective view of the preferred embodiment of the lens receiver guide 3200 of the present invention. The lens receiver guide 3200 comprises a first member 3202 , a second member 3204 , where the first member 3202 and the second member 3204 are separated by an angle 3203 . The angle 3203 coincides with the angle at the corners of the lens cover, which in the present embodiment is 90 degrees. The first member 3202 and the second member 3204 have corresponding apertures 3211 , 3111 A, 3112 , 3112 A, 3113 , 3113 A. Each aperture 3211 , 3111 A, 3112 , 3112 A, 3113 , 3113 A has a protrusion 3220 therein. The protrusion 3220 is for removeably securing a lens clip 3300 (see FIG. 33 ) therein.
FIG. 32B is an elevation view of the preferred embodiment of the lens receiver guide 3200 of the present invention as illustrated in FIG. 32A . The lens receiver guide 3200 has a first member 3202 with three apertures 3211 , 3112 , 3113 . The number of apertures 3211 , 3112 , 3113 is determined by the number of thicknesses of lens that will be accommodated by the lens receiver guide 3200 . In the embodiment illustrated, the three apertures 3211 , 3112 , 3113 correspond to lens with thicknesses of the three gaps, G 11 , G 12 and G 13 .
FIG. 32C is a plan view of the preferred embodiment of the lens receiver guide 3200 of the present invention as illustrated in FIG. 32A .
FIG. 33A is a perspective view of a preferred embodiment of the lens clip 3300 of the present invention. The lens clip 3300 comprises a base member 3302 , a side member 3304 , an angled member 3306 , an engagement member 3308 and an pressing member 3310 . The side member 3304 can be any shape, e.g., round or square. The angled member 3306 has an aperture 3312 therein. The aperture 3312 in the angled member 3306 of the lens clip 3300 is for receiving the protrusion 3220 in the aperture 3211 when the lens clip 3300 is engaged in the aperture 3211 of the lens receiver guide 3200 . The lens clip 3300 is inserted for securing the lens and removed for changing the lens.
FIG. 33B is an elevation view of the preferred embodiment of the lens clip of the present invention as illustrated in FIG. 33A .
Additional advantages and modification will readily occur to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus, and the illustrative examples shown and described herein. Accordingly, the departures may be made from the details without departing from the spirit or scope of the disclosed general inventive concept.
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The present invention relates generally to the field of lighting. More particularly, the present invention relates to decorative, reconfigurable or energy and maintenance efficient fluorescent light fixtures that use energy efficient lamps and ballasts, and to an apparatus for new fluorescent light fixtures and for replacing an existing fluorescent light fixture for energy efficient use. Further, the present invention relates to a system that integrates light fixtures with a suspended grid ceiling or a solid ceiling.
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This application is based on and claims priority under 35 U.S.C. § 119 with respect to Swedish Application No. 0302855-2 filed on Oct. 29, 2003, the entire content of which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention generally relates to a combination of a bearing housing and a load measuring plate. More particularly, the invention pertains to the combination of a bearing housing and a load measuring plate of the type designed as a plate or block positioned between a base and a bearing housing, the load upon which shall be measured. The measuring plate can have a parallelepipedic structure, and can be armed with transducers producing measurement signals as a result of changes in magnetic fields. Such transducers can, for example, be strain gauges arranged in Wheatstone bridges for measuring the load acting thereon.
BACKGROUND DISCUSSION
A known load measuring block generally of the type referred to above is armed with Pressductor® transducers manufactured and marketed by ABB AB. These transducers operate with a measurement principle based on the magneto-elastic effect in which the magnetic properties of a material are influenced by the mechanical force applied to it.
There are a number of load cell configurations and several standard sizes, which are used primarily for roll force measurement in rolling mills, such as circular for installation under the mill screws or hydraulic actuators, rectangular for installation under the lower backup roll chock or annular for installation between the mill stand and nut.
Earlier, such load cells have also been used for measuring the load applied under operation to bearings supporting a shaft. It has been considered sufficient just to place the load cell or plate under the foot of the bearing housing. A load cell has thus been chosen, preferably of rectangular configuration and of a size big enough to allow the foot of the bearing housing to be positioned well inside the outer edges of the load cell.
With bearing housings having a substantially planar outer contour, it has been believed that this combination of a bearing housing foot resting well inside the edges of a load measuring plate, which has a bigger planar contact area against the base than the contact area between load measuring plate and the bearing housing, will give a satisfactory measuring result.
However, in modern bearing technology, the bearing housings have often been designed with a foot member, which has a number of recesses or cavities opening in a direction away from the bearing seat, i.e. downwards. This design reduces the weight of the bearing housing. In addition, though, the almost shell-like outer contour of the foot part of the bearing housing has become weakened. There is thus a risk for deformation under influence of high loads, and for that reason the outer walls of the bearing housing foot have been made more stiff by providing reinforcing transverse intermediate walls.
This design means that the earlier used combination of standard load measuring plates and a bearing housing, which has outer contours smaller than that of the load measuring plate, will give a non-secure and unsatisfactory measuring result, as the wall portions of the bearing housing foot contacting the surface of the load measuring plate will be randomly distributed over the load measuring plate, with a measurement result which might be incorrect.
SUMMARY
According to one aspect, the combination of a bearing housing and a load measuring plate comprises a load measuring plate internally equipped with load measuring devices, and a bearing housing comprising a foot member possessing a substantially rectangular outer contour that includes outer wall portions, transverse intermediate wall portions and a planar contact surface adapted to contact and rest upon the load measuring plate. The load measuring plate possesses an outer contour substantially the same as the outer contour of the foot member. The load measuring plate possesses an upper surface and a lower surface, with the upper surface configured to include raised upper end portions projecting above at least a portion of the upper surface located between the raised upper end portions, and with the lower surface configured to include lower end portions positioned above at least a portion of the lower surface located between the raised lower end portions. The raised upper end portions extend from the outer edge of the load measuring plate by a distance less than the distance over which the lower end portions extend from the outer edge of the load measuring plate, thereby creating oblique measurement planes in the load measuring plate.
According to another aspect, a bearing housing and load measuring plate combination comprises a load measuring plate provided with at least one load measuring device, and a bearing housing adapted to rest on a base and comprising a foot member possessing outer wall portions, transverse intermediate wall portions and a planar contact surface adapted to contact and rest upon the load measuring plate. The load measuring plate possesses an outer contour that is substantially the same as the outer contour of the foot member. The load measuring plate also possesses an upper surface and a lower surface, with the upper surface having upper end portions positioned in a plane that is offset from a central portion of the upper surface of the load measuring plate, and with the lower surface having lower end portions positioned in a plane that is offset relative to a central portion of the lower surface of the load measuring plate. The foot member of the bearing housing rests on the upper end portions of the load measuring plate, and a lower central portion of the lower surface is adapted to rest on the base with the lower end portions of the lower surface spaced from the base.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The foregoing and additional details will become more apparent from the following detailed description considered with reference to the accompanying drawing figures in which like elements are designated by like reference numerals.
FIG. 1 is a perspective view a bearing housing of a type used in the combination according the invention as viewed obliquely from the bottom or foot side thereof.
FIG. 2 is a perspective view of a load measuring plate used in combination with the bearing housing shown in FIG. 1 .
FIG. 3 is a plan view from above of the load measuring plate with certain hidden portions shown in phantom lines.
FIG. 4 is a side view of the load measuring plate with certain hidden portions shown in phantom lines.
DETAILED DESCRIPTION
FIG. 1 shows a bearing housing 1 in perspective view, as seen obliquely from the bottom of the foot member 2 , with a tubular main portion 3 facing away from the viewer. The bottom surface of the foot member 2 has a substantially rectangular outer contour 4 , although the four corners thereof are bevelled. As can be seen, the foot member 2 is substantially or generally shell-formed and has two parallel, thin outer long-side walls 5 , 6 and two parallel thin short-side walls 7 , 8 interconnecting the long-side walls 5 , 6 . Several transverse wall portions 9 , 10 , 11 extend between the tubular main body 3 and the long-side walls 5 , 6 to reinforce the housing base. In the embodiment shown, one of these transverse wall portions 11 is positioned just under the center of the tubular main portion, whereas the other two transverse wall portions 9 , 10 are situated a short distance from the adjacent short-side walls. These transverse wall portions 9 , 10 , 11 are positioned substantially reducing the weight of the bearing housing. The tubular main portion 3 , which has an inner, substantially cylindrical seat for accommodating the outer ring of a bearing, is spaced apart from the bottom surface of the foot member 2 , thereby leaving spaces opening downwards.
Due to this design of the bottom of the foot member 2 , the load on the bearing housing will be transferred to the surface on which it is positioned, only via the side walls 5 , 6 , 7 , 8 and the transverse walls 9 , 10 , 11 which, in the illustrated embodiment, are relatively thin. The areas between these walls 5 – 11 inside the outer contour of the foot member will not participate in any transfer of the load. The end sections outside the transverse reinforcing walls 9 , 10 are provided with through-holes 12 for attachment bolts, by which the bearing housing can be fitted to a base.
With the earlier load measuring blocks, for example, of the Pressductor® transducer type, where the contact surface of a bearing housing foot member of the type described is limited, there will be a random coincidence between the load transferring areas of the bearing housing and the load receiving areas of these earlier load measuring blocks. This means that the result of the measurement will be very much dependent on the mutual positioning of the two components in relation to each other.
FIG. 2 shows in a perspective view a load measuring plate 13 adapted to the bearing housing foot member of the type shown in FIG. 1 and described above. As can be seen, this load measuring plate 13 has a substantially parallelepipedic shape with an outer contour closely adapted to, and preferably the same as, the outer contour of the foot member 4 of the bearing housing 1 . Thus, the size and the shape of the load measuring plate 13 is closely adapted to, and preferably the same as, that of the bearing housing foot member.
Thus, the upper surface 14 of the load measuring plate 13 has a size and shape carefully corresponding to the size and shape of the foot member of the bearing housing, which foot member 2 is positioned on the surface 14 of the load measuring plate 13 . As can be clearly seen in FIG. 2 , the load measuring plate 13 has also the same bevelled side corners as the bearing housing foot member.
The upper side surface 14 of the load measuring plate 13 is not completely planar, but rather has raised or offset upper end portions 15 , 16 . The upper end portions 15 , 16 are offset relative to at least a portion of the central portion of the plate 13 located between the end portions 15 , 16 . With this configuration, the foot member 4 of the bearing housing 1 will rest on the load measuring plate 13 only at these raised upper end portions 15 , 16 of the load measuring plate 13 . The portion of the load measuring plate 13 situated between these raised upper end portions 15 , 16 has a number of through holes 17 for coupling members, for example, bolts, for attaching the load measuring plate 13 to a base. In addition, each of the offset end portions 15 , 16 has one through-hole 18 . These through-holes 18 are intended to receive bolts which will also pass through the through-openings 12 in the bearing housing foot member 2 , and thereby attach the bearing housing 1 to the load measuring plate 13 .
As best seen in FIG. 4 , the lower side surface 19 of the load measuring plate 13 has a shape which is also not completely planar, but rather has lower end portions 20 , 21 which are slightly raised above and offset relative to at least a portion of the lower surface positioned between the lower end portions 20 , 21 . Thus, at the upper and lower surfaces 14 , 19 of the load measuring plate 13 , the end portions lie in a plane that is offset from the plane containing the central portion of the respective surfaces. The length of the lower end portions 20 , 21 in the lengthwise direction of the plate 13 (i.e., left-to-right direction in FIG. 4 ) is greater than that of the upper end portions 15 , 16 . Thus, the load by which the bearing housing will act upon the load measuring plate 13 will act as forces attacking or acting upon the upper end portions 15 , 16 , with such load being transferred to strain acting in the direction of the arrow A (oblique measurement plane) shown in FIG. 4 .
The load measuring plate 13 is also provided with a plurality of chambers 22 . In the disclosed embodiment, these chambers 22 extend substantially parallel to the upper and lower surfaces 14 , 19 and are located at a position between the upper and lower surfaces 14 , 19 . In the illustrated embodiment, the load measuring plate 13 is provided with a pair of chambers 22 . The respective chambers 22 are located in the areas between each of the raised upper end portions 15 , 16 and their associated raised lower end portions 20 , 21 , respectively, as shown in FIG. 2 . Each of the chambers 22 also extends substantially perpendicular to the longitudinal direction of the load measuring plate. Additional characteristics pertaining to the configuration and function of the chamber 22 will be described below with reference to FIG. 3
The load measuring plate 13 has at least one additional opening or chamber. In the illustrated embodiment, the load measuring plate 23 is provided with three such additional chambers or openings 23 , 24 , which also will be further described below in connection with FIG. 3 .
Referring to FIG. 3 , each one of the chambers 22 is comprised of two bottom holes or blind holes 22 a , 22 b separated by an intermediate wall 22 c . The intermediate wall 22 c is positioned in the measurement plane A. On each side of these intermediate walls is attached a load measurement device which can be in the form of a strain measurement device schematically shown at 25 . These strain measurement devices can, for instance, be designed as strain gauges arranged in the form of a Wheatstone bridge.
The additional chambers 23 , 24 are made as bottom or blind holes extending into the plate. These additional chambers 23 , 24 communicate with the chambers 22 via channels 26 . These channels 26 are intended to contain conduits arranged to feed electric power to the strain measurement devices 25 and to transfer signals representative of the current measurement to output cables. The electric power can be supplied via a socket 27 positioned in the additional chamber 23 . The conduits arranged in the additional chambers 24 can lead the output signals to an external signal processor and/or recorder. Alternatively, both power supply and measurement signals can be arranged via only one chamber 23 .
FIG. 4 is a side view of the load measuring plate 13 and illustrates how the upper end portions 15 , 16 and the lower end portions 20 , 21 are displaced (in the direction of the plane of the plate 13 ) so much from each other that there will be a resulting bending force applied to the area where the strain measurement devices are positioned in the chambers 22 , thereby ensuring that the strain caused by the current load exerted by the bearing housing on the load measuring plate is positively applied in the positions of the load measuring devices.
Thus, the length of the raised or offset upper end portions 15 , 16 in the lengthwise longitudinal direction of the plate 13 (i.e., the left-to-right direction of the plate 13 ) is less than the length of the raised or offset lower end portions 20 , 21 . In addition, each of the chambers 22 is generally located at least partially between two vertical planes, namely one plane X located generally at the transition between the raised or offset upper end portion 15 , 16 and the adjoining upper central portion, and the other plane Y located generally at the transition between the offset lower end portion 20 , 21 and the adjoining lower central portion. As discussed above, the load measuring plate 13 is adapted to rest on a base. With the configuration of the load measuring plate and bearing housing described above, the foot member 2 of the bearing housing rests on the upper end portions 15 , 16 of the load measuring plate 13 , and the lower central portion of the lower surface of the load measuring plate rests on the base with the lower end portions 20 , 21 of the lower surface spaced from the base.
The bearing housing and load measuring plate combination described above produces a reliable and secure measurement result independent of the positioning of the outer walls and reinforcing intermediate walls of the bearing housing foot member.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. However, the invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. Further, the embodiments described herein are to be regarded as illustrative rather than restrictive. Variations and changes may be made by others, and equivalents employed, without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such variations, changes and equivalents which fall within the spirit and scope of the present invention as defined in the claims, be embraced thereby.
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The combination of a bearing housing and a load measuring plate includes a bearing housing having a foot member possessing a substantially rectangular outer contour, with outer wall portions and transverse intermediate wall portions forming a planar overall contact surface to be in contact with and resting upon a load measuring plate. The load measuring plate is internally equipped with load measuring devices. The outer contour of the load measuring plate is closely adapted to the outer contour of the foot member of the bearing housing.
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BACKGROUND OF THE INVENTION
The present invention relates to outboard marine motors, and more particularly to a cowl assembly for housing the engine portion of an outboard marine motor.
An outboard marine motor generally includes an engine portion and a depending gear case. The engine portion of the outboard motor is typically housed by a cowl assembly. In some outboard motors, the cowl assembly includes an upper cowl section adapted to fit together with a lower cowl section to house the engine portion of the motor. While this configuration is generally desirable and effective for certain sizes of outboard motors, there have been drawbacks to such a construction from the standpoint of resistance to entry of water into the cowl assembly. Certain other features of prior cowl assemblies of this type are undesirable, including the latch mechanism and the lower skirt which depends from the lower cowl section at the upper end of the gear case.
SUMMARY OF THE INVENTION
The present invention incorporates several improvements in a cowl assembly having an upper cowl section and a lower cowl section for housing the engine portion of an outboard marine motor. In combination, the improvements herein disclosed provide a more rigid and water-resistant cowl assembly for an outboard motor, and also facilitate the easy servicing of the outboard motor.
According to one aspect of the present invention, a cowl assembly, including an upper cowl section adapted to fit together with a lower cowl section to house the engine of an outboard motor, is provided with an opening for allowing one or more cables to pass into the interior of the cowl assembly. The opening is provided with sealing means interconnected with the cowl assembly for providing a water resistant seal around the cable at its point of entry into the interior of the cowl assembly. More particularly, the opening is formed by a cut-out portion in the upstanding side wall of the lower pan comprising the lower cowl section. The sealing means is an insert adapted to fit within the cut-out portion in the upstanding side wall of the lower pan. The insert includes cable surrounding means for providing a water resistant seal at the point of entry of the cable into the interior of the cowl assembly. In one embodiment, the cut-out portion forms a bottom cable passage in the bottom of the lower pan section for allowing a cable to enter the interior of the cowl assembly in a direction substantially parallel to the front-rear longitudinal axis of the cowl assembly. The insert is provided with an inverted channel adapted for placement on the bottom of the lower pan section for surrounding the cable at the bottom cable passage. In another embodiment, a shift lever extends through the cut-out portion in the upstanding side wall of the lower cowl section, and is disposed at its point of entry into the interior of the cowl assembly so as to be substantially perpendicular to the front-rear longitudinal axis of the cowl assembly. The insert is provided with an opening and a flexible grommet for placement within the opening to surround the shift lever at its point of entry to provide a water-resistant seal. In yet another embodiment, a cable is adapted to enter the interior of the cowl assembly through the cut-out portion in the upstanding side wall of the lower cowl section, and is disposed at its point of entry so as to be substantially parallel to the front-rear longitudinal axis of the cowl assembly. A resilient plug is provided to surround the cable at its point of entry, and is adapted to mate with the insert to provide a water-resistant seal at the point of entry.
In accordance with another aspect of the invention, a rotary latch means is provided to secure the upper and lower cowl sections together. The rotary latch means includes a rotatable external handle connected to a shaft extending through the lower cowl section and provided with an internal hook rotatable in response to rotation of the external handle. The shaft extends beyond the hook in the interior of the cowl assembly, and is supported by a support means for preventing lateral movement of the shaft. In one embodiment, the support means comprises an upstanding bearing formed integrally with the lower cowl section and adapted to receive the distal end of the shaft. The hook is engageable with a catch disposed on the upper cowl section. The catch includes a hook engaging portion having a support means disposed on either side of the hook when the hook is engaged with the hook engaging portion of the catch. The catch is supported adjacent an end wall of the upper cowl section, and is also supported at a point spaced from the end wall of the upper cowl section, and the hook engaging portion of the catch means is disposed between the support points.
In accordance with yet another aspect of the invention, an improved air intake duct provides a water-resistant feature for preventing entry of water through the air intake opening which provides combustion air to the engine portion of the outboard motor. The air intake duct also allows air to pass over the portion of the engine which is heated during operation, to pre-heat the combustion air. The air intake duct is adapted for placement in an air intake opening provided in the top rear portion of the upper cowl section. The air intake duct includes a bottom wall, a pair of upstanding side walls connected to the bottom wall, an upstanding back wall extending between the side walls and connected to the bottom wall, and a top wall. The top wall is provided with an upwardly facing opening forming an air inlet, to define an air flow path in which air enters the air intake duct at the air intake opening in the top rear portion of the upper cowl section, and flows in a forward direction toward the back wall of the air intake duct. The air is then deflected upward by the back wall and passes through the opening in the top wall, thereafter entering the interior cavity of the cowl assembly. In this manner, any moisture contained within the air is prevented from entering the interior of the cowl assembly by the upstanding back wall of the intake duct. Furthermore, positioning of the air intake opening at the rear top portion of the cowl section allows air to pass over the engine portion prior to its entry into the combustion chamber through the carburetor. This pre-heating of the combustion air prevents icing of the carburetor in cold conditions. Additionally, the air intake duct provides a convenient hand grip for manually manipulating the motor when necessary.
In accordance with yet another aspect of the invention, a one-piece lower skirt extends downwardly from the cowl assembly at the upper end of the depending gear case. The one-piece lower skirt includes a pair of spaced sides and a back wall, which define an opening for receiving the upper end of the depending gear case. The one-piece skirt is provided with a flange for connecting the skirt to the lower cowl portion, and is adapted for easy removal and attachment to facilitate servicing the motor.
In accordance with yet another aspect of the invention, a sealing means provides a water resistant seal at the joint between the upper and lower cowl sections about the entire periphery of the joint. The lower cowl section is provided with an upstanding lip about its periphery, and a resilient abutting strip is disposed about the periphery of the upper cowl section to abut the lip when the upper and lower sections are fit together for forming a water resistant seal at the joint. A portion of the periphery, generally the front end of the cowl assembly, is provided with a face, and the upstanding lip adjacent the face is generally parallel to the upstanding side wall of the lower cowl section forming the face. The resilient abutting strip has an abutting surface to engage this portion of the lip.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawing illustrate the best mode presently contemplated of carrying out the invention.
In the drawings:
FIG. 1 is a side elevation view of an outboard motor showing a cowl assembly including the features of the present invention;
FIG. 2 is an exploded perspective view showing a prior art cowl assembly construction;
FIG. 3 is an exploded perspective view showing various of the features of the cowl assembly of the present invention;
FIG. 4 is a partial longitudinal sectional view of the cowl assembly of the present invention;
FIG. 5 is a perspective view showing one embodiment of the cable entrance sealing means of the present invention;
FIG. 6 is a perspective view similar to that of FIG. 5, showing another embodiment thereof;
FIG. 7 is a sectional view taken generally along lines 7--7 of FIG. 5;
FIG. 8 is a perspective view similar to that of FIGS. 5 and 6, showing another embodiment thereof;
FIG. 9 is an exploded perspective view of the various components of the cable entrance sealing means of FIG. 8;
FIG. 10 is a perspective view showing the latch mechanism of the present invention;
FIG. 11 is a top plan view showing the air intake duct of the present invention; and
FIG. 12 is a detailed sectional view showing the front-end sealing means of the present invention.
DETAILED DESCRIPTION
As shown in FIG. 1, an outboard motor 10 includes an upper engine portion 12 and a lower depending gear case 14. A propeller 16 is provided at the lower end of gear case 14, for propelling a boat through water, as is well known.
Referring to FIGS. 1-3, engine portion 12 of outboard motor 10 generally includes an engine 18 adapted for mounting on an adaptor plate 20, which is adapted for mounting to the upper end of gear case 14. An upper cowl section 22 and a lower cowl section 24 house engine 18 of outboard motor 10. Upper and lower cowl sections 22 and 24 extend generally along parallel and coplanar longitudinal front-rear axes 23 and 25, respectively. Lower cowl section 24 is adapted to receive adaptor plate 20, and engine 18 is positioned thereabove so as to be contained within a cavity formed by upper cowl section 22 and lower cowl section 24 when fit together.
Referring to FIG. 1, a tiller arm 26 extends from lower cowl section 24. Tiller arm 26 includes a throttle handle 28 for controlling motor 10, and is also used to control the orientation of motor 12 about a vertical axis, to steer the boat to which motor 10 is attached. In addition, shift controls may also be provided in the tiller arm 26, including forward, neutral and reverse. Tiller arm 26 generally includes a stop control.
Lower cowl section 24 is formed of a lower pan having a bottom 30 and an upstanding side wall 32 extending therefrom about the periphery of bottom 30. Upstanding side wall 32 includes a top edge 33. Upstanding side wall 32 is provided with a cut-out portion 34 (FIG. 9), which is adapted to receive cables or other mechanical components for several different engine models and configurations, to allow the same lower cowl section 24 to be used for each of the different models. Referring to FIG. 9, a bottom passage 36 is formed in bottom 30 of lower cowl section 24 and extends inwardly into bottom 30. Bottom passage 36 is generally perpendicular to front-rear axis 25 of lower cowl section 24.
With reference to FIG. 5, in an outboard motor configuration having a manual tiller-operated motor with a separate shift lever, a throttle cable 38 is located exteriorly of lower cowl section 24, and is adapted to pass therethrough at bottom passage 36 for entry into the interior of the cowl assembly for connection to internal throttle controls connected to engine 18 (not shown). Throttle cable 38 extends from tiller arm 26 adjacent the point where tiller arm 26 is connected to lower cowl section 24, and is disposed at bottom passage 36 so as to be generally parallel to front-rear axis 25 of lower cowl section 24. A manual shift lever 40 extends through lower cowl section 24 at cut-out portion 34, and is manually operable by the user for shifting the gears of outboard motor 10. The shaft of shift lever 40 is disposed at its point of entry into lower cowl section 24 so as to be substantially perpendicular to front-rear axis 25 of lower cowl section 24.
An insert 42 is adapted for placement within cut-out portion 34 of upstanding side wall 32. Insert 42 fills the void created by cut-out portion 34 in upstanding side wall 30, and is intended to provide a water resistant seal thereat. Insert 42 includes a top edge 43, which is generally aligned with top edge 33 of upstanding side wall 32 at cut-out portion 34. As seen in FIG. 7, insert 42 includes an inverted channel 44, which is adapted for placement on bottom 30 of lower cowl section 24 at bottom passage 36, to define a rectangular cable-receiving passage leading into the interior of the cowl assembly. The cable receiving passage so defined is substantially perpendicular to front-rear axis 25 of lower cowl section 24.
Insert 42 is held in place within cut-out portion 34 by a bolt/nut combination extending through bottom 30 and engaging a bolt-receiving portion formed on insert 42. When insert 42 is so held, cable 38 is effectively clamped between bottom 30 and the top of inverted channel 44. In this manner, flexing of cable 38 due to engine vibration, shake and torque reactions takes place outside of the cowl assembly, thereby eliminating chafing of cable 38.
Insert 42 also includes an opening in its side for accommodating the shaft of shift lever 40. The opening in insert 42 for shift lever 40 is provided with a circular grommet 46, which is sized so as to fit relatively closely about the shaft of shift lever 40 extending therethrough. In this manner, with the placement of insert 42 within cut-out portion 34 of upstanding side wall 32, and with the provision of inverted channel 44 and grommet 46 therein, a substantially water-resistant seal is provided at the points of entry of throttle cable 38 and the shaft of shift lever 40 into the interior of the cowl assembly.
In another embodiment shown in FIG. 6 involving an outboard motor having manual throttle and shift controls in the tiller arm, a single cable 48 leads from tiller arm 26 and contains the throttle cable and the shift cable. When the shift control is included in a cable such as 48, the shift lever 40 of FIG. 5 is thereby eliminated. In the embodiment of FIG. 6, throttle/shift cable 48 enters into the interior of the cowl assembly through bottom passage 36 provided in bottom 30 of lower cowl section 24. Throttle/shift cable 48 is disposed at its point of entry into the interior of the cowl assembly so as to be substantially parallel to front-rear axis 25 of lower cowl section 24. In this embodiment, an insert 49 serves to close cut-out portion 34 of upstanding side wall 32, and includes an inverted channel such as 44 to accommodate the entry of throttle/shift cable 48 through bottom passage 36 formed in bottom 30 of lower cowl section 24. As in the embodiment of FIG. 5, insert 49 is held in place within cut-out portion 34 by a bolt/nut combination, which serves to clamp cable 48 within opening 36 to eliminate chafing of cable 48 as described above.
In the embodiment of FIG. 8 involving an outboard motor having remote throttle and shift controls, a throttle cable 50 and a shift cable 52 extend from a remote control (not shown) for outboard motor 10. Throttle cable 50 and shift cable 52 are disposed at their point of entry into the interior of the cowl assembly through cut-out portion 34 so as to be substantially parallel to longitudinal front-rear axis 25 of lower cowl section 24. To accommodate the entry of cables 50 and 52 through cut-out portion 34 of upstanding side wall 32, a resilient plug 54 having an opening 56 extending therethrough is adapted to surround cables 50 and 52. Plug 54 has a slit 57 along its length at the bottom of opening 56. The outer wall 58 of plug 54 is thereby movable to accommodate passage of cables 50 and 52 therethrough into opening 56.
With cables 50 and 52 in a side-by-side relationship, there is no need for any cable to enter into the cowl assembly through bottom passage 36. Therefore, resilient plug 54 is provided with a lower plug portion 58, which is adapted to plug bottom passage 36 in bottom 30 of lower cowl section 24. After cables 50 and 52 have been positioned within opening 56 of resilient plug 54, lower plug 58 is inserted into bottom passage 40.
Referring to FIG. 9, an insert 62 includes a passage 64 for mating with and receiving plug 54. After plug 54 is positioned so as to surround cables 50 and 52 and lower plug portion 58 inserted in bottom passage 36, insert 62 is positioned above cut-out portion 34 and slid downwardly so that passage 64 in insert 62 mates with plug 54, as shown in FIG. 8. This installation of insert 62 provides a water-resistant seal at the point of entry of cables 50 and 52 into the interior of the cowl assembly, and also seals unused bottom passage 36. A bolt 66 is passed through an opening 68 provided in bottom 30 of lower cowl section 24, and also through a passage 70 provided in a lug 72 connected to insert 62. A nut 74 is threaded onto bolt 66 to secure insert 62 within cut-out portion 34 of upstanding side wall 36.
As shown in FIG. 9, a series of upstanding locating tabs 76, 78, 80 are formed on lower cowl section 24 adjacent cut-out portion 34 of upstanding side wall 32 for locating and reinforcing the placement of insert 62 within cut-out portion 34. Tab 76 is formed on the inside of upstanding side wall 32, while tabs 78 and 80 are formed on bottom 30 of lower cowl section 24. Tabs 76-80 prevent lateral movement of insert 62 after it has been secured within cut-out portion 34. Tabs 76-80 also serve the same function in connection with the installation of inserts 42 and 48 within cut-out portion 34 of upstanding side wall 32.
The above three embodiments of the cable entrance sealing means of the present invention all provide for entry of one or more cables into the interior of the cowl assembly so that the cables are disposed at their point of entry so as to be substantially parallel to front-rear axis 25 of lower cowl section 24. In contrast, prior art systems generally provided for cable entry in a direction substantially perpendicular to the front-rear longitudinal axis of the cowl assembly. Positioning of the cables at their point of entry in accordance with the present invention facilitates the elimination of chafing on the cables due to their movement during operation.
The sealing means of the present invention is also a substantial advance over the art in that a single lower cowl section 24 may be used for several different outboard motor styles and configurations. As above described, the insert for placement within cut-out portion 34 of upstanding side wall 32 need only be modified to accommodate the entry of certain cables at certain locations, and also provision of a manual shift lever, if desired.
Referring now to FIGS. 4 and 10, a latch mechanism 82 disposed on one end wall of upper cowl section 22 includes a rotary latch 84 and a catch mechanism 86. The other end wall of upper cowl section 22 is provided with a depending hook 87, which is bolted at its upper end to a columnar boss 88 formed integrally with the end wall of upper cowl section 22. Hook 87 is engageable with a projecting tongue 89 formed integrally with upstanding side wall 32 of lower cowl section 24. Engagement of hook 87 with tongue 89 secures upper cowl section 22 to lower cowl section 24 at one end, and latch mechanism 82 releasably secures the cowl sections at the other end.
Rotary latch 84 has an external rotatable handle 90 connected to a shaft 91 extending therefrom. Shaft 91 has a proximal end 92 adjacent handle 90, and a distal end 94 spaced therefrom. Shaft 91 extends through and mates with an opening provided in upstanding side wall 32 of lower cowl section 24. Proximal end 92 of shaft 91 is provided with a rounded portion adjacent to and extending from external handle 90 for mating with the opening provided in upstanding side wall 32. A rectangular portion 98 is provided on shaft 91 adjacent to and extending from rounded portion 96. An internal hook 100 is mounted on shaft 91 at rectangular portion 98. Hook 100 is provided with a rectangular opening adapted to mate with and be engaged by rectangular portion 98 of shaft 91, so that hook 100 is rotatable in response to rotation of external handle 90. Distal end 94 of shaft 91 is provided with a rounded portion 102, which has an internal longitudinal passage adapted to receive and mate with rectangular portion 98. An enlarged portion 104 is provided adjacent rounded portion 102.
A screw 106, the end of which is shown in FIG. 10, extends through the components of shaft 91 to hold the various components together in an assembled relation. The head of screw 106 fits within a recess in external handle 90.
As seen in FIG. 4, shaft 91 is supported adjacent its proximal end by the bearing of rounded portion 96 on the internal surface of the opening provided through upstanding side wall 32 of lower cowl section 34. Shaft 91 is also supported adjacent its distal end by an upstanding bearing 108, so that hook 100 is disposed between the points of support of shaft 91. Upstanding bearing 108 is formed integrally with bottom 30 of lower cowl section 24, and has an opening sized so as to mate with rounded portion 102 of shaft 91. Tightening of screw 106 brings enlarged portion 104 of shaft 91 to bear against the side of upstanding support 108, where a wave washer 110 is disposed therebetween to provide smooth turning of rotary latch 84.
Provision of support 108 for shaft 91 at a point beyond hook 100 ensures a secure connection of upper cowl section 22 to lower cowl section 24. Support 108 prevents movement of shaft 91 when outboard motor 10 is subject to jarring, such as that resulting from a collision with an obstacle such as a submerged log during operation. Such support for shaft 91 ensures that hook 100 will remain in place during such jarring.
Hook 100 is engageable with catch mechanism 86, which includes a hook engaging portion 112 extending substantially perpendicular to the end wall of upper cowl section 22. Hook engaging portion 112 is supported at its ends by right support 114 and left support 116, which in turn depend from an upper plate 118. Left support 116 is adjacent the end wall of upper cowl section 22, and right support 114 is spaced therefrom. Hook 100 engages hook engaging portion 112 at a point between right support 114 and left support 116. Upper plate 118 is adapted for connection to a pair of columnar bosses 120, 122 formed integrally with the end wall of upper cowl section 22, by means of a pair of bolts, one of which is shown at 124.
The above-described construction of catch mechanism 86 provides a hook engaging surface which is supported at both ends for receiving the hook of latch mechanism 86 therebetween, thereby eliminating the cantilever of the hook engaging portion from the end wall of upper cowl section 22 normally found in such a catch mechanism. This again ensures a secure attachment of upper cowl section 22 to lower cowl section 24.
Referring now to FIG. 4, the present invention includes an air intake duct 130 for placement within an air intake opening 132 formed in the top rear portion of upper cowl section 22. The air intake opening 132 is formed between an upper top wall 134 and a lower top wall 136 of upper cowl section 22. A pair of bosses 138, only one of which is shown, depend from upper top wall 134. Similarly, a pair of bosses 140, only one of which is shown, depend from lower top wall 136. Air intake duct 130 is adapted for placement in the interior of upper cowl section 22 adjacent air intake opening 132, and is connected to upper and lower top wall bosses 138, 140 using screws 142, 144 through openings provided in tabs on air intake duct 130 (FIG. 11).
Air intake duct 130 includes a bottom wall 145 and a pair of spaced upstanding side walls 146, 147 connected thereto. A back wall 148 is connected to bottom wall 145. Back wall 148 is curved to provide an upper lip 150 (FIG. 4), and is also curved in a horizontal plane (FIG. 11).
A top wall 152 extends between side walls 146, 147, and is provided with an upwardly facing opening 154 to form an air inlet for allowing air to pass into the interior of the cowl assembly. As shown in FIG. 11, top wall 152 extends less than the full distance between side walls 146 and 147, to thereby form auxiliary upwardly facing air inlet openings 155, 156 adjacent the top of each side wall for passage of air therethrough into the interior cavity of the cowl assembly. Back wall portions 157, 158 define the back of upwardly facing openings 155, 156, respectively.
As best seen in FIG. 4, the innermost edge of top wall 152 is provided on its underside with a depending curved lip 159. The top of back wall 148 is disposed at an elevation below that of top wall 152, so that the air inlet formed by the termination of top wall 152 is disposed at an elevation lower than that of top wall 152. It should be understood that the invention also contemplates the extension of top wall 148 the full height of side walls 146, 147, so that the air inlet formed by opening 154 is coplanar with top wall 152. It should also be understood that the upwardly facing air inlet openings adjacent the top edges of side walls 146, 147 may also be eliminated by increasing the size of opening 154 and extending top wall 152 the entire distance between side walls 146, 147.
Air intake duct 130 thus defines an air flow path in which air enters intake duct 130 at air intake opening 132 and flows in a forward direction toward back wall 148, and is then deflected upwardly by back wall 148 through opening 154 to enter the interior cavity of the cowl assembly. The upward deflection of the air during its entrance into the interior of the cowl assembly prevents the entrance of any moisture contained within the air into the interior cavity as a result of the change in direction of the air flow provided by the air flow path defined by air intake duct 130. Lips 150, 159 also act to capture and prevent the entrance of any moisture contained within the air into the interior of the cowl assembly.
Furthermore, the placement of air intake opening 132 in the rear top portion of upper cowl section 22 allows for passage of combustion air over the heated portion of the outboard motor engine. Such air flow pre-heats the combustion air prior to its entry to the combustion chamber through the carburetor, to prevent icing of the carburetor in cold weather operating conditions.
The above described construction of air intake duct 130 provides an unobstructed hand grip for use in manually manipulating outboard motor 10. For example, the user's fingers may be inserted into the space between bottom wall 142 and top wall 152 to aid in tilting the motor forward.
Referring to FIG. 4, bottom wall 145 of air intake duct 130 slopes rearwardly away from back wall 148, so that moisture collected within duct 130 from air flowing therethrough may exit duct 130 and drain therefrom via rearwardly-sloping lower top wall 136 of upper cowl section 22.
With reference to FIG. 2, prior outboard motor structures provided an upper cowl section 22 and a two-piece lower cowl section comprising longitudinally split halves 160, 162. Each of longitudinal split halves 160, 162 included a lower depending skirt half 164, 166, respectively. Lower cowl sections 160, 162, when interconnected, are adapted to surround the edge of adaptor plate 20. A foam rubber sealing strip 168 is placed about the edge of adaptor plate 20, to provide a water resistant seal at the joint between adaptor plate 20 and lower cowl halves 160, 162. When lower cowl halves 160, 162 are fit together, depending skirt halves 164, 166 surround the sides and rear of depending gear case 14. Skirt halves 164, 166 are generally formed integrally with lower cowl halves 160, 162.
In the improved construction of FIG. 3, as noted previously, lower cowl section 24 includes a bottom 30 and an upstanding side wall 32 extending therearound. Bottom 30 of lower cowl section 24 is provided with an opening 170 for receiving adaptor plate 20 from the underside of bottom 30.
A one-piece lower skirt 172 includes a pair of depending sides 176, 178 and a rear depending wall 180 extending therebetween. Sides 176, 178 and rear wall 180 define an opening adapted to receive the upper end of depending gear case 14, which is formed accordingly.
Lower skirt 172 includes a flange 182, which is adapted for connection to the underside of bottom 30 of lower cowl section 24. The underside of lower cowl section 24 is provided with a recessed portion adjacent opening 170 for accommodating flange 182 of lower skirt 172. The one-piece construction of skirt 172 allows quick and easy removal and attachment of skirt 172 to facilitate servicing of the motor and the upper portion of gear case 14.
To assemble the lower components of the cowl assembly, sealing strip 168 is again provided about the edge of adaptor plate 20, after which plate 20 is placed against the underside of bottom 30 at opening 170. One-piece lower skirt 172 is placed against the bottom of adaptor plate 20 to sandwich adaptor plate 20 between lower cowl section 24 and skirt 172. One-piece skirt 72 is then attached to the underside of lower cowl section 24 using a series of bolts extending through holes provided at the corners of flange 182 of skirt 172, with mating nuts being provided at nut-receiving pockets 184 in lower cowl section 24. This construction provides highly desirable vibration and noise isolation. After connection of skirt 172 to lower cowl section 24, engine portion 18 is mounted to adaptor plate 20 above bottom 30 of lower cowl section 24.
Lower skirt 172 is constructed so that, after assembly, flange 182 lies in a plane substantially transverse to a longitudinal gear case axis 183.
When upper cowl section 22 and lower cowl section 24 are fit together, a peripheral joint is formed therebetween. In previous constructions, the peripheral joint between upper cowl section 22 and lower cowl section 24 was sealed about the sides and rear of the cowl assembly, but the front joint was generally left unsealed. The present invention discloses a structure for sealing the front joint.
As shown in FIG. 4, a rear joint 190 includes a substantially horizontal upper lip 192 disposed at the top of upstanding side wall 32 of lower cowl section 24. Horizontal lip 192 extends across the rear of upstanding side wall 32, and also along the sides of upstanding side wall 32. A rubber molding strip 194 is provided at the lower edge of upper cowl section 22, and has a substantially horizontal lower surface adapted to abut the top of upper lip 192 for providing a water tight seal therebetween. This construction is known in the prior art.
At front joint 195 (FIG. 12), which in the past has been unsealed, the present invention provides an upstanding lip 196 extending upwardly from a face 197 formed by upstanding side wall 32 of lower cowl section 24. Lip 196 is disposed in a plane substantially parallel to that of face 197, which may be substantially vertical. As seen in FIGS. 3 and 5-8, each corner of lower cowl section 24 adjacent face 197 is formed so as to provide a smooth transition between horizontal lip 192 on the side portions of upstanding side wall 32 of lower cowl section 24 and vertical lip 196.
Similarly, sealing strip 194 is modified at the front side of upper cowl section 22, so that the plane of sealing between lip 196 and sealing strip 194 is substantially vertical. The inwardly facing portion of sealing strip 194 is provided at its upper end with a horizontal portion 198 for abutting the top of vertical lip 196, to ensure a water-resistant seal thereat.
It is understood that various alternatives and modifications are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention.
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An outboard marine motor housing by a cowl assembly having an upper cowl section and a lower cowl section includes various features for improving the structural integrity of the cowl assembly and for providing a water-resistant seal at the joint between the cowl sections and at various points of entry of cables and other mechanical devices. A rotary latch mechanism includes an internal hook connected to a shaft leading to an external rotatable handle. The shaft is supported on either side of the point of engagement of the hook to the shaft. In particular, a bearing is formed integrally with the bottom of the lower cowl section and is adapted to receive an end of the shaft for support thereof. The catch for the latch mechanism is provided with a hook-receiving member having support on both sides of the point of engagement of the hook-receiving member by the hook. In pair of depending arms connected to an upper plate, which is adapted for direct connection to a pair of columnar lugs formed integrally with an end of the upper cowl section.
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RELATED APPLICATIONS
[0001] This application is a continuation under 35 U.S.C. 111(a) of International Application No. PCT/US02/40722 filed Dec. 19, 2002 and published in English as WO 03/058194 A2 on Jul. 17, 2003, which claimed priority under 35 U.S.C. 119(e) from U.S. Provisional Application Ser. No. 60/342,778 filed Dec. 21, 2001, which applications and publication are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Proteases are essential components in the cellular disassembly process that drives the programmed cell death mechanism called apoptosis. The involvement of cysteine proteases that specifically cleave peptides at the carboxyl side of aspartate residues (caspases) has been extensively studied (Alnemri et al., Cell, 1996, 87:171-173; Kaufmann et al., Cancer Res., 1993, 53:3976-3985; Lazebnik et al., Nature, 1994, 371:346-347; Budihardjo et al., Annu Rev Cell Dev Biol, 1999, 15:269-290; Earnshaw et al., Annu Rev Biochem, 1999, 68:383-424; Nicholson et al., Cell Death Differ, 1999, 6:1028-1042; Zhang et al., Cell Death Differ, 1999, 6:1043-1053; Stennicke et al., Cell Death Differ, 1999, 6:1060-1066).
[0003] Compared to caspases, participation of proteases in the cell's demise by apoptosis, is less understood (Johnson et al., Leukemia, 2000, 14:1695-1703). One group of proteases is the serine (Ser) proteases. These enzymes contain Ser at the active center, which participates in the formation of an intermediate ester to transiently form an acyl-enzyme complex. The most characterized enzymes of this type are trypsin and chymotrypsin. Involvement of Ser proteases in apoptosis has been mostly studied by observing whether particular apoptotic events can be prevented by the specific inhibitors of these enzymes. In the early studies Gorczyca et al., (Gorczyca et al., Int J Oncol, 1992, 1:639-648) have shown that fragmentation of DNA in HL-60 cells treated with DNA topoisomerase inhibitors to induce apoptosis was prevented by irreversible inhibitors of Ser proteases such as diisopropylfluorophosphate (DFP), N-tosyl-L-phenylalanine chloromethyl ketone (TPCK) and N-tosyl-L-lysine chloromethyl ketone (TLCK), as well as by excess of the substrates N-tosyl-L-argininemethyl ester (TAME) and N-benzoyl-L-tyrosine ethyl ester (BTEE).
[0004] Concurrently, Bruno et al., (Bruno et al., Leukemia, 1992, 6:1113-1120; Bruno et al., Oncol. Res., 1992, 4:29-35) observed that the same inhibitors and substrates inhibited nuclear fragmentation as well as fragmentation of DNA in other cell types, including thymocytes treated with the corticosteroid prednisolone. It was also observed that these inhibitors prevented destabilization of double-stranded DNA (Hara et al., Exp Cell Res, 1996, 223:372-384), which during apoptosis becomes sensitive to denaturing agents and can be detected as single-stranded DNA (Hotz et al., Exp. Cell Res., 1992, 201:184-191). These initial observations were confirmed in many subsequent studies and in other cell systems (Hughes et al., Cell Death Differ., 1998, 5:1017-1027; Kim et al., Int. J. Oncol., 2001, 18:1227-1232; Ghibelli et al., FEBS Lett., 1995, 377:9-14; Lotem et al., Proc Natl Acad Sci USA, 1996, 93:12507-12; Mansat et al., FASEB J, 1997, 11:695-702; Gong et al., Cell Growth Differ, 1999, 10:491-502; Komatsu et al., J. Biochem ( Tokyo ), 1998, 124:1038-44; Yoshida et al., Leukemia, 1996, 10:821-4; Weaver et al., Biochem Cell Biol, 71:488-500; Park et al., Cytokine, 2001, 15:166-70). It should be noted, however, that while serine protease inhibitors prevent nuclear and DNA fragmentation triggered by different inducers, they themselves, especially after prolonged cell exposure, induce cell death that resembles apoptosis (Hara et al., Exp Cell Res, 1996, 223:372-384; Lu et al., Arch Biochem Biophys, 1996, 334:175-81).
[0005] The best recognized Ser proteases are granzymes A and B which are abundant in granules of cytotoxic T lymphocytes (CTL) and natural killer (NK) cells (Zapata et al., J. Biol. Chem., 1998, 273:6916-6920; Wright et al., Biochem. Biophys. Res. Commun., 1998, 245:797-803; Shi et al., J Exp Med, 1992, 176:1521-9; Kam et al., Biochim Biophys Acta, 2000, 1477:307-23; Jans et al., J Cell Sci, 1998, 111:2645-54; Estabanez-Perpina et al., J Biol Chem, 2000, 321:1203-1214). Granzyme B can cleave procaspase-3, −6, −7, −8, −9, and −10, and most likely, it activates endogenous caspases of the lymphocyte-target cells, thereby inducing their apoptosis (Zapata et al., J. Biol. Chem., 1998, 273:6916-6920). Granzyme A appears not to be associated with activation of caspases and it cleaves proteins independently of the latter (Shi et al., J Exp Med, 1992, 176:1521-9; Kam et al., Biochim Biophys Acta, 2000, 1477:307-23). Since granzymes A and B were studied predominantly in CTL or NK cells, it is unknown whether they play any role in apoptosis of other cell types.
[0006] Another apoptotic Ser protease is the 24-kD enzyme (AP24) shown to have the capacity to activate internucleosomal DNA fragmentation (Wright et al., J Exp Med, 1997, 186:1107-17; Wright et al., Cancer Res, 1998, 58:5570-6). Other Ser proteases that may function during apoptosis are the nuclear matrix-associated histone H1 specific enzyme induced by DNA damage (Kutsyi et al., Radiat Res, 1994, 140:224-229), the protease activated by Ca 2+ (Zhivotovsky et al., Biochem Biophys Res Commun, 1997, 233:96-101) and myeoloblastin (Bories et al., Cell, 1989, 59:959-968). Most recently a new Ser protease, HtrA2/Omni, that is released from the mitochondria and interacts with the caspase inhibitor XIAP in a similar way as Smac/Diablo promoting cell death, have been identified (Suzuki et al., Molecular Cell, 2001, 8:613-621; Verhagen et al., J Biol Chem, 2001, 277:445-454; Martins et al., J Biol Chem, 2001, 277:439-444. It is unknown whether the Ser cathepsins A and G are involved in apoptosis although the cysteine cathepsin B and aspartate cathepsin D are present in lysosomes and endosomes and they may participate in heterophagic degradation of apoptotic bodies (Johnson et al., Leukemia, 2000, 14:1695-1703, Leist et al., Nature Rev Mol Cell Biol, 2001, 2:589-598).
[0007] Ser proteases also play an important role as markers of tumor malignancy. For example, several Ser proteases have been identified in prostate cells and their enzymatic activity has been shown to have a positive correlation with the development of prostate cancer as well as the degree of tumor malignancy (Yousef et al., J Biol Chem 2001, 276:53-61, Chen et al., J Biol Chem 2001, 276:21434-42, Takayama et al., Biochemistry, 2001, 40:1679-87, Magee et al., Cancer Res., 2001, 61:5692-6). Ser protease activity is also a diagnostic and prognostic marker in other tumors, such as breast carcinoma (Ulutin & Pak, Radiat Med 2000, 18:273-6,Yousef et al., Genomics, 2000, 69:331-41), and carcinomas of the head and neck (Lang et al., Br. J Cancer 2001, 84:237-43).
[0008] Activities of Ser proteases are also altered in a variety of other diseases. As mentioned, the Ser protease, granzyme B, is the key enzyme that is activated in a variety of cell-mediated immunological reactions. These cell-mediated responses include rejection of transplanted tissue (organs) and infections (Zapata et al., J. Biol. Chem., 1998, 273:6916-6920; Wright et al., Biochem. Biophys. Res. Commun., 1998, 245:797-803; Shi et al., J Exp Med, 1992, 176:1521-9; Kam et al., Biochim Biophys Acta, 2000, 1477:307-23; Jans et al., J Cell Sci, 1998, 111:2645-54; Estabanez-Perpina et al., J Biol Chem, 2000, 321:1203-1214).
[0009] The use of fluorochrome-labeled inhibitors of caspases (FLICA), to detect activation of these enzymes in living cells, has been reported (Bedner et al., Exp Cell Res., 2000, 259:308-313; Smolewski et al., Cytometry, 2001, 44:73-82; Darzynkiewicz et al., Methods Mol Biol (in press); Smolewski et al., Int J Oncol, 2001, 19:657-663). The FLICA are affinity labeling ligands that consist of carboxyfluorescein-tagged or sulforhodamine B-tagged peptide fluoromethyl ketones. They penetrate through the plasma membrane, covalently binding to active centers of caspases and at least during short-term incubations, remain relatively nontoxic to the cell. The amino acid sequence of the peptide residues that make up these reagents renders some binding selectivity toward the active center of the particular caspase. A good correlation was observed between activation of caspases detected by this assay and other markers of apoptosis (Bedner et al., Exp Cell Res., 2000, 259:308-313).
[0010] There is currently a need for novel assay methods that are useful for determining the apoptotic state of a cell. Such methods would be useful for detecting the presence of an apoptosis related disease in a subject. Such methods would also be useful for evaluating whether a therapeutic agent alters the apoptotic state of a cell.
SUMMARY OF THE INVENTION
[0011] Applicant has discovered that the apoptotic state of a cell can be evaluated by measuring the level of caspase activity and the level of one or more active serine proteases in the cell. Due to the combined roles of caspases and serine proteases in apoptosis, the evaluation of the activity of both types of enzymes provides a better measure of the apoptotic state of a cell than the measurement of the activity of either type of enzyme alone.
[0012] Thus, the invention provides a method for determining the apoptotic state of one or more viable whole cells, comprising: 1) contacting the cells with a caspase affinity labeling agent and with a serine protease affinity labeling agent; and 2) detecting the presence of each affinity labeling agent in the cells; wherein the presence and relative abundance of the caspase affinity labeling agent and the presence and relative abundance of the serine protease affinity labeling agent correlate with the apoptotic state of the cells.
[0013] The invention also provides:
an assay reagent comprising a caspase affinity labeling agent and a serine protease affinity labeling agent; and a suitable carrier; a method for detecting and/or predicting rejection of tissue or organ transplant where the presence or level (content) of the group L in the patient lymphocytes (“natural killer”; NK cells) or in cells of the transplanted organ (tissue) differs prior to- or at the time-of rejection from non-stimulated or pre-transplant tissue, by: 1) contacting the respective NK (or organ tissue) cells with the compound of invention; and 2) detecting the presence or relative abundance of the group L is predictive of the tissue rejection response or NK cell activation; a method for diagnosis and prognosis assessment of other cell-mediated immunological reactions where the presence or relative abundance of the different group L detector molecules is characteristic of a particular type of cell mediated immunological reaction by; 1) contacting the cells with at least one compound of the invention, and 2) detecting the presence or relative abundance of the group L in the cells wherein the presence or relative abundance of L correlates with the detection and severity of the disease.
[0017] Preferably, the methods of the invention utilize a combination of reporter groups as exemplified in the following Table.
Red Serpase Green Serpase Cold Serpase Red Caspase + +++ ++ Green Caspase +++ + ++ Cold Caspase ++ ++ — Where + = claim; ++ = preferred; +++ = most preferred.
Definitions:
[0018] Red caspase=e.g. sulforhodamine-VAD-FMK
[0019] Green caspase=e.g. fluorescein-VAD-FMK
[0020] Cold caspase=e.g. Z-VAD-FMK
[0021] Red serpase=e.g. sulforhodamine-FCK
[0022] Green serpase=e.g. fluorescein-FCK
[0023] Cold serpase=e.g. TPCK or TLCK
[0024] The invention also provides novel compounds of formula (I) and formula (II) disclosed herein, as well as salts thereof.
[0025] The invention provides methods which are useful for screening compounds, including libraries of chemical compounds, to identify therapeutic agents that modulate serine protease activity. The methods of the invention can be used to identify agents which induce, or reduce or inhibit apoptosis, as well as to identify therapeutic agents that are useful to treat diseases that are associated with serine protease activity. Techniques for screening chemical libraries are known in the art, and can be adapted for use in the methods described herein.
BRIEF DESCRIPTION OF THE FIGURES
[0026] FIGS. 1A-1D . Illustrate the changes in the ability of HL-60 cells to bind 5(6)-Carboxyfluoresceinyl-L-valylalanylaspartylflyoromethyl ketone (FAM-VAD-FMK) and PI during apoptosis.
[0027] FIG. 2A-2H . Illustrate apoptosis-induced changes in the ability of HL-60 cells to bind 5(6)-Carboxyfluoresceinyl-L-phenylalanylchloromethyl ketone (FFCK) or 5(6)-carboxyfluoresceinyl-L-leucylchloromethyl ketone (FLCK).
[0028] FIGS. 3A-3B . Show the correlation between cell labeling with FAM-VAD-FMK and FFCK or FLCK.
[0029] FIGS. 4A-4C . Illustrate dual labeling of CPT-treated HL-60 cells with FFCK and Sulforhodaminyl-L-valylalanylaspartylflyoromethyl ketone (SR-VAD-FMK)
[0030] FIGS. 5A-5C . Illustrate dual labeling of CPT-treated HL-60 cells with FLCK and SR-VAD-FMK
DETAILED DESCRIPTION
[0031] The following definitions are used, unless otherwise described. “Red” is a fluorescent dye such as a rhodamine, BODIPY, Cy dye, etc. which is excited by light >520 nm. “Green” is a fluorescent dye such as fluorescein, BODIPY FL or Cy-2 etc, which is excited around 488 nm. “Cold” refers to a group that does not fluoresce, is not colored, is not radioactive and which is not normally considered a hapten. Examples of “cold” groups include, but are not limited to tosyl and carbobenzyloxy (Z). Halo is fluoro, chloro, bromo, or iodo. Alkyl, denotes both straight and branched groups; but reference to an individual radical such as “propyl” embraces only the straight chain radical, a branched chain isomer such as “isopropyl” being specifically referred to. Aryl denotes a phenyl radical or an ortho-fused bicyclic carbocyclic radical having about nine to ten ring atoms in which at least one ring is aromatic. Heteroaryl encompasses a radical attached via a ring carbon of a monocyclic aromatic ring containing 4 to 9 ring atoms consisting of carbon and one to four heteroatoms each selected from the group consisting of non-peroxide oxygen, sulfur, and N(X) wherein X is absent or is H, O, (C 1 -C 4 )alkyl, phenyl or benzyl, as well as a radical of an ortho-fused bicyclic heterocycle of about eight to ten ring atoms derived therefrom, particularly a benz-derivative or one derived by fusing a dimethylene, trimethylene, or tetramethylene diradical thereto.
[0032] The term “serine protease affinity labeling agent” includes any agent capable of selectively binding, in a covalent manner, to one or more active serine proteases and facilitating their detection by analytical means. Accordingly, such an agent can include a florescent label, a radioactive label, or a hapten, or biotin as described herein. For example, one serine protease affinity labeling agent that can be used in the methods of the invention is a compound of formula I:
L-A-X—NH—CH(R′)C(═O)CH 2 Cl (I)
wherein:
L is a detectable group; A is a direct bond or a linker; X is absent, an amino acid, or a peptide; R′ is hydrogen, benzyl, 4-hydroxybenzyl, 3′-indolylmethyl, 2-methylpropyl, 1-methylpropyl, isopropyl, 4-aminobutyl, imidazolylmethyl or propylguanidino or (C 1 -C 6 )alkyl, wherein the alkyl is optionally substituted with one or more (1, 2, 3, or 4) substituents independently selected from the group consisting of guanidino, —C(═O)NR a R b , —C(═O)OR c , halo, —NR a R b , aryl, heteroaryl, —OR c , or —SR c ; each R a and R b is independently hydrogen, (C 1 -C 6 )alkyl, phenyl, benzyl, or phenethyl; or R a and R b together with the nitrogen to which they are attached form a pyrrolidino, morpholino, or thiomorpholino ring; and each R c is independently hydrogen, (C 1 -C 6 )alkyl, phenyl, benzyl, or phenethyl; wherein any aryl or heteroaryl is optionally substituted with one or more (e.g. 1, 2, 3, or 4) substituents independently, selected from the group consisting of halo, nitro, cyano, hydroxy, mercapto, (C 1 -C 6 )alkyl, (C 1 -C 6 )alkoxy, trifluoromethyl, or trifluoromethoxy; or a salt thereof.
[0041] For a compound of formula (I), L can preferably be a fluorescent label, a colored label, a radioactive label or hapten, or biotin; more preferably, L can be a fluorescent label (e.g. 5(6)-carboxyfluorescein, sulforhodamine B), or a colored label (e.g. 4-nitrophenyl or 2,4-dintrophenyl), or biotin. For a compound of formula (I), X can preferably be a peptide having about 2 to about 10 amino acids; more preferably, X can be a peptide having about 2 to about 5 amino acids.
[0042] Specifically, L is a fluorescent label, a colored label, a radioactive label, biotin or a hapten.
[0043] More specifically, L is a fluorescent label or biotin.
[0044] Preferably, L is 5(6)-carboxyfluorescein, or sulforhodamine B.
[0045] Specifically, X is a peptide containing from 2 to 10 amino acids. The amino acid composition of peptide X will define the enzyme selectivity of the affinity label. Enzymes will frequently target a 1 to 10 amino acid sequence identifying hydrophilic and hydrophobic residues within the sequence via complimentary amino acid sequences within the enzyme catalytic region. By selectively defining the composition of the peptide sequence, it has been shown that the target specificity of the enzyme substrate can be changed (Melo et al., Analytical Biochem, 2001, 293:71-77).
[0046] More specifically, X is a peptide having about 2 to 5 amino acids.
[0047] Preferably, X is an amino acid sequence consisting of: phenylalanine-proline (FP), phenylalanine-arginine (FR), isoleucine-alanine-methionine (IAM), alanine-alanine (AA), valine-proline (VP), glutamic acid-glycine (EG) or alanine-alanine-proline (AAP) dimers and trimers of glycine and alanine (GG, GGG, AA, and AAA), and dimers and trimers of a mixture of these amino acids (GA, GAA, GGA, GAG, AGG, AGA, AAG and AG).
[0048] Additionally, X can be an amino acid sequence that is a caspase target consisting of: VAD, YVAD, WEHD, VDVAD, DEHD, DEVD, WEHD, LEHD, VEID, LETD, AEVD, LELD and LEED (single letter abbreviations used are as follows; Ala (A), Arg (R), Asn (N), Asp (D), Cys (C), Glu (E), Gln (Q), Gly (G), His (H), Ile (I), Leu (L), Lys (K), Met (M), Phe (F), Pro (P), Ser (S), Thr (T), Trp (W), Tyr (Y), and Val (V)).
[0049] For a compound of formula (I), X can preferably be a natural amino acid (e.g. alanine, glutamic acid, valine); more preferably, X is absent.
[0050] For a compound of formula (I), R′ can preferably be benzyl, 2-methylpropyl, 1-methylpropyl, 4-aminobutyl, or propylguanidino (arginine).
[0051] In a more preferred embodiment of the present invention, R′ is hydrogen or (C 1 -C 6 )alkyl, wherein the alkyl is optionally substituted with one or more (1, 2, 3, or 4) substituents independently selected from the group consisting of guanidino, —C(═O)NR a R b , —C(═O)OR c , halo, —NR a R b , aryl, heteroaryl, —OR c , or —SR c .
[0052] A preferred group of compounds of formula (I) are compounds wherein L is 5(6)-carboxyfluorescein, sulforhodamine B, or biotin; and R′ is benzyl, 2-methylpropyl, 1-methylpropyl, 4-aminobutyl, or propylguanidino (arginine).
[0053] A preferred compound of formula (I) is 5(6)-carboxyfluorescyl-L-phenylalanylchloromethyl ketone, 5(6)-carboxyfluorescyl-L-leucylchloromethyl ketone, or 5(6)-carboxyfluorescyl-L-lysylchloromethyl ketone; or a salt thereof. Other preferred compound groups of this invention would include fluorescein-5 or 6-isothiocyanate (FITC) and sulforhodamine labeled formulations of the same phenylalanyl, leucyl, or lysyl chloromethyl ketone compounds.
[0054] Preferred serine protease affinity labeling agents include the following compounds:
5(6)-Carboxyfluoresceinyl-L-phenylalanylchloromethyl ketone (FFCK)
[0055]
5(6)-Carboxyfluorescyl-L-leucylchloromethyl ketone (FLCK)
[0056]
5(6)-Carboxyfluoresceinyl-L-lysylchloromethyl ketone
[0057]
5(6)-Carboxyfluoresceinyl-L-arginylchloromethyl ketone
[0058]
Sulforhodarninyl-L-phenylalanylchloromethyl ketone
[0059]
Sulforhodaminyl-L-leucylchloromethyl ketone
[0060]
Sulforhodaminyl-L-lysylchloromethyl ketone
[0061]
Sulforhodaminyl-L-arginylchloromethyl ketone
[0062]
[0063] The term “caspase affinity labeling agent” includes any agent capable of selectively binding, in a covalent manner, to one or more active caspases and facilitating their detection by analytical means. The following table lists several caspase affinity labeling reagents and their corresponding caspase selectivity:
Target Caspase Product and Sequence Other Sequences Poly-Caspase FAM-D-FMK Poly-Caspase FAM-VAD-FMK Caspase-1 FAM-YVAD-FMK WEHD Caspase-2 FAM-VDVAD-FMK DEHD Caspase-3 and 7 FAM-DEVD-FMK Caspases-4 and 5 (W/L)EHD Caspase-6 FAM-VEID-FMK Caspase-8 FAM-LETD-FMK Caspase-9 FAM-LEHD-FMK Caspase-10 FAM-AEVD-FMK LELD Caspase-13 FAM-LEED-FMK Thornberry et al., Methods in Enzymology, 2000, 322: 100-125.
[0064] For example, such agents may include fluorescent labels (e.g. fluorescein derivatives, sulforhodamine derivatives, Cy dye derivatives, BODIPY derivatives, coumarin derivatives, or any fluorescent dye that can be attached to an amino group directly or by linkers), colored labels (e.g. 4-nitrophenyl or 2,4-dintrophenyl, or any colored label that can be attached to an amino group directly or by linkers), a radioactive label (e.g. tritium, carbon-14 phosphorus-32), or biotin, or a hapten (e.g. digoxigenin, and dinitrophenyl), or the like. Other labels such as biotin and the various high affinity binding type hapten groups (digoxigenin and dinitrophenyl) can be coupled to the affinity ligands to allow for the use of enzyme reporter group signal amplification. Commonly used enzymes include horseradish peroxidase (HRP), alkaline phosphatase (AP), β-galactosidase (BG), and urease (U). When coupled to avidin or IgG, for use in an avidin-biotin or hapten system respectively, the aforementioned enzyme molecules can convert colorless enzyme substrates to colored readout product. The most commonly used chromogenic substrates include tetramethylbenzidine (TMB) for use with HRP labels, and nitro blue tetrazolium/5-bromo-4-chloro-3-indolyl phosphate (NBT/BCIP) for use with AP labels. Commercial chemiluminescent substrates of these enzymes can also be used. Radioactive labels, such as tritium, carbon-14, and phosphorous-32 can be used as a direct label or can also be coupled to avidin or anti-hapten IgG for radioactive detection.
[0065] Other caspase affinity labeling agents would contain the same labels and 1 to 5 amino acid sequences but utilize an aldehyde modification of the aspartic terminal carboxyl group (HC═O), a chloromethyl ketone group (CH 2 Cl), or an acyloxy reactive group ((C═O)O—Ar, where Ar is [2,6-(CF 3 ) 2 ]benzoate and various derivative of same (Krantz et al., Biochemistry, 1991, 30:4678-4687, and Thomberry et al., Biochemistry, 1994, 33:3934-3940).
[0066] For example, one caspase affinity labeling agent that can be used in the methods of the invention is the compound of formula II:
L 1 -A 1 -X 1 —NH—CH(R 1 ′)C(═O)CH 2 F (II)
wherein:
L 1 is a detectable group; A 1 is a direct bond or a linker; X 1 is absent, an amino acid, or a peptide; and R 1 ′ is CH 2 —COOH or CH 2 CO 2 R″, where R″ is methyl, ethyl, benzyl or t-butyl.
[0071] For a compound of formula (II), L 1 can preferably be a fluorescent label, a colored label, a radioactive label, a hapten or biotin; more preferably, L can be a fluorescent label (e.g. 5(6)-carboxyfluorescein, sulforhodamine B), or biotin. For a compound of formula (II), X 1 can preferably be a peptide having about 2 to 10 amino acids; more preferably, X 1 can be a peptide having about 2 to 4 amino acids (e.g. VA, YVA, DEV, LEE, LEH, VDVA, or AEV). For a compound of formula (II), X 1 can preferably be a natural amino acid (e.g. A, V, or E). The letter symbol V=valine, A=alanine, D=glutamic acid, L=leucine, and Y=tyrosine. For a compound of formula (II), R 1 ′ should be a methylene carboxy (ethanoic) side-chain (CH 2 —COOH) as the caspases typically have a requirement for aspartate in the P 1 position of the peptide substrate. In a preferred configuration, the carboxyl groups of all aspartic and glutamic amino acid residues should exist as methyl esters of the carboxyl containing side-chains of —CH 2 CO 2 R, or CH 2 CH 2 CO 2 R, where R is CH 3 , other groups could include C 2 H 5 , C 4 H 9 , or CH 2 C 6 H 5 molecules.
[0072] A preferred compound of formula (II) is 5(6)-carboxylfluoresceinyl-L-valylalanylaspartylfluoromethyl ketone (FAM-VAD-FMK) or sulforhodaminyl-L-valylalanylaspartylfluoromethyl ketone (SR-VAD-FMK); or an ester thereof, or a salt thereof.
[0073] There are two main classes of α-amino acids: “natural” and “unnatural” α-amino acids. Additionally there are a wide variety of β-amino acids, homologues of amino acids and molecules that mimic amino acids, such as isosteres.
[0074] “Natural amino acids” refers to the naturally occurring α-amino acid molecules typically found in proteins. These are: glycine, alanine, valine, leucine, isoleucine, serine, methionine, threonine, phenylalanine, tyrosine, tryptophan, cysteine, proline, histidine, aspartic acid, asparagine, glutamic acid, glutamine, arginine, and lysine.
[0075] “Natural amino acids” also exist in nature, which are not typically incorporated into naturally occurring proteins. Examples of these amino acids are: ornithine, γ-carboxyglutamic acid, hydroxylysine, citrulline, kynurenine, 5-hydroxytryptophan, norleucine, norvaline, hydroxyproline, phenylglycine, sarcosine, γ-aminobutyric acid and many others.
[0076] “Unnatural amino acids” are defined as those amino acids that are not found in nature and may be obtained by synthetic means well known to those schooled in amino acid and peptide synthesis. Examples of this class, which numbers in the many thousands of known molecules include: (t-butyl)glycine, hexafluoro-valine, hexafluoroleucine, trifluoroalanine, β-thienylalanine isomers, β-pyridylalanine isomers, ring substituted aromatic amino acids, at the ortho, meta, or para position of the phenyl moiety with one or more of standard groups of organic chemistry such as: fluoro-, chloro-, bromo-, iodo-, hydroxy-, methoxy-, amino-, nitro-, alkyl-, alkenyl-, alkynyl-, thio-, aryl-, heteroaryl- and the like.
[0077] It will be appreciated that amino acids and peptides can exist in L- or D-forms (enantiomers) and that certain amino acids with more than one chiral center, such as threonine, may exist in diastereomeric form. Further, when linked together in peptide chains, a mixture of L- and D-amino acids may be chosen to confer desired properties known in the art. Therefore, enantiomers, diastereomers and mixtures of these types are included in the claims.
[0078] Further, unnatural amino acids may exhibit other types of isomerism, such as positional and geometrical isomerism. These types of isomerism, coupled with or independent of optical isomerism, are also included in these claims.
[0079] In a specific preferred embodiment, the term “amino acid,” comprises the residues of the natural amino acids (e.g. Ala (A), Arg (R), Asn (N), Asp (D), Cys (C), Glu (E), Gln (Q), Gly (G), His (H), Hyl, Hyp, ile (I), Leu (L), Lys (K), Met (M), Phe (F), Pro (P), Ser (S), Thr (T), Trp (W), Tyr (Y), and Val (V)) in D or L form, as well as unnatural amino acids (e.g. phosphoserine, phosphothreonine, phosphotyrosine, hydroxyproline, gamma-carboxyglutamate; hippuric acid, octahydroindole-2-carboxylic acid, statine, 1,2,3,4,-tetrahydroisoquinoline-3-carboxylic acid, penicillamine, ornithine, citruline, -methyl-alanine, para-benzoylphenylalanine, phenylglycine, propargylglycine, sarcosine, and tert-butylglycine). When X is an amino acid in a compound of formula I, the amino terminus is on the left and the carboxy terminus is on the right.
[0080] The term “peptide” describes a sequence of 2 to 20 amino acids (e.g. as defined hereinabove) or peptidyl residues. Preferably a peptide comprises 2 to 10, or 2 to 5 amino acids. When X is a peptide in a compound of formula I, the amino terminus is on the left and the carboxy terminus is on the right.
[0081] It will be appreciated that the methods of this invention can be used with all cell types that contain or express serine proteases. The cells may come from plant, bacteria or animal origins and may be from tissue samples, fluid samples or immortalized cell lines. Cells originating from animals include cells from; Protozoa, Mastigophora or Flagellata, Sarcodina, Sporozoa, Cnidospora and Ciliata; Porifera; Coelenterata; Platyhelminthes; Pseudocoelomates, Rotifera, Gastrotricha and Nematoda; Molluska; Annelida; Arthropoda; Bryozoa; Eichinodermata; Chordata; Hemichordata; Vertabrates, Fishes, Amphibians, Reptiles, Birds and Mammals. More specific, Mammalian cells include but are not limited to cells such as lypmhocytes, neutrophiles, mast cells, neutrophiles, basophilic leukocytes, eosinophilic leukocytes, erythrocytes, monocytes, osteoblasts, osteoclasts, neurons, astrocytes, oligodendricites, hepatocytes, squamous cells, macrophages, fibroblasts, endothelial cells, chondrocytes, granulocytes, karyocytes, spermatocytes, spermatozoa, and cells of Sertoli. Imortalized cell lines include but are not limited to HL-60, MCF-7, Jurkat, U937, Hela, and THP-1.
[0082] The term “detectable group” includes any group that can be detected by analytical means. For example, suitable groups may be detectable by fluorescence spectroscopy, fluorescence microscopy, confocal fluorescence microscopy, fluorescence image analysis, flow cytometry, laser scanning cytometry, or plate multi-well fluorescence reader. Thus, suitable groups include florescent labels (e.g. fluorescein, rhodamines, Cy dyes, Bodipys, sulforhodamine 101, phycobiliproteins, etc. Other labels such as biotin and the various high affinity binding type hapten groups (digoxigenin and dinitrophenyl) can be coupled to the affinity ligands to allow for the use of enzyme reporter group signal amplification. Commonly used enzymes include horseradish peroxidase (HRP), alkaline phosphatase (AP), β-galctosidase (BG), and urease (U). When coupled to avidin or IgG, for use in an avidin-biotin or hapten system respectively, the aforementioned enzyme molecules can convert colorless enzyme substrates to colored readout product. The most commonly used chromogenic substrates include tetramethylbenzidine (TMB) for use with HRP labels, and nitro blue tetrazolium 5-bromo-4-chloro-3-indolyl phosphate (NBT/BCIP) for use with AP labels. Commercial chemiluminescent substrates of these enzymes can also be used. Radioactive labels, such as tritium, carbon-14, and phosphate-32 can be used as a direct label or can also be coupled to avidin or anti-hapten IgG for radioactive detection.
[0083] The nature of the “linker” is not critical provided the final compound of formula I has suitable properties (e.g. suitable solubility, cell toxicity, cell permeability, and ability to selectively react with the targeted serine protease group) for its intended application. The linker, denoted by the letter “A”, in the case where “A” can simply be a covalent bond, the detectable group (L) is attached directly to the N-terminal amino group of the peptide or amino acid (e.g., amide linkage L-(C═O)—NH—R). “A” can also be any member of the class of linkers well known to those experienced in this field. Linkers are typically 4-18 atoms long, consisting of carbon, nitrogen, oxygen or sulfur atoms. Specific examples of linkers include ε-aminocaproic acid (6 atoms), di-ε-aminocaproic acid (12 atoms), oligomers of ethylene glycol (—O—(CH 2 CH 2 O) n CH 2 CH 2 —, where n=0-5); or di- and triamines separated by 2 to 6 methylene groups, for example: —HN(CH 2 ) n —NH(CH 2 ) m —NH(CH 2 ) o — where n, m and o are integers from 0 to 6. Typical linkers include ester (—OC(═O)—), thioester (SC(═O)—), thionoester (—OC(═S)—), carbonyl (—C(═O)—), and amide (—NHC(═O)—) groups, as well as divalent phenyl groups, and a 1 to 10 membered carbon chain, which chain can optionally comprise one or more double or triple bonds, and which chain can also optionally comprise one or more oxy (—O) or thioxy (—S—) groups between carbon atoms of the chain. A preferred linker is a simple amide linkage ((—NHC(═O)—) or —C(═O)NH—) facilitated by an activated carboxyl-N-hydroxysuccinimide leaving group coupling system.
[0084] The assay reagents of the invention can also comprise one or more suitable carriers. Suitable carriers include polar, aprotic solvents (e.g. acetonitrile, DMSO or DMF) or protic solvents (e.g. water, methanol, ethanol, etc.).
[0085] The term “active serine protease” is defined as an active enzyme representative of a family of proteases which utilize serine as the electron exchange group. An “active serine protease” is an enzyme which is in its catalytically active form. Some examples of this type of enzyme includes the known apoptosis-associated Ser proteases such as A24, granzymes A and B, Cathepsins A and G, HtrA2/Omni protease, as well as numerous yet unrecognized proteases that become activated during apoptosis. This term also includes other Ser proteases such as those associated with prostate tissue or cancer (prostate specific antigen (PSA), hepsin, prostasin, etc.) and with other tissues and organs.
[0086] The term “agent that promotes cell death” is defined as those agents whose function is to disrupt the normal stasis condition of the cell beyond which the cell can accommodate and recover. This pushes the cell to undergo apoptosis, and eventual cell death. Anti-cancer treatment agents fall into this classification. They are used in an attempt to reduce the rate of cancer cell proliferation and at the same time, induce the target cancer conversion to apoptosis. All of these anti-cancer therapeutic agents are designed to induce cellular stress by targeting key cellular structures such as the DNA, lipid component of the cell membranes, and key cellular proteins responsible for maintaining the metabolic equilibrium (stasis). When the damage exceeds the ability of the cells to make adjustments and repairs, then apoptosis often ensues. The table below provides several examples of some key target mechanisms a long with their respective therapeutic agents:
Mechanism Therapeutic Agents DNA Damaging Reagents Cyclophosphamide, Cisplatin, Doxorubicin, Ionizing Radiation Anti-metabolites Methotrexate, 5-Flurouracil, 5-Azacytidine Mitotic Inhibitors Vincristine Nucleotide Analogs 6-Mercaptopurine Topoisomerase Inhibitors Etoposide, Camptothecins Herr et al., Blood, 2001, 98: 2603-2614.
[0087] The term “topoisomerase inhibitor” is defined as those reagents, which bind to either Type I or Type II topoisomerases, causing errors in DNA replication leading to induction of apoptosis (Juo, Concise Dictionary of Biomedicine and Molecular Biology, 1996). Camptothecin is an example of a topoisomerase I inhibitor. This reagent binds to the DNA-topoisomerase I complex, interfering with the DNA unfolding process. Etoposide also interferes with DNA synthesis by inducing double and single strand breakage via inhibition of topoisomerase II (Hertzberg et al., J. Biol Chem, 1990, 265:19287).
[0088] The term “agent that protects the cell from cell death” includes all the treatments whose strategy is to prevent cell apoptosis. They include scavengers of the reactive oxygen species (radicals) such as acetylcysteine, etc., agents and treatments that down-regulate the pro-apoptotic members of Bcl-2 family of proteins or up-regulate the anti-apoptotic members of the Bcl-2 family.
[0089] The term “apoptotic state of a cell” means the current status of the cell, whether it continues to be functioning normally, or entering into the various characteristic stages of the apoptotic process. Cells usually progress through the process of apoptosis, generally showing one or more features (morphological, biochemical or molecular) characteristic of apoptosis.
[0090] The term “induces apoptosis” means the treatment that commits and/or preconditions the cell to enter the apoptotic process.
[0091] The term “reduces or inhibits apoptosis” means the treatment causes a reduction in the eventuality or probability of the cell entering the process of apoptotic or prolongs or halts the process itself. This is important when considering treatments for neurodegenerative disease such as Alzheimers disease (AD). Alzheimers disease is a neurodegenerative disease characterized by a progressive memory loss and increasing levels of dementia. One of the key pathological features of the disease is the expression of a high frequency of extracellular plaques which are formed from the deposition of amyloid β (Aβ) peptides that are derived from (Aβ) protein precursor (AβPP). Caspase-6 is capable of cleaving AβPP and the presenilins. It is also localized to pathological lesions associated with AD. Upstream caspases such as caspases-8 and 9 are also elevated in the AD neurons. Given the association of caspases with the active form of this disease, treatment strategies have evolved around the use of caspase inhibitors that transverse the cell membrane. The earliest therapeutic inhibitor agents consisted of benzyloxycarboxyl-L-valylalanylaspartylfluoromethyl ketone (z-VAD-FMK) and benzyloxycarboxyl-L-tyrosinylvalylalanylaspartylfluoromethyl ketone (z-YVAD-FMK). These inhibitors form covalent linkages with a SH-cysteine within the caspase reactive centers, thus inactivating the caspase enzyme activity. A number of pharmaceutical companies are using this attack strategy in their development of peptoid inhibitors and non-peptide inhibitors such as the Isatin Sulfonamides. Other and as yet undefined therapeutic strategies would include up-regulation of the anti-apoptotic members of the Bcl-2 family (e.g. Bcl-xL and Bcl-W) and conversely down regulate the pro-apoptotic Bcl-2 membership proteins such as Bax, Bak, Bok, or Bid, Bad, Bih as example. Nicholson et al., Nature, 2000, 407:810-815; Raina et al., Acta Neuropathol, 2001, 101:305-310; and Lee et al., J. Med Chem, 2001, 44:2015-2026.
[0092] The term “necrosis” means the alternative, disorderly mode of cell death. Cells undergoing necrosis usually swell up and burst, releasing the cytoplasmic contents into the surrounding environment. Necrotic cell death does not require the energy derived from ATP.
[0093] The term “relative abundance” can be defined as; 1) the amount of fluorescent label observed in stimulated cells or tissue compared to the non-stimulated cells or tissue, 2) the ratio of one fluorescently labeled affinity ligand to the other fluorescently labeled affinity ligand in stimulated versus non-stimulated cells or tissue, 3) the amount of fluorescent label observed in disease state cells or tissue compared to normal/healthy cells or tissue, and 4) the ratio of one fluorescently labeled affinity ligand to the other fluorescently labeled affinity ligand in disease state cells or tissue versus normal/healthy cells or tissue.
[0094] Specific and preferred values listed below for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for the radicals and substituents.
[0095] Specifically, (C 1 -C 6 )alkyl can be methyl, ethyl, propyl, isopropyl, butyl, iso-butyl, sec-butyl, pentyl, 3-pentyl, or hexyl; (C 1 -C 6 )alkoxy can be methoxy, ethoxy, propoxy, isopropoxy, butoxy, iso-butoxy, sec-butoxy, pentyloxy, 3-pentyloxy, or hexyloxy; aryl can be phenyl, indenyl, or naphthyl; and heteroaryl can be furyl, imidazolyl, triazolyl, triazinyl, oxazoyl, isoxazoyl, thiazolyl, isothiazoyl, pyrazolyl, pyrrolyl, pyrazinyl, tetrazolyl, pyridyl, (or its N-oxide), thienyl, pyrimidinyl (or its N-oxide), indolyl, isoquinolyl (or its N-oxide) or quinolyl (or its N-oxide).
[0096] The assay reagents of the invention can also comprise one or more suitable carriers. Suitable carriers include DMSO, DMF, or other organic solvents which, when diluted out in aqueous buffer media, present minimal toxicity to the cell system being analyzed.
[0097] In cases where the affinity labels are sufficiently basic or acidic to form stable acid or base salts, use of the compounds as salts may be appropriate. Examples of such salts are organic acid addition salts formed with acids which form an acceptable anion, for example, tosylate, methanesulfonate, acetate, citrate, malonate, tartarate, succinate, benzoate, ascorbate, αketoglutarate, and α-glycerophosphate. Suitable inorganic salts may also be formed, including hydrochloride, sulfate, nitrate, bicarbonate, and carbonate salts.
[0098] Salts may be obtained using standard procedures well known in the art, for example by reacting a sufficiently basic compound such as an amine with a suitable acid affording an acceptable anion. Alkali metal (for example, sodium, potassium or lithium) or alkaline earth metal (for example calcium) salts of carboxylic acids can also be made.
[0099] The invention will now be illustrated by the following non-limiting Examples.
EXAMPLE 1
[0000] General Protocol for Use of Novel Affinity Labels
[0100] Preparation of reagents: Fluorescent inhibitors of serine proteases (FLISP) reagents, 5(6)-Carboxyfluoresceinyl-L-phenylalanylchloromethyl ketone (FFCK) and 5(6)-carboxyfluoresceinyl-L-leucylchloromethyl ketone (FLCK) were dissolved initially in dimethyl sulfoxide (DMSO; Sigma) to yield a 10 mM concentration. Aliquots were made from this stock solution and stored frozen at −20° C. protected from light. This reagent stock was then diluted directly into the cell culture media to give a 1× working reagent concentration of 10 μM. Dilution of the reagent into aqueous (cell culture) media is done just prior to cell exposure to preserve the labile chloromethyl ketone reactivity of FLISP reagent.
[0101] Fluorescent inhibitors of caspases (FLICA) reagents, namely the fluorescein labeled VAD-FMK (FAM-VAD-FMK) and sulforhodamine labeled VAD-FMK (SR-VAD-FMK) (Immunochemistry Technologies; Bloomington, Minn.) were both designed to detect the presence of active caspases within apoptotic cells. These inhibitors were dissolved in DMSO to obtain a 150× concentrated stock solution. Aliquots of these solutions were stored at −20° C. in the dark. Prior to use, a 30× working solution of either FAM-VAD-FMK or SR-VAD-FMK was prepared by diluting the stock solution 1:5 in phosphate buffered saline (PBS) and mixing until the solution become clear. The 30× working solution was diluted 1:30 cell culture media to give a final 1× working reagent concentration of 10 μM.
[0102] Unlabeled (cold) N-tosyl-phenylalanylchloromethyl ketone (TPCK) and N-tosyl-lysylchloromethyl keytone (TLCK) were obtained from Sigma Chemical Co.; concentrated solutions at 10 mM were freshly prepared in DMSO. Further dilutions were made in tissue culture media.
[0103] The non-fluorescent poly-caspase inhibitor Z-VAD-FMK was obtained from Enzyme Systems Products. A 20 mM stock solution of Z-VAD-FMK was made in DMSO (Sigma) and the inhibitor was then diluted in culture media to obtain the final 50 μM concentration in the cultures.
[0104] Cells: Human promyelocytic leukemic HL-60 cells were obtained from American Type Culture Collection (ATCC; Rockville, Md.). They were cultured in 25 mL FALCON flasks (Becton Dickinson Co., Franklin Lakes, N.J.) using RPMI 1640 supplemented with 10% fetal calf serum, 100 units/mL penicillin, 100 mg/mL streptomycin and 2 mM L-glutamine (all from Gibco/BRL Life Technologies, Inc., Grand Island, N.Y.) in a humidified incubator set to maintain 37.5° C. and 5% CO 2 as previously described (Bedner et al., Exp Cell Res., 2000, 259:308-313; Smolewski et al., Cytometry, 2001, 44:73-82). At the onset of experiments, there were fewer than 5×10 5 cells/ml in culture. To induce apoptosis the cells were treated with 0.15 μM DNA topoisomerase I inhibitor camptothecin (CPT; Sigma Chemical Co., St. Louis, Mo.) for 3 hours.
[0105] Cell staining and fluorescence measurement by LSC: The HL-60 cells from the untreated or CPT treated cultures were centrifuged (200 g, 5 min) and resuspended in PBS at approximately 10 4 cells per 5 mL volume. Cells were then attached electrostatically to microscope slides as described before (Bedner et al., Exp Cell Res., 2000, 259:308-313; Smolewski et al., Cytometry, 2001, 44:73-82). The attachment was achieved by the incubation (15 min) of cells suspended in serum-free PBS in shallow (<1 mm depth; 1.5×1.5 cm) wells on horizontally placed microscope slides that were rinsed in 100% ethanol and air dried prior to use, at 100% humidity. The electrostatically attached cells remain viable, exclude such dyes as trypan blue and propidium iodide (PI), and have unchanged morphology for several hours (Bedner et al., Exp Cell Res., 2000, 259:308-313). After the cells became attached, PBS was removed from the wells and was replaced by 150 μL of the culture medium containing 10% FCS. FLISP staining solutions were prepared by diluting 5 μL of the 10 mM FFCK or FLCK stock solution into 5 mL of culture medium yielding a final FLISP concentration 10 μM. The medium from above the cells on the slide was then replaced with 150 μL of this staining solution. A polyethylene foil (2.5×2.5 cm) was positioned over the staining solution to prevent drying. The slides were subsequently incubated for 1 h at 37° C. in a closed box with wet tissue to additionally prevent drying. The FLISP staining solution was removed by immersing the slides for 2 min in PBS in Coplin jars, containing fresh PBS. The washing step was repeated once more with fresh PBS. If desired, a 100 μL aliquot of PBS solution containing 0.1 μg of propidium iodide (PI; Molecular Probes, Eugene, Oreg.) can be layered atop the cells and the specimen was covered with a glass coverslip (if PI is not used, layer 100 μL of PBS atop the cells). The slides were placed on the motorized stage of laser scanning microscope (LSC) for fluorescence measurement. Cell fluorescence was then measured using a 488 nm excitation laser line and recording integral and maximal pixel intensities of the green FFCK or FLCK. FLICA staining was measured under the same conditions as FLISP staining. Fluorescence can also be measured by flow cytometer and fluorescence microscopy.
EXAMPLE 1A
Correlation Between CPT Apoptosis Induction and Binding of FFCK, FLCK and Caspase Detector, FAM-VAD-FMK.
[0106] FIG. 1 illustrates changes in the capability of HL-60 cells treated with CPT to bind FAM-VAD-FMK and PI. Based on observable fluorochrome binding differences, four cell subpopulations were identified on the bivariate PI (red) vs FAM-VAD-FMK (green) fluorescence distributions (scatterplots) Table 1:
TABLE 1 Quadrant Fluorescence Cell State A FLICA−/PI− Non-Apoptotic Cells B FLICA+/PI− Early Apoptotic Cells C FLICA+/PI+ Late Apoptotic Cells D FLICA−/PI+ Very Late Apoptotic or Necrotic Cells
[0107] The FLICA−/PI− cells were most frequent (>95%) in the untreated, control cultures. The CPT treatment initially led to a marked increase in percentage of FLICA+/PI− ( FIG. 1 ), which was later followed by the appearance of FLICA+/PI+ and then FLICA+/PI−, cells. Activation of caspases was an early event, followed later by the loss of plasma membrane ability to exclude PI.
[0108] FIG. 2 shows the binding of FFCK or FLCK, each combined with PI, by the untreated (control) cells and by the cells treated for 3 h with CPT. It is apparent that treatment with CPT induced binding of both ligands. In analogy to cultures subjected to FAM-VAD-FMK and PI binding ( FIG. 1 ) relatively few cells become labeled with PI in the cultures after 3 h CPT exposure and assay using FFCK or FLCK ( FIG. 2 ).
[0109] FIG. 3 represents the repeated analysis of the untreated and CPT-treated cultures with respect to the frequency of FAM-VAD-FMK vs FFCK or FLCK labeled cells that showed a high degree of correlation. Such a correlation suggests that activation of caspases detected by FAM-VAD-FMK binding occurred in the same cells that reacted with FFCK or FLCK. Also, the time-frame during which the cells remained reactive with each of these probes, appeared to be of similar length.
EXAMPLE 1B
Sequential Activation of Caspases and Serine Proteases During Apoptosis
[0110] Experiments were conducted to reveal whether activation of caspases and appearance of the FFCK or FLCK binding sites depend on each other. Towards this end the cells were treated with CPT in the presence or absence of the unlabeled poly-caspase inhibitor Z-VAD-FMK for 3 h and then assayed for activation of either FFCK or FLCK binding sites. And conversely, the cells induced to apoptosis by CPT were maintained in the presence or absence of either unlabeled TPCK or TLCK and activation of their caspases was subsequently assayed by FMK-VAD-FMK binding. The results of these experiments are shown in Table 2.
TABLE 2 Effect of the pretreatment of HL-60 cells during induction of apoptosis with Z-VAD-FMK, TPCK or TLCK on the subsequent binding of FAM-VAD-FMK, FFCK and FLCK. Pretreatment FAM-VAD-FMK FFCK FLCK Z-VAD-FMK 95.0 83.0 ± 3.6 77.2 ± 3.2 TPCK 27.7 ± 5.8 94.2 38.9 ± 1.7 TLCK 0.5 ± 5.2 2.2 ± 2.3 1.74 ± 4.6
[0111] The data in Table 2 show percent decrease in frequency of the labeled cells pre-treated with the unlabeled protease inhibitors compared to the respective controls, namely to the cells treated with CPT in the absence of the unlabeled inhibitors. Between 3,000-10,000 cells were recorded per each measurement. Mean values SE) of three independent experiments are presented.
[0112] It is apparent that pretreatment with Z-VAD-FMK quite effectively prevented the appearance of either FFCK or FLCK binding sites, as the cell labeling with these ligands was reduced by 83.0 or 77.2%, respectively. Compared to Z-VAD-FMK, the protective effect of TPCK was less pronounced. Namely, the FAM-VAD-FMK- or FLCK-reactivity of cells pre-treated with TPCK was diminished only by 27.7 or 38.9%. However, unlabeled TPCK prevented the subsequent binding of its fluorescein-conjugated analog by as much as 94.2%. TLCK offered no protection at all for the subsequent binding of either FAM-VAD-FMK, FFCK or FLCK.
Experiment 1C. Dual Labeleing With SR-VAD-FMK and FFCK or FLCK
[0113] The availability of the red fluorescing poly-caspase inhibitor SR-VAD-FMK and green fluorescing FLISP reagents, offered an opportunity to compare, within the same cells, labeling of activated caspases vis-à-vis the FFCK and FLCK binding sites. When examined by fluorescence microscopy or imaged by LSC, it was seen that fluorescence of induced cells treated simultaneously with SR-VAD-FMK and FFCK (or FLCK) was primarily restricted to the cells that showed morphological changes characteristic of apoptosis. These changes included overall cell shrinkage as well as shedding of apoptotic bodies (“budding” of the plasma membrane) into the surrounding media. Essentially all such cells were fluorochrome-labeled. In contrast, few cells (<10%) with unchanged morphology were labeled.
[0114] FIGS. 4 and 5 reveal an interesting pattern of significant variability in overall proportions of the sites reactive with SR-VAD-FMK vs FFCK or FLCK in individual cells, as well as in their intracellular localization. Some cells displayed prominent green- or red-fluorescence while others fluoresced in various hues of yellow. This heterogeneity was mirrored by a widely scattered distribution plotting of individual cells on the bivariate scatterplots representing intensity (integral values) of cellular red (SR-VAD-FMK) vs green (FFCK or FLCK) fluorescence. The green fluorescence of FFCK was strong and often localized in the cytoplasm in a single or two distinct and relatively large perinuclear foci. Also, nucleoli were frequently labeled with FFCK. Fluorescence of cells treated with FLCK was faint and more uniformly distributed. The red fluorescence of SR-VAD-FMK was uniformly dispersed.
[0115] It was shown before (Bedner et al., Exp Cell Res., 2000, 259:308-313) that frequency of cells reactive with FAM-VAD-FMK was strongly correlated with the fraction of apoptotic cells identified by the presence of DNA strand breaks (r=0.96). A strong correlation was seen between the percentage of cells labeled with FAM-VAD-FMK (or SR-VAD-FMK) and either with FFCK or FLCK ( FIGS. 3-5 ). It is quite evident that the ability of cells to bind either FFCK or FLCK concurred with induction of the binding of the poly-caspase labeled inhibitor FAM-VAD-FMK (or SR-VAD-FMK) and both reactivities were markers of apoptosis.
[0116] Induction of apoptosis in HL-60 cells by CPT led to a rapid increase in binding of FFCK or FLCK concomitant with binding of FAM-VAD-FMK (or SR-VAD-FMK). The fraction of cells labeled with each of these ligands was similar, varying after 3 h of treatment with CPT, between 35-45% in repeated experiments, and generally approximating the percentage of the S-phase cells in these cultures. Most labeled cells showed signs typical of apoptosis.
[0117] The present invention provides novel fluorochrome-labeled affinity markers of the enzymatic centers of serine proteases (e.g. FFCK and FLCK). It was proposed that if serine proteases are activated during cellular processes their active sites may become accessible to these ligands. Indeed, it was found that during apoptosis the sites reactive with FFCK and FLCK become accessible and reacted with these inhibitors. Most likely, the binding is covalent because it withstands subsequent cell fixation, permeabilization and rinses.
[0118] The following evidence is consistent with the assumption that the observed binding was indeed specific to enzymatic centers of Ser proteases and thus signaled their intracellular activation:
(1) Analogs of FFCK and FLCK ligands (e.g. TPCK) exhibit a high affinity interaction with the active centers of the chymotrypsin-like enzymes, binding covalently via the alkylation of the imidazole ring of His-57 (Shaw et al., Biochem Biophys Res Commun., 1967, 27:391-7; Blow, D. M., Acc Chem Res, 1976, 9:145-152; Wilcox, P. E., Methods Enzymol, 1970,19:64-108). As such, they are widely used as specific inhibitors of these enzymes. Indeed, it was observed that TPCK (TFCK, using current amino acid symbols) prevented binding of FFCK (Table 2), indicating that both ligands compete for the same sites; (2) Prior cell exposure to TLCK during induction of apoptosis did not prevent the subsequent binding of FAM-VAD-FMK. Pre-exposure to TPCK had only a modest suppressive effect on the FAM-VAD-FMK binding (Table 2). This evidence suggests that despite the similarity of the reactive moieties (halomethyl ketone) the binding sites of FAM-VAD-FMK and FLISP are different; FLISP reagents do not bind to caspases and serine proteases do not bind FLICA reagents; the binding sites are different because they are different enzymes; (3) The intracellular localization of the enzymes detected by SR-VAD-FMK and FFCK or FLCK in many cells was distinctly different ( FIGS. 4 and 5 ); (4) Dual cell labeling with SR-VAD-FMK and FFCK or FLCK led to a mixed ratio of red to green fluorescence within individual cells. Some cells exhibited a red fluorescence, while others displayed a green fluorescence and still others fluoresced yellow ( FIGS. 4 and 5 ). Were the same enzymatic sites reacting with SR-VAD-FMK and FFCK or FPCK, all cells would be uniformly stained, with equal mixtures of red and green fluorescence. Given the above, the binding sites that become accessible to FFCK and FLCK during apoptosis cannot be of the activated caspases. Furthermore, FFCK and FLCK do not have the requisite aspartic acid residue for optimal caspase binding and they are optimally designed for chymase binding, so these results fit with expectations. It is likely, therefore, that the observed binding of these ligands reflects the increased accessibility of the enzymatic centers of Ser proteases. As mentioned above, there is strong evidence that several Ser proteases undergo activation during apoptosis; among them AP24 (Wright et al., Biochem. Biophys. Res. Commun., 1998, 245:797-803; Wright et al., J Exp Med, 1997, 186:1107-17; Wright et al., Cancer Res, 1998, 58:5570-6)and HtrA2/Omni (Suzuki et al., Molecular Cell, 2001; 8:613-621; Verhagen et al., J Biol Chem, 2001, 277:445-454; Martins et al., Biochem Biophys Res Commun, 1998, 245:797-803) are the best characterized.
[0123] From the present data, FFCK and FLCK do not bind to the active centers of the same enzymes and therefore it is possible that detection of the activation of two different serpases of the chymotrypsin-like family (chymases) occurred. FFCK, having a Phe moiety, is expected to be a specific inhibitor of chymotrypsin (EC 3.4.21.1). FLCK, with a Leu moiety, should have preference to chymotrypsin C (EC 3.4.21.2) (Blow, D. M., Acc Chem Res, 1976,9:145-152; Wilcox, P. E., Methods Enzymol, 1970, 19:64-108).
[0124] Additional support for the notion that activation of two enzymes has been detected was provided by the observation that the pattern of cell labeling with FFCK and SR-VAD-FMK was different than that observed using FLCK and SR-VAD-FMK ( FIGS. 4 and 5 ). Furthermore, while pretreatment with TPCK prevented the subsequent binding of FFCK by 94.2% it had lesser effect (38.9% suppression) on the binding of FLCK (Table 2). Also different, was the absolute intensity of cell fluorescence after labeling with either FFCK or FLCK. Namely, when measured under identical settings of the photomultiplier sensitivity, the FLCK labeled cells had approximately 60% greater fluorescence intensity compared to the cells labeled with FFCK. All this evidence supports the concept that the labeled inhibitors FFCK and FLCK did not compete for the same binding sites and thus, most likely, are bound to separate enzymes.
[0125] Activation of each of the sites, the one reactive with FFCK, and the other, with FLCK, appeared to depend on a prior caspase activation event. This transpired from results of the experiments showing that binding of these ligands was greatly diminished when the poly-caspase inhibitor Z-VAD-FMK was present in the media during CPT stimulation. In contrast, activation of caspases was unaffected by TLCK and only modestly suppressed by TPCK (Table 2). TLCK, having the charged amino acid Lys, is a specific inhibitor of the trypsin-like enzyme family (tryptases) (Blow, D. M., Acc Chem Res, 1976, 9:145-152; Wilcox, P. E., Methods Enzymol, 1970, 19:64-108). The lack of protective effect of TLCK on the subsequent binding of FAM-VAD-FMK, FFCK or FLCK provides additional evidence that chemical reactivity of halomethyl ketone moiety alone does not play a significant role in observed affinity of these ligands to their respective binding sites.
[0126] Interestingly, there was no evidence of a significant number of cells that would have activated caspases only, without the activation of either the sites reactive with FFCK or FLCK. Such cells would appear on the bivariate distributions of the SR-VAD-FMK vs FFCK or FLCK ( FIGS. 4 and 5 ) as the cells that have only red, with no green fluorescence; the vast majority of cells had components of both green and red fluorescence. This indicates that activation of caspases was rapidly followed by activation of the serpases and the time-window when only the former would be active, was relatively short.
[0127] The methodology of using affinity binding inhibitors to label the active enzymatic center (affinity-labeling of enzymatic center; ALEC) in situ has been introduced before, to detect active esterases in situ, in different tissues, (Ostrowski et al., (1963) Exp. Cell Res., 1963, 31:89-99), proteases (Darzynkiewicz et al., Nature, 1966, 212:1198-1203), or folate reductase (Darzynkiewicz et al., Science, 1966, 131:1538-1530) by radioisotope-labeled specific inhibitors of these enzymes. Application of FLICA to assay activation of caspases opens new possibilities to study these enzymes in living cells, detect their localization, and correlate the process of their activation with other events of apoptosis (Bedner et al., Exp Cell Res., 2000, 259:308-313; Smolewski et al., Cytometry, 2001, 44:73-82; Darzynkiewicz et al., Methods Mol Biol 2002, 203:289-299).
[0128] Recently, FLICA was applied in dual function, to arrest apoptosis and to label the cells arrested in apoptosis. This application allowed estimates of the kinetics of cell entry into apoptosis or cell death rate to be made (Smolewski et al., Int J Oncol, 2001, 19:657-663). As the present data indicate, based on the same principle, the in situ affinity labeling of enzyme active centers, FLISP offers a useful tool to investigate activation of Ser proteases. This tool will be particularly useful, because unlike caspases, little is known regarding particular Ser proteases, their mode of activation, intracellular distribution, and their preferred substrates. In addition to establishing the specificity of the FLISP reagents with respect to the caspase inhibitors, and with each other (described above), the affinity labels of the invention can also be used to determine the differences in activation of caspases compared to Ser proteases in different cell systems. These affinity labels can be used to study different models of apoptosis, and to differentiate between apoptosis and necrosis in a cell. The affinity labels of this invention also provide an opportunity to detect activation of these enzymes in situ, within the live cells, and thus to explore their localization and possible translocations. Based on a covalent 1:1 stoichiometry binding relationship to the active enzyme centers, these affinity labels also offer the means to quantify the respective enzymes within individual cells or cell organelles.
EXAMPLE 2
Synthesis of 5(6)-carboxyfluoresceinyl-L-phenylalanylchloromethyl ketone (FFCK)
[0129]
5-(and-6-)-Carboxyfluorescein, succinimidyl ester (80 mg, 0.17 mmole, FW 473.39, 5(6)-FAM) (Molecular Probes Inc., Eugene, Oreg., catalog number C-1311) was dissolved in 3 mL of dimethyl formamide (DMF). Phenylalanylchloromethyl ketone hydrochloride (40 mg, 0.17 mmole, FW 234) (Bachem Bioscience Inc., King of Prussia, Pa., catalog number N-1060) and diisopropylethyl amine (90 μL, Aldrich, Milwaukee, Wis.) were added to the solution. The reaction mixture was protected from light, stirred at room temperature for one hour and the solvent removed by rotary evaporation to provide an orange solid. The solid was partitioned between ethyl acetate and 10% aqueous hydrochloric acid (HCl), washed with 10% HCl and then water. The ethyl acetate fraction was dried over magnesium sulfate and the ethyl acetate removed by rotary evaporation to provide 35 mg dry weight, (37% yield) of 5(6)-carboxyfluoresceinyl-L-phenylalanylchloromethyl ketone (FFCK). Thin layer chromatography on silica gel (ethyl acetate: acetic acid, 97:3) gave a single spot of R f 0.6.
EXAMPLE 3
Synthesis of 5(6)-carboxyfluorescyl-L-leucylchloromethyl ketone (FLCK)
[0130]
[0131] 5-(and-6-)-Carboxyfluorescein, succinimidyl ester (82 mg, 0.17 mmole, FW 473.39, 5(6)-FAM) (Molecular Probes Inc., Eugene, Oreg., catalog number C-1311) was dissolved in 3 mL of dimethyl formamide (DMF). Leucylchloromethyl ketone ((35 mg, 0.17 mmole, FW 200.11) (Bachem Bioscience Inc., King of Prussia, Pa., catalog number N-1105) and diisopropylethyl amine (92 ul, Aldrich, Milwaukee, Wis.) were added to the solution. The reaction mixture was protected from light, stirred at room temperature for one hour and the solvent removed by rotary evaporation to provide an orange solid. The solid was partitioned between ethyl acetate and 15% aqueous hydrochloric acid (HCl), washed with 15% HCl and then water. The ethyl acetate fraction was dried over magnesium sulfate and the ethyl acetate removed by rotary evaporation to provide 72 mg dry weight, (81% yield) of 5(6)-carboxyfluoresceinyl-L-leucylchloromethyl ketone (FLCK). Thin layer chromatography on silica gel (ethyl acetate:acetic acid, 97:3) gave a single spot of R f 0.7.
EXAMPLE 4
[0132] Using procedures similar to those described herein, the following compounds of the formula (I) can also be prepared.
5(6)-Carboxyfluoresceinyl-L-lysylchloromethyl ketone
[0133]
5(6)-Carboxyfluoresceinyl-L-arginylchloromethyl ketone
[0134]
Sulforhodaminyl-L-phenylalanylchloromethyl ketone
[0135]
Sulforhodaminyl-L-leucylchloromethyl ketone
[0136]
Sulforhodarninyl-L-lysylchloromethyl ketone
[0137]
Sulforhodaminyl-L-arginylchloromethyl ketone(I)
[0138]
[0139] All publications, patents, and patent documents including 60/342,955, 60/342,778 and 60/342,704 are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention.
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The invention provides assay methods and reagents useful for evaluating the level of enzyme activities within living cells. Enzyme activity levels within living cells, such as caspases and Serine proteases, can be key determinates in assessing; 1) the apoptotic state of a cell, 2) the presence of tumor (cancer) cells, 3) the predictive efficacy of a chemotherapeutic treatment regimen using a particular therapeutic agent or process, 4) the probability of graft rejection or acceptance, identification of the up or down regulation relationships of serine proteases and caspases within living cell systems, provides a rapid, yet finely tuned mechanism for predicting the current and future state of these cell populations, and 5) the disease state status of a cell.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improved electric steam iron.
2. Description of the Related Art
In all cases, a steam iron comprises a baseplate heated by means of an electrical resistor, a device for supplying water to the vaporization chamber which is located above the baseplate, and means for regulating the inlet flow of water into this chamber.
Known irons also comprise means such as a bimetallic-strip thermostat for regulating the heating temperature of the baseplate, electrical connections for connecting the mains to the heating resistor of the baseplate and electrical elements in order to regulate the temperature of the baseplate.
Known steam irons thus comprise a large number of different mechanical and electrical elements.
Given that all these elements each have an individual function, they are mounted inside the iron, one after the other, in any order.
Thus, the device for supplying water and regulating the flow of this water is mounted at a certain point in the iron, usually located at the front of the latter, the regulating button being located at the front of the handle of the iron.
Moreover, the thermostat is generally fixed close to the rear part of the iron, the button for regulating the temperature being located in the recess made underneath the handle of the iron.
The mounting of this thermostat requires several pieces to fix it to the iron, insulate certain of its parts and produce the electrical connections with the electrical heating resistor of the baseplate and the power cable.
In addition to the abovementioned elements, an electric iron also comprises a circuit breaker which comprises a fuse which is liable to melt in the event of the iron overheating, and an indicator light for monitoring operation of the iron.
Bearing in mind the large number of pieces to be manipulated, assembly of all these elements inside the iron is a long and thus costly operation.
SUMMARY OF THE INVENTION
The present invention aims to remedy the drawbacks of known embodiments by producing a steam iron which can be assembled under markedly more economical and reliable conditions.
The invention thus refers to an electric steam iron comprising a heating baseplate, a vaporization chamber, a device for feeding water to this chamber, means for regulating the inlet flow of water into this chamber, means for regulating the heating temperature of the baseplate, electrical connections for connecting the mains to the electrical resistor of the baseplate and to said means for regulating the temperature of this baseplate and, if appropriate, an indicator light.
According to the invention, this steam iron comprises a plate on which are fixed or are formed at least part of the device for feeding water to the vaporization chamber, the means for regulating the flow of water, and/or the means for regulating the heating temperature and the abovementioned electrical connections, said plate forming at least part of the structure of said device and/or of said means.
This plate thus forms a support which carries all or part of the mechanical elements for regulating the flow of the steam and/or the electrical elements for controlling the temperature.
A plate of this type pre-equipped with all these elements can be produced separately at the factory under very easy conditions, given that these elements are mounted on a common support. This pre-equipped plate is then easy to mount in the iron, for example by means of a few screws. Once this plate has been positioned in the iron, it suffices to make a few electrical or mechanical connections such as, for example, the link between the water reservoir and the water feed device, and the positioning of one or two control knobs.
According to an advantageous version of the invention, the plate is fixed above the vaporization chamber substantially parallel to the baseplate.
This position does not affect the height dimension of the iron and permits an easy link between the water feed device and the vaporization chamber.
According to a preferred version of the invention, the plate carries all of the water feed device and the device for regulating this flow of water, including the means for connecting the latter to the water reservoir of the iron and the vaporization chamber.
The plate preferably carries all of the means for regulating the temperature of the baseplate, including the electrical connections.
In the most advantageous version of the invention, the plate comprises all of the water feed device and the device for regulating the flow as well as all the means for regulating the temperature, including the attachment and connection means.
All the functional equipment of the iron is thus concentrated on this plate, which simplifies the construction of the iron and, above all, its assembly.
Other features and advantages of the invention will, in addition, become apparent from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
In the appended drawings, which are given by way of nonlimiting examples:
FIG. 1 is a diagrammatic view in longitudinal section of an iron according to the invention,
FIG. 2 is another view in longitudinal section parallel to the above view,
FIG. 3 is a plan view of the plate and of the heating baseplate, the housing of the iron and the control knobs of the elements carried by the plate having been removed,
FIG. 4 is a sectional view according to the plane IV--IV in FIG. 1,
FIG. 5 is a sectional view according to the plane V--V in FIG. 1,
FIG. 6 is a sectional view according to the plane VI--VI in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the embodiment in FIGS. 1 and 2, the electric steam iron comprises a baseplate 1 heated by means of an electrical resistor (not shown), a vaporization chamber 2 located above the baseplate, a device 3 for feeding water to the chamber 2 and a pipe 4 for regulating the inlet flow of water to this chamber 2. The iron also comprises a thermostat 5 for regulating the heating temperature of the baseplate 1 and electrical connections for connecting the mains to the electrical resistor of the baseplate and to the thermostat 5 in order to regulate the temperature of this baseplate. Provision is also made for an indicator light 6 in order to show that the iron is operating.
The iron comprises a plate 7 on which are fixed or are formed at least part of the device 3 for feeding water to the vaporization chamber 2, including the pipe 4 for regulating the flow of water, and at least part of the means for regulating the heating temperature and the abovementioned electrical connections.
The plate 7 forming a support for the abovementioned elements is fixed above the vaporization chamber 2 and extends substantially parallel to the baseplate 1.
In the example shown in FIGS. 1 and 2, the plate 7 carries all of the device 3 for feeding water and for adjusting the flow of this water, including means (to be described below) for attachment of the latter to the water reservoir 8 of the iron and the vaporization chamber 2.
The plate 7 also carries all of the means for regulating the temperature of the baseplate 1, including the electrical connections.
More precisely, in the example shown, the plate 7 carries (see FIG. 1) on its face 7a adjacent the vaporization chamber 2 the body 9 of the device 3 for regulating the flow of water in which the pipe 4 in the form of a rod of said device is engaged. This body 9 carries at its end opposite the plate 7 a flexible seal 10 permitting a leaktight link with an opening 11 communicating with the vaporization chamber 2.
The face 7a of the plate 7 also comprises a water inlet conduit 12 molded with the plate 7 and opening out into the body 9. The end of this conduit 12 opposite the body 9 comprises a connector 13 linking with the base of the water reservoir 8.
The other face 7b of the plate carries mechanical elements 14, 15 for controlling the displacement of the pipe 4 in the body 9 and adjusting the flow of water, and the thermostat 5.
The elements 14, 15 are movable in translation relative to the plate 7 and comprise cavities 14a, 15a for fixing to the latter control knobs 16, 17 which are accessible to the user.
In the embodiment shown, the iron comprises, above the plate 7, a recess 18, made in the housing, forming the handle 19 of the iron. The knobs 16, 17 are fixed vertically in the cavities 14a, 15a of the elements 14, 15 and project into the recess 18. These control knobs 16, 17 are thus easily accessible to the users' fingers.
The first element 14 is mounted so as to slide on the plate 7 in the longitudinal direction of the iron. This element 14 comprises an inclined ramp 20 interacting with a bearing surface 21 (see FIGS. 1 and 6) of the pipe 4 in order to control the displacement of the latter in a direction perpendicular to the plate 7 against the action of a spring 22 pushing the pipe 4 towards the vaporization chamber 2. The user can thus regulate the flow of water into the vaporization chamber 2.
The second element 15 (see FIGS. 1 and 5) is mounted so as to slide on the plate 7 in a direction which is transverse to that of the first element 14. This element also comprises an inclined ramp 23 formed by a groove in which a finger 24 belonging to a part 25 integral with the pipe 4 is engaged. Thus, the displacement of the element 15 also controls the displacement of the pipe 4 in a direction perpendicular to the plate 7. The technical effects linked to the displacements of the elements 14 and 15 will be explained in detail during the description of the iron's operation.
Moreover, the plate 7, made from an insulating plastic material, comprises on its face 7b (see FIG. 3) strip conductors 26, 27, 28 which are, for example, metallized. The ends 26a, 27a and 28a of these strips located at the rear of the iron are intended to be connected to the electrical power cable of the iron. The other ends of these strips are connected to the components of the thermostat 5 in order to regulate the . heating temperature of the baseplate and/or of the circuit breaker with a thermal fuse.
The thermostat 5 will not be described in detail here, since it is well known to a person skilled in the art. This is a conventional adjustable bimetallic-strip thermostat.
Similarly, the circuit breaker with a thermal fuse will not be described in detail. It may consist of a meltable material incorporated into the baseplate on which a rod which holds a switch in the closed position bears. In the event of an overload, the material melts and the rod sinks into this material, opening the switch.
Of course, the components of the thermostat 5 and/or of the circuit breaker are fixed on the face 7a of the plate 7 in a manner such that the latter acts as an electrically insulating support for these components.
In the example shown, the components of the thermostat 5 and/or those of the circuit breaker are fixed on the face 7a of the plate 7 opposite that carrying the elements 14, 15 for controlling the displacement of the pipe 4.
FIG. 2 also shows that the element 14 for controlling the displacement of the pipe 4 comprises means which interact with the regulating component 5a of the thermostat 5 in order to act on the latter upon displacement of said element 14.
To this end, the element 14 comprises on its face adjacent the plate 7 a surface 30 which is slightly inclined relative to the latter. This surface 30 interacts with a transmission rod 31 which passes through the plate 7 and bears on the regulating component 5a of the thermostat 5.
Moreover, the face 7b of the plate 7 carries an indicator light 6 which is visible in a zone 32 of the recess 18.
The operation of the device which has just been described will now be explained.
Upon displacement of the element 14 towards the right in FIG. 2, the rod 31 in contact with the component 5a of the thermostat and with the inclined surface 30 gradually sinks, pushing the component 5a of the thermostat 5 downwards. Thus, the displacement of the element 14a results in a modification of the setting of the thermostat 5 and thus in a modification of the temperature of the baseplate.
During the displacement operation of the element 14, the rod of the pipe 4 stressed by the spring descends due to the ramp 20, this resulting in a modification of the flow of the steam by virtue of the variable section of the well-known recess provided at the end of the pipe.
Thus, the displacement of the element 14 makes it possible simultaneously to modify the temperature of the baseplate and the flow of water and of steam.
This opportunity exists only when the control knob 17 of the other element 15 is in the position shown in FIGS. 1 and 5.
In fact, it is only in this position that the surface 21 of the pipe 4 bears on the top of the element 14 and is thus capable of descending on the ramp.
By pushing the control knob 17 towards the right the finger 23 engaged in the ramp 20 rises along the latter, which causes a displacement of the pipe 4 upwards. During this displacement and according to the configuration of the recess made at the lower end of the pipe, the user can choose various regulating positions, such as the following:
automatic control position (that shown in FIGS. 1 and 5),
steam position,
double steam position,
dry position (no steam),
cleaning position.
The principal advantages of the invention are the following:
Given that the plate 7 supports and groups together all the elements for regulating the flow of water and the temperature, including the mechanical and electrical connection elements, the time for assembling the iron is considerably limited.
It suffices, in fact, to fix the plate 7 in the iron, for example by means of a few screws.
Moreover, given that the plate acts as a support for several elements, including some which are molded in a single piece with this plate, the number of pieces and thus the cost of the iron is reduced.
Moreover, the arrangement of these elements on a common plate makes it possible to produce a compact subassembly which reduces the size of the iron.
Of course, the invention is not restricted to the illustrative embodiment just described and several modifications may be made to it without departing from the scope of the invention.
Thus, the invention also covers those embodiments in which the plate groups together only the elements which serve to regulate the flow of water into the vaporization chamber or only the elements which serve to regulate the temperature of the heating plate.
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An electric steam iron having a heating baseplate (1) and a vaporization chamber (2), and further including a plate (7) on which are fixed or formed at least part of the device (3) for feeding water to the vaporization chamber (2), an assembly (4) for regulating the flow of water and components for regulating the heating temperature and the electrical connections. The plate (7) and parts mounted thereon are preassembled and then assembled as a module into the iron.
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RELATED APPLICATIONS
The present application is a continuation application of and claims the benefit of U.S. patent application Ser. No. 09/994,428, filed Nov. 26, 2001 now U.S. Pat. No. 7,221,851, entitled “METHOD AND SYSTEM FOR DVD SMOOTH SEARCH TRANSITIONS,” naming James van Welzen, Brian Falardeau, and Jonathan White as inventors, assigned to the assignee of the present invention. That application is incorporated herein by reference in its entirety and for all purposes.
BACKGROUND OF THE INVENTION
The DVD (digital versatile disk) format was designed by various members of the consumer electronics industry as a means of storing high quality audio-video content (e.g., a feature length film) on a single disk. To facilitate such efficient storage, the DVD format uses contemporary compression technologies to reduce the sizes of the video and audio bit streams comprising the content.
The DVD format employs the ISO MPEG-2 standard to compress video. MPEG-2 represents video content as a compressed series of frames. Each frame is a rectangular array of picture elements (pixels) depicting the content at a particular instant in time. Thus, playback consists of decompressing and then displaying this series of frames.
In conventional DVD players, the playback of DVD content is typically implemented in one of three ways: using dedicated hardware, using a software implementation, or using a combination of software and hardware. The most common or conventional implementation takes the form of a consumer electronics components with limited resources targeted exclusively at DVD playback. Less common or conventional implementations take the form of PC-based implementations or game consoles (e.g., Sony PLAYSTATION2, Microsoft X-BOX, etc.) which, because they target multiple functions, tend to have more extensive resources.
The MPEG-2 video standard employs three types of compressed frames: intra-frames (I-frames), predictive frames (P-frames), and bi-directionally predictive frames (B-frames). I-frames have no dependencies. Thus, an I-frame is self-contained and includes all information necessary to reproduce the associated original frame. P-frames may have forward dependencies, i.e., a P-frame is not self-contained. It may re-use information from the preceding decompressed reference frame (where a reference frame is either an I-frame or another P-frame). Thus, a playback implementation must decode reference frame preceding a P-frame before it decodes the P-frame itself and must keep the preceding reference frame resident in memory throughout the decoding of a P-frame. For the B-frames, B-frames are not self-contained and may have forward and backward dependencies, such that it may reuse information from either the preceding or the subsequent decompressed reference frame. Thus, a playback implementation must decode the reference frames both preceding and following a B-frame before it decodes the B-frame itself and must keep both the preceding and subsequent reference frames resident in memory throughout the decoding of a B-frame.
Normally, a playback implementation maintains four frame buffers (i.e., arrays of memory) of MPEG-2 video at any one time: 1) the currently decoded frame; 2) a forwards reference; 3) a backwards reference; and 4) the currently displayed frame. The forwards reference is the reference preceding the currently decoded frame, which is sometimes co-incident with the currently displayed frame. The backwards reference is the reference following the currently decoded frame. Additionally, the currently displayed frame is distinct from the currently decoded frame to prevent the player from updating a frame while it is being displayed, which causes an undesirable visual artifact called “tearing”.
Conventional DVD players have limited memory resources to reduce cost and enable forwards playback at normal speeds. However, the memory resources are insufficient for many fast-forwarding and rewinding operations. For example, conventional DVD players avoid decoding P or B frames when playing backwards, and instead only decode the self-contained I-frames. This leads to decoding less than 10% of the frames and providing jerky, low frame-rate play.
SUMMARY OF THE INVENTION
Accordingly, a need exists for improved video playback when performing fast-forwarding and rewinding operations. Embodiments of the present invention provide novel solutions to these needs and others as described below.
Embodiments of the present invention are directed to methods, systems and computer-readable medium for changing video playback speed. More specifically, video playback speed may be changed by determining a first frame rate and a second frame rate for which a frame rate transition is to be made. An instantaneous frame rate is calculated to produce a calculated instantaneous frame rate, wherein the calculated instantaneous frame rate is between the first frame rate and the second frame rate. A timestamp of a frame is adjusted based on the calculated instantaneous frame rate to produce an adjusted timestamp. Graphical data for the frame is provided in accordance with the adjusted timestamp to enable display of the frame. Thereafter, the frame may be displayed in accordance with the adjusted timestamp.
In one embodiment, the playback may comprise a smooth search transition (e.g., forward, backward, etc.). With the use of adjusted timestamps, the video playback appears as a smooth increase or decrease in playback speed (e.g., without the “jerk” associated with conventional systems) when transitioning between speeds (e.g., 0.5×, 1×, 2×, 4×, 8×, etc.).
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements.
FIG. 1 illustrates a block diagram of a DVD player system with at least seven frame buffers in accordance with one embodiment of the present invention.
FIG. 2 illustrates an example of I-, P-, and B-frames representing an original sequence of 24 frames in accordance with one embodiment of the present invention.
FIG. 3 illustrates a block flow diagram for smooth reverse playback in the DVD player system in accordance with one embodiment of the present invention.
FIG. 4 illustrates an example step-by-step reconstruction diagram for the original sequence of frames in accordance with one embodiment of the present invention.
FIG. 5 illustrates a block flow diagram for a single frame backwards playback in accordance with one embodiment of the present invention.
FIG. 6 illustrates a block flow diagram for smooth frame search transitions in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings. While the present invention will be discussed in conjunction with the following embodiments, it will be understood that they are not intended to limit the present invention to these embodiments alone. On the contrary, the present invention is intended to cover alternatives, modifications, and equivalents which may be included with the spirit and scope of the present invention as defined by the appended claims. Furthermore, in the following detailed description of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, embodiments of the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the present invention.
Notation and Nomenclature
Some portions of the detailed descriptions which follow are presented in terms of procedures, logic blocks, processing and other symbolic representations of operations on data bits within a computer memory. These descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. In the present application, a procedure, logic block, process, or the like, is conceived to be a self-consistent sequence of steps or instructions leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, although not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a computer system.
It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussions, it is appreciated that throughout the present invention, discussions utilizing the terms such as “accepting,” “accessing,” “adding,” “adjusting,” “analyzing,” “applying,” “assembling,” “assigning,” “calculating,” “capturing,” “combining,” “comparing,” “collecting,” “controlling,” “creating,” “defining,” “depicting,” “determining,” “displaying,” “distinguishing,” “establishing,” “executing,” “generating,” “grouping,” “identifying,” “modifying,” “moving,” “outputting,” “performing,” “placing,” “presenting,” “processing,” “programming,” “providing,” “querying,” “removing,” “repeating,” “sampling,” “sorting,” “storing,” “using,” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.
EMBODIMENTS OF THE INVENTION
The present invention provides aspects of displaying additional types of frames (e.g., in addition to I-frames) during the backwards playback in a DVD player. These aspects include smooth rewind, single frame stepping backwards, and smooth search transitions. FIG. 1 illustrates a block diagram of a DVD player system for implementing the aspects of the present invention. Actual implementations of this DVD player include but are not limited to PC-based DVD players and game console-based DVD systems (e.g., Sony PLAYSTATION, Microsoft X-BOX, etc.). As shown in FIG. 1 , the DVD player system includes a DVD drive (content storage) 100 , a decoding engine 102 (e.g., a CPU, etc.) for performing the processing of the present invention, an audio codec (audio rendering) 104 , audio amplifiers (audio medium) 106 , Memory 108 (e.g., comprising at least 7 video frame buffers), display controller (video rendering) 110 , and a display (visual medium) I 12 . In one embodiment, the at least 7 frame buffers are allocated either from system memory or the video memory of any resident graphics hardware, as is well appreciated by those skilled in the art.
Smooth Rewind
The DVD standard for the operation of the DVD player system prescribes that I-frames occur no less frequently than every 12 frames, as demonstrated by an example sequence of 24 original frames shown in FIG. 2 . In accordance with the present invention, smooth backwards playback of such a sequence occurs as described with reference to the overall block flow diagram of FIG. 3 and the step-by-step reconstruction diagram of FIG. 4 . Referring to FIG. 3 , to provide for the reverse playback from a currently displayed frame, reconstruction occurs from a last I-frame preceding a currently displayed frame to the frame immediately preceding the currently displayed frame (step 114 ). The process further includes utilizing at least 7 frame buffers to support the reconstruction (step 116 ). The data is displayed from memory in reverse order to provide a smooth playback of all the frames (step 118 ).
By way of example, for the process of FIG. 3 , a sequence of 24 original frames, as shown in FIG. 2 , is reconstructed as demonstrated by the step-by-step diagram of FIG. 4 . In the diagram of FIG. 4 , at each step, a decode is begun on a frame indicated in italicized type with the decode completed at the start of a next frame decode, a frame indicated in boldfaced type is displayed, and a frame indicated with strikethrough type is released from memory. Frame numbers indicated in normal type are held in memory.
In the example of FIG. 4 , the process of reverse playback begins with a first frame I 24 , as the one immediately preceding a currently displayed frame. The I-frame preceding I 24 is determined to be I 12 , which is shown as being decoded in step 1). With I 12 decoded in step 2), it is able to provide the reference data for the frame P 15 , which starts its decode. With P 15 decoded in step 3), it is able to provide the reference data for the frame P 18 , which starts its decode. In step 4), P 18 is decoded and provides the reference data necessary for starting the decode of frame P 21 . In step 5), the data needed for frame I 24 is present and its decode is started. Continuing with step 6), the I 24 frame is displayed, and its data, together with the data from P 21 , provides the needed reference data to begin the decode of frame B 23 . Thus, in step 7), the decoded B 23 data is displayed and the decode of B 22 begins. With B 22 decoded and displayed in step 8), the memory for B 23 and I 24 data is released, since neither will be used in any further decode. Further, since the next preceding frame P 21 is already decoded, a next preceding I-frame, 10 , is located and decoded in step 8). The data decoded for P 21 is displayed in step 9), while the decode for the B 20 frame is begun and the memory for B 22 is released. In step 10), B 20 is displayed while the decode of B 19 is begun. In step 11), B 19 is displayed, the memory for B 20 and P 21 is released, and the decode of P 3 is begun. In step 12), P 18 is displayed, the decode of B 17 is begun, and the memory for B 19 is released. With B 17 decoded, it is displayed in step 13), while the decode of B 16 begins. The decoded B 16 is displayed in step 14), allowing the release of memory for its reference P 18 . Also in step 14), the memory for B 17 is released and the decode of P 6 is begun. In step 15), P 15 is displayed, the decode for B 14 is begun, and the memory for B 16 is released. Once decoded, B 14 is displayed in step 16), and the decode for B 13 is begun. B 13 is then displayed in step 17), the memory for B 14 and P 15 is released, and the decode of P 9 occurs. In step 18), I 12 is finally displayed, the memory for B 13 is released, and the decode of B 11 begins.
The process demonstrated by FIG. 4 is cyclic. Thus, continuing with steps 19-30 would repeat steps 7-18 except on differently numbered frames, where the indices for the frame number are decremented by 12 every cycle. Further, in each step of the diagram, only 7 frames of data is stored in memory in one embodiment. For example, in step 1), only one buffer is allocated to store I 12 . In step 4), four buffers are allocated to store I 12 , P 15 , P 18 , and P 21 . In step 10), seven buffers are allocated to store 10 , I 12 , P 15 , P 18 , B 19 , B 20 , and P 21 . Thus, the reconstruction for backwards playback need not use more than seven frame buffers during any one step in one embodiment. Of course, more buffers could be used in other embodiments. The decode process of the present invention may operate on sets of 12 frames (e.g., in accordance with the DVD standard which prescribes that I-frames occur no less frequently than every 12 frames). At a high level, the player appears to decode the sets in reverse order. At a low level, the player decodes each frame within a set in forwards order, which computationally is well within the existing capacity of a DVD player system, as represented in FIG. 1 .
Single Frame Stepping Backwards
In a further aspect, the reverse playback is modified to allow the DVD player system to display one frame at a time in reverse order. The implementation occurs as described above for smooth rewind, with the following differences, as shown in FIG. 5 . The DVD player system waits for a signal from the user to step the frame backward (step 120 ) before starting the reconstruction of a preceding frame (step 121 ). The data is stored utilizing one of at least seven frame buffers (step 122 ). Once reconstructed, the frame is displayed (step 123 ) and the process returns to step 120 to await another signal indicating selection for single frame reverse.
Smooth Search Transitions
In yet another embodiment, the present invention provides for smooth search transitions in a DVD player system (e.g., transitions between one playback rate and another with reduced jerk). The limited frame rates of some displays, such as televisions, force DVD players to make the transition between one display rate and another abruptly. However, the frame rates of PC displays, for example, are flexible and thus, a PC-based DVD player system can make the transition between display rates smoothly. Thus, the aspect of smooth search transitions preferably is utilized in a DVD player system that provides data to displays that do not have limited frame rates.
In order to achieve smooth transition between display rates, the present invention linearly interpolates between one rate and another over a brief transition interval. Thus, with a given starting rate (r 0 ), a new rate (r 1 ), the time the player is aware of the eminent transition (t 0 ), and the time of the scheduled transition (t 1 ), the transition interval is defined to be the time between t 0 and t 1 +(t 1 −t 0 ), which provides a sufficient interval to maintain the overall average rate and in turn keeps audio and video in synchronization in one embodiment. A parametric equation R(t) is defined for the rate over the interval where the parametric u varies from 0 to 1, where 0 represents t 0 and 1 represents t 1 +(t 1 −t 0 ).
U =(now− t 0)/( t 1 −t 0)
R ( t )= r 0 +u ( r 1 −r 0)
FIG. 6 illustrates a block flow diagram for performing smooth search transitions. As shown in FIG. 6 , an instantaneous rate is calculated for every frame using the frame's original timestamp as input (e.g., the “now” variable above) (step 124 ). The resulting rate is then used to calculate an adjusted timestamp for the frame (step 126 ). The frame is then displayed according to the adjusted timestamp (step 128 ). Thus, when the frames are provided with the adjusted timestamps, video playback appears as a smooth increase or decrease in playback speed (e.g., without the “jerk” associated with conventional systems) when transitioning between speeds (e.g., 0.5×, 1×, 2×, 4×, 8×, etc.).
In the foregoing specification, embodiments of the invention have been described with reference to numerous specific details that may vary from implementation to implementation. Thus, the sole and exclusive indicator of what is, and is intended by the applicant to be, the invention is the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction. Hence, no limitation, element, property, feature, advantage, or attribute that is not expressly recited in a claim should limit the scope of such claim in any way. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
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Methods, systems and computer-readable medium for changing video playback speed are disclosed. Video playback speed may be changed by determining a first frame rate and a second frame rate for which a frame rate transition is to be made. An instantaneous frame rate is calculated to produce a calculated instantaneous frame rate, wherein the calculated instantaneous frame rate is between the first frame rate and the second frame rate. A timestamp of a frame is adjusted based on the calculated instantaneous frame rate to produce an adjusted timestamp. Graphical data for the frame is provided in accordance with the adjusted timestamp to enable display of the frame. Thereafter, the frame may be displayed in accordance with the adjusted timestamp.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. patent application Ser. No. 11/869,283, filed Oct. 9, 2007 now U.S. Pat. No. 8,296,053, issued on Jun. 7, 2012 by Edward M. Brennan et al., titled “System and Method for Determining Relative Motion Between Ship Combat System Elements”, the entirety of which application is incorporated herein by reference.
GOVERNMENT LICENSE RIGHTS
This invention was made with Government support under contract number N00024-03-C-6110 awarded by the Department of the Navy. The Government has certain rights in this invention.
FIELD OF THE INVENTION
The invention relates to systems and methods for determining relative motion between bodies, and more particularly to systems and methods for compensating for relative motion between ship combat system elements.
BACKGROUND OF THE INVENTION
Ship hull structures deform during at-sea operations due to vibration and wave interaction. Such deformations result in relative motion between combat system elements such as radar systems, inertial navigation system (INS) sensors, and weapons systems. Since these combat system elements are often located on different parts of the ship, relative motion between them can introduce error into the targeting information provided to the weapons systems. Current Aegis combat systems do not compensate for this relative motion because the errors are deemed to be tolerable. It is expected that future combat systems, such as future Aegis Ballistic Missile Defense (BMD) baselines and CG(X), will need to compensate for relative motion between the primary radar and the INS sensors. This is because it is expected that future BMD and CG(X) will have tighter weapons system accuracy requirements, which will require relative motion compensation to meet those requirements.
Motion compensation systems are known. For example, U.S. Pat. No. 5,072,389 to Wernli et al. describes a method for compensating alignment errors in modular marine fire-control systems. The Wernli method involves the direct measurement of rotational speeds and linear accelerations at various system components to determine stabilization data for the associated equipment units. One problem with the Wernli system is that it requires the use of gyroscopes to measure rotational speeds. Such gyroscopes are expensive and require complex isolation systems to meet Navy shock requirements, resulting in substantial acquisition and maintenance costs. Thus, there is a need for a highly reliable and easy to maintain system to compensate for relative motion between combat system elements.
SUMMARY OF THE INVENTION
A system for determining relative motion between combat system elements on a ship having a hull is disclosed, comprising: first and second accelerometers associated with first and second combat system elements, respectively for generating first and second acceleration signals; first and second filter modules coupled to said first and second accelerometers for receiving and conditioning said first and second acceleration signals, respectively for thereby generating conditioned accelerometer signals; and first and second displacement control modules coupled to said first and second filter modules for receiving said conditioned accelerometer signals from said first and second filter modules, respectively, and first and second ship attitude signals, and generating first and second signals representative of rotational and translational displacements of said combat system elements and calculating relative motion between the first and second combat system elements. The first and second displacement control modules may be configured to: (a) determine the translational and rotational displacements of the first and second combat system elements due to hull modal vibration at times T 1 and T 2 ; (b) determine the translational and rotational displacements of the first and second combat system elements due to forced vibration at times T 1 and T 2 ; and (c) determine relative motion between the first and second combat system elements by differencing the translational and rotational displacements at each of the first and second combat system elements at times T 1 and T 2 .
A method for determining motion between first and second combat system elements on a ship is disclosed, comprising: providing first and second accelerometers associated with first and second combat system elements, respectively for generating first and second acceleration signals; conditioning said first and second acceleration signals; generating first and second signals representative of rotational and translational displacements of said combat system elements based on said conditioned first and second acceleration signals, and first and second ship attitude signals; determining the translational and rotational displacements of the first and second combat system elements due to hull modal vibration at times T 1 and T 2 ; determining the translational and rotational displacements of the first and second combat system elements due to forced vibration at times T 1 and T 2 ; and determining relative motion between the first and second combat system elements by differencing the translational and rotational displacements at each of the first and second combat system elements at times T 1 and T 2 .
A machine readable storage device tangibly embodying a series of instructions executable by the machine to perform a series of steps is disclosed, the steps comprising: directing first and second signals from first and second accelerometers to first and second filter modules, said first and second accelerometers associated with first and second combat system elements, respectively; conditioning said signals produced by the first and second accelerometers; generating first and second signals representative of rotational and translational displacements of said combat system elements based on said conditioned input signals and first and second ship attitude signals; determining the translational and rotational displacements of the first and second combat system elements due to hull modal vibration at times T 1 and T 2 ; determining the translational and rotational displacements of the first and second combat system elements due to forced vibration at times T 1 and T 2 ; and determining relative motion between the first and second combat system elements by differencing the translational and rotational displacements at each of the first and second combat system elements at times T 1 and T 2 .
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be more fully disclosed in, or rendered obvious by, the following detailed description of the preferred embodiments of the invention, which are to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:
FIG. 1 is a side view of an exemplary ship showing various combat system elements;
FIG. 2 is a mathematical description of relative motion between combat system elements;
FIG. 3 is a flowchart illustrating an exemplary algorithm in accordance with the invention;
FIG. 4 is a flowchart illustrating exemplary elements of the pre-filter module of the algorithm of FIG. 3 ;
FIG. 5 is a flowchart illustrating exemplary elements of the filter module of the algorithm of FIG. 3 ;
FIG. 6 is an exemplary accelerometer frequency domain representation;
FIG. 7 is a flowchart illustrating exemplary elements of the displacement calculation module of the algorithm of FIG. 3 ; and
FIG. 8 is a graphical example of fitting a pre-determined mode shape derived from a ship structural finite element model with a mode shape derived from filtered accelerometer signals.
DETAILED DESCRIPTION
The invention is a system and method for determining relative motion between combat system elements positioned on a naval vessel 1 , such as that illustrated in FIG. 1 . The combat system elements may comprise radar systems 2 , forward and aft inertial navigation system (INS) sensors 4 , and weapons systems 6 . “Relative motion” is described in relation to FIG. 2 , in which a pair of combat system elements are labeled “A” and “B.” These elements can be any of the aforementioned components (radar, INS sensors, weaponry, etc.) The translational and rotational positions of combat system elements A and B at time t 1 may be designated [A] 1 and [B] 1 , while the translational and rotational positions of those same elements at time T 2 may be designated [A] 2 and [B] 2 . The positions may be further defined as follows:
[ A] 1 =[T A1 ,R A1 ], where:
T A1 =[t ax1 ,t ay1 ,t az1 ] (Translational position)
R A1 =[r ax1 ,r ay1 ,r az1 ] (Rotational position)
Thus defined, the relative motion between combat system elements A and B may be determined as: ([B] 1 −[A] 1 )−([B] 2 −[A] 2 ).
FIG. 3 illustrates an exemplary algorithm for use in calculating the relative motions between elements A and B. As will be appreciated, this algorithm will be a component of the larger system used to compensate for motion between combat system elements. Such a larger system may include accelerometers 8 placed at desired locations on the individual combat system elements, ship INS sensor locations, and other locations on the ship. Examples of such “other locations” would be the main structural bulkheads in the hull and deckhouse superstructure. These locations would be utilized to help determine the deformed hull shapes due to forced and modal vibration. The output from the algorithm will be utilized to correct errors in radar target information due to relative motion.
As shown in FIG. 3 , the Algorithm may accept signals from the accelerometers 8 mounted on or adjacent to combat system elements A and B. In this example, elements A and B are a primary radar 2 and weapon system 6 ( FIG. 1 ), though it will be appreciated that the Algorithm may accept signals from accelerometers mounted on any of a variety of ship's structures as previously noted. In addition to the accelerometer signals, the Algorithm may also accept attitude signals from a pair of INS's 4 that are part of the ship's existing equipment. The Algorithm may utilize these signal inputs to determine the relative motion between the combat system elements A, B.
Generally, the signals 10 A, B from respective accelerometers 8 connected to elements A and B are sent through respective Pre-Filter Modules 12 A, B, which prepare the raw signals for further processing. The pre-filtered signals 14 A, B are then sent through respective Filter Modules 16 A, B to extract those components of the signals necessary for the relative motion calculation. The filtered signals 18 A, B are then sent to respective Displacement Calculation Modules 20 A, B, which combine the filtered accelerometer signal information with ship's attitude signal information 22 , 24 provided by the Ship INS's. The output 26 A, B from the Displacement Calculation Modules 20 A, B are then differenced to determine resulting values for the relative motion between the combat system elements A, B. This relative motion information will be utilized to correct errors in radar target information due to relative motion.
One advantage of the invention is that it enables relative rotational displacement between elements A and B to be determined using only the respective accelerometers and the ship's existing INS's. In other words, relative rotational displacement between combat system elements can be determined without the need for high-performance angular rate sensors positioned at the combat system elements. Such angular rate sensors are expensive and require complex mechanical isolation systems to meet Navy shock requirements. Thus, the inventive system presents a simplified approach, resulting in enhanced reliability as well as reduced acquisition and maintenance costs.
The individual Modules will now be described in greater detail. For efficiency, the Pre-Filter Module, the Filter Module and the Displacement Calculation Module will be described in relation to combat system element “A” only. It will be appreciated, however, that the description applies equally to the Modules associated with combat system element “B.”
Pre-Filter Module
Referring now to FIG. 4 , the Pre-Filter Module 12 A will be described in greater detail. As previously noted, the Pre-Filter Module 12 A, may be used to prepare the raw signal 10 A produced by the accelerometers on or adjacent to individual combat system element A, so that it may be processed further in the Filter Module 16 A. Thus, at step 28 , an accelerometer data sample is selected for processing. At step 30 , the sample is then truncated or zero padded (i.e., zeroes are added to the end of the sample) as necessary to meet the sample length requirements of the Filter Module 16 A. The data sample is then smoothed to improve the resolution of the sample data in the frequency domain. This technique is often referred to as “windowing” and it serves to “smooth” the signal to a value of zero at the start and end points of the sample.
Filter Module
Referring now to FIG. 5 , the Filter Module 16 A extract desired components from the signal 14 A while leaving unwanted or unnecessary components behind. When accelerometers are placed on ship structures, they produce signals that represent acceleration due to hull vibration as well as ship rigid body motion (i.e., the normal pitch/roll, etc. motion of a ship caused by the forces of the sea). These signals may further contain components of electrical interference.
Hull vibration results in relative motion between combat system elements, but rigid body motion will not. Electrical interference, if not properly identified in the signal, can mistakenly be interpreted as relative motion. Thus, it is desirable to identify and remove those components of the signal attributable to ship rigid body motion and electrical interference, since these components would introduce significant errors into the calculation.
Thus, at step 36 the signal 14 A received from the Pre-Filter Module 12 A is converted from time to frequency domain, and then directed through appropriate high pass filter 38 and low pass filter 40 . Note the high and low pass filters may comprise a band pass filter. At step 42 , the signal is converted back from frequency domain to time domain before it is sent on to the Displacement Calculation Module 20 A.
FIG. 6 shows a frequency-domain representation of a typical ship-mounted accelerometer signal. Hull vibration can be categorized as modal vibration and forced response vibration. In the Filter Modules 16 A, B, acceleration due to forced response vibration is removed along with acceleration due to rigid body motion because forced response vibration and rigid body motion occur at the same frequency. However, forced response vibration is important because it results in relative motion between combat system elements. Therefore, the displacements due to forced response vibration are estimated in the Displacement Calculation Module 22 A, B, as will be described in the next section.
During the filtering process, it is necessary to preserve signal phase because the signals will be mathematically combined by the algorithm to determine relative motion. A slight phase shift in the filtering process can introduce significant errors. Thus, to remove the targeted content while still preserving phase, filtering is performed in the frequency domain using a Fast Fourier Transform (FFT) algorithm. Using an FFT in lieu of a conventional time-domain digital filter also significantly reduces computation time.
The FFT provides a complex signal representation of real and imaginary components. For each frequency, the magnitude is the square root of the sum of the squares of the real and imaginary components. For each frequency, the phase is the inverse tangent of the ratio of imaginary to real component. To extract the desired frequencies, the unwanted frequencies are essentially zeroed out by multiplying their corresponding real and imaginary components by a very small non-zero value. For each frequency, it is important that the real and imaginary components are multiplied by the same small non-zero value as this will keep the imaginary-to-real component ratio constant and preserve phase.
The algorithm also determines filter cut-off frequencies. It is desirable to select cut-off frequencies such that all rigid body motion is removed and all relative motion is retained. The algorithm identifies rigid body motion frequencies and modal vibration frequencies in the FFT signal representation by comparison to predetermined expected rigid body motion and modal vibration frequencies.
Displacement Calculation Module
Referring now to FIG. 7 , Displacement Calculation Module 22 A is shown. The Displacement Calculation Module 22 A calculates the rotational and translational displacement of the associated combat system element A.
As can be seen, the filtered accelerometer signal 18 A is received from the filter module, and at step 44 , the translational displacement due to hull modal vibration is calculated by double integrating the signals. In order to obtain meaningful results, the algorithm must employ a mechanism to limit or eliminate the drift associated with the numerical integration operation. This obstacle is dealt with using a digital finite-impulse response (FIR) filter at step 46 in a manner that does not impact the signal's phase angle. Although the filter attenuates the signal, it also modifies the phase angle of the signal over a very wide frequency domain, including the frequencies corresponding to the hull modes. This phase angle distortion can impart a very large error in relative displacement calculations and must be minimized. The chosen solution is to reverse the FIR-filtered data in time, i.e. begin with the maximum time and end at time zero, and pass the signal through the FIR filter a second time. The end result is a FIR filter that applies the square of the gain of the original filter, but does not impact the signal's phase angle.
Next, at steps 48 and 50 , the rotational displacement due to hull modal vibration is calculated. The first three hull vibration modes are identified (step 48 ) by analyzing the filtered accelerometer signals in the frequency domain. A mode shape factor for each of the three modes is then calculated by fitting a pre-determined mode shape derived from a ship structural finite element model with a mode shape derived from the filtered accelerometer signals. FIG. 8 shows an example of fitted mode shapes for the first vibration mode. Next, the rotational displacement for each of the first three vibration modes is calculated (step 50 ) by multiplying the predetermined rotational displacement from the finite element by the mode shape factor. Total rotational displacement is calculated by summing calculated rotational displacements from the first three vibration modes.
Next, the translational and rotational displacements due to forced vibration are calculated. Recall from above that the acceleration due to forced vibration was removed from the accelerometer signals in the Filter Module 16 . Therefore, the accelerometer signals are not used in this calculation. Instead, the forward and aft INS attitude signals 22 , 24 are used to determine the hull's deflected shape due to forced vibration. The forward and aft attitude signals 22 , 24 in three axes are differenced which essentially removes rigid body motion and leaves relative rotation due to forced vibration. Hull bending shapes and magnitudes are then determined at step 52 by comparing the differenced attitude data to forced vibration deflection shapes determined previously from at-sea vibration data collection. Translational and rotational displacements at the combat system elements are then calculated at step 54 using the hull bending shape data.
Next, the rotational and translational displacement at each combat system element is calculated at step 56 by summing the rotational/translational displacement due to hull modal vibration and the rotational/translational displacement due to forced vibration. Finally the relative motion between combat system elements is calculated as shown in FIG. 2 by differencing the rotational/translation displacements at each combat system element [([B] 1 −[A] 1 )−[B] 2 −[A] 2 )].
This calculated relative motion information may then be utilized to correct errors in radar target information due to relative motion.
The invention described herein may be automated by, for example, tangibly embodying a program of instructions upon a computer readable storage media, capable of being read by machine capable of executing the instructions. A general purpose computer is one example of such a machine. Examples of appropriate storage media are well known in the art and would include such devices as a readable or writeable CD, flash memory chips (e.g., thumb drive), various magnetic storage media, and the like.
The features of the invention have been disclosed, and further variations will be apparent to persons skilled in the art. All such variations are considered to be within the scope of the appended claims. Reference should be made to the appended claims, rather than the foregoing specification, as indicating the true scope of the subject invention.
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A method is disclosed for determining relative motion between equipment systems positioned on a structure that is subject to deformation due to vibrations, using accelerometers. Relative motion between equipment systems can introduce error into the targeting information provided to a system such as a weapons system, and thus the method facilitates compensation for such relative motion. A method is disclosed in which the raw accelerometer signals are filtered, then combined with attitude signals in a displacement calculation module (DCM). Within the DCM, the signals are manipulated to calculate, for each equipment system, the translational and rotational displacements due to hull modal vibration and the translational and rotational displacements due to force vibration. The sum of these values represent the movement of each of the affected equipment systems. Relative motion between systems is calculated as the difference between the calculated movement values.
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FIELD OF THE INVENTION
This invention relates to a method of initially setting a stepping motor for controlling stitches in a sewing machine.
BACKGROUND OF THE INVENTION
When the stepping motor is used for controlling the stitches, a load torque of a motor should be lower than a generated torque thereof for preventing the stepping motor from going out of service. However, although this condition is satisfied under the normal driving state, the mechanism is made heavy due to, e.g., exposure in the low temperatures, and the load torque is increased, and then if the motor were driven at high speed, it would be out of order.
With respect to a build of the stepping motor and a control thereof, a surplus or room may be kept therefore, but a cost is increased or responsibility at high speed is sacrificed.
SUMMARY OF THE INVENTION
The present invention sets the stepping motor while, at initial setting time, passing it through a full moving region of the motor at comparatively low pulse frequency, and it is discriminated whether the motor moves accurately in response to driving pulses between detecting points until the motor passes one detecting point, and again reaches this detecting point. If it is not normal, an abnormality is indicated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow chart of initial setting control, showing an embodiment of the invention;
FIG. 2 shows dissolved elemental parts of a sewing machine relating to the present invention;
FIG. 3 shows setting of parts thereof;
FIG. 4 is an explanatory view of stepping actuation of a stepping motor; and
FIG. 5 is a block diagram of the control.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the invention will be explained in reference to the attached drawings. Since a needle amplitude and a fabric feed are the same in regard to controls, an explanation will be made concerning the needle amplitude.
In FIGS. 2 and 3, a stepping motor 1 for the needle amplitude is fixed to an attaching plate 2. A motor shaft 3 is mounted thereon with a gear 4 and a switch cam 5 for actuating a later mentioned switch. A shaft 6 of the attaching plate 2 is mounted thereon with an actuating gear 7 whose shaft 8 will be attached with an actuating arm 9 formed with a hole 10 to be engaged with a gear shaft 11. The gear 7 and the arm 9 are worked integrally by a coil spring 12. A shaft 13 of the actuating arm 9 is connected to a needle bar supporter 15 via an amplitude rod 14, so that the actuation of the stepping motor 1 is transmitted to the needle supporter 15, and the needle bar 16 is swingingly moved around a turning shaft 17. Stoppers 18, 19 restrain a moving range of the actuating gear 7.
A micro switch 20 is fixed to the attaching plate 2, and an actuator 21 is served by a switch cam 5.
FIG. 4 is an explanatory view concerning actuation of the stepping motor 1 which moves in 40 steps from -16 to 24 of a coordinate between the stoppers 18 and 19.
In a range (A), the stepping motor 1 is driven in actual stitching, a center position (M) thereof is a coordinate 0, a right position (R) is -15 and a left position (L) is 15. FIG. 3 shows these positions (M)(R)(L) which corresponds to the center position of the needle amplitude range, the right end thereof and the left end. In a range (B), the stepping motor 1 is driven at an initially setting time, and this range is a full length from -16 to 24 of the coordinate. A range (C) comprises the coordinates 20 to 24 where the micro switch 20 is turned ON. A range (D) comprises the coordinates -16 to 19 where the micro switch 20 is turned OFF.
At any of the coordinates (P0) to (P5), the stepping motor 1 is positioned when it is energized at a determined energizing phase (called it as PHO). When the energizing phase PHO is energized at ON of the power source, the stepping motor is set at the nearest coordinate among the coordinates (P0) to (P5).
FIG. 5 is a control block diagram, where a central calculation treatment device (CPU) plays an important role of the micro computers, and an initially setting data memory (ROM) stores later mentioned program control signals for initially setting the stepping motor 1. A drive motor (DR) is moved in cooperation of these members, and drives the stepping motor 1 for the needle amplitude and the stepping motor 1a for the fabric feed, and receives actuating condition of the micro switch 20 or 20a.
FIG. 1 is a control flow chart. The control is carried out by the micro computer of CPU in dependence upon the data of ROM.
Herein, an explanation will be made to the control of FIG. 1. When the control power source is supplied, the initially setting program is started (START). The determined energizing phase (PHO) of the stepping motor 1 is energized, and the stepping motor 1 is moved to any one of the coordinates (P0) to (P5), and ON or OFF of the micro switch 20 is selected. Now suppose that said moving position is, for example, the coordinate (P3), then the micro switch 20 is OFF. The stepping motor 1 successively changes the energizations, and is moved at low speed by 8 steps in the left direction (L) of FIG. 4 to the coordinate (P4). Since the micro switch 20 is OFF, it is further moved in the left direction by 8 steps to the coordinate point (P5), and the micro switch 20 is turned ON. If the stepping motor 1 does not reach the coordinate point (P5) due to such as heavy load thereon, the micro switch 20 is OFF and the stepping motor is further moved by 8 steps. When the micro switch 20 is turned OFF by the 40 steps, an indicating lamp (not shown) of the sewing machine shows an error and stops (END) the stepping motor 1 and the program. The reason why said total steps are 40, 15 because although the stepping motor 1 is positioned at any one of the coordinates (P0) to (P5) when supplying the power source, the stepping motor 1 can reach all the coordinate (P1) (P5) by the 40 steps.
When the micro switch 20 is turned ON, the stepping motor 1 is moved in the right direction (R) by 39 steps, and is converted at the stopper 18 and moved in the left direction by 39 steps. If the stepping motor is, at this time, turned to the coordinate (P5), the micro switch 20 is ON and the stepping motor is moved in the right direction by 24 steps, and stops at the coordinate (P2). This coordinate (P2) is a center point (M) and is set as an initial standard position, from which the needle amplitude starts controlling. If the micro switch 20 is OFF after 39 steps, an error is indicated, and the stepping motor 1 is stopped.
As mentioned above, according to the invention, the stepping motor is, at initial setting, driven over the full moving range at the low frequency, and the mechanical parts are set. Therefore, although the mechanical part is exposed, e.g., in the low temperatures, and the load torque is made comparatively large, it is normally driven in response to a drive pulse, and said load torque is decreased during the initial setting, so that the normal drive for subsequent stitching is not troubled. The above operation may be performed by easy program without requiring additional members.
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A stepping motor is initially set while it passes through a full moving range at comparatively low pulse frequency, and it is discriminated whether the motor moves accurately in response to driving pulses between detecting points until the motor passes one detecting point and again reaches this detecting point.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of co-pending, commonly owned provisional U.S. patent application Ser. No. 60/132,975, invented by Bernard J. New and filed May 7, 1999, which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates generally to methods and apparatus for accelerating complex, processor-intensive signal-processing algorithms, in particular algorithms in which the evaluation depends upon a single final data point.
BACKGROUND
Some complex signal processing algorithms depend upon a single final data point to produce a processed result. One such algorithm is the finite-impulse-response (FIR) filter, which is commonly found among the algorithms evaluated by a digital signal processor (DSP).
FIG. 1 is a flowchart 10 of a direct form of a conventional FIR filter. A series of N input data samples is shifted into shift registers 11 1 through 11 N . Thus, register 11 1 contains a current data sample D N and registers 11 2 through 11 N contain a set of previous data samples D 4 , D 3 , D 2 , and D 1 .
Registers 11 1 through 11 N present their corresponding data samples D 1 through D N on like-named register output lines. Data samples D 1 through D N are then multiplied in a set of multiply steps 12 1 through 12 N by a respective set of weighting coefficients C 1 through C N . Finally, an adder 13 sums the resulting weighted samples to provide a filtered output sample D F , where D F =D 1 C 1 +D 2 C 2 . . . +D N C N . Output sample D F is then loaded into an output register 14 .
FIG. 2 depicts a typical hardware implementation 20 of the flowchart of FIG. 1, like-numbered elements being the same in both Figures. For ease of illustration, FIG. 2 illustrates a four-tap filter employing weighting coefficients C 1 -C 4 . The depicted example is limited to five input samples D 1 -D 5 , sample D 5 being the newest and sample D 1 being the eldest. A register 11 , including five individual registers 11 1 through 11 5 , connects to a multiplier 22 via a multiplexer 24 . A register block 26 stores weighting coefficients C 1 through C 4 in a series of registers 26 1 through 26 4 and presents the coefficients to multiplier 22 via a second multiplexer 28 .
As depicted below in Table 1, the example begins with the first (eldest) data sample D 1 stored in register 11 5 , the second data sample D 2 stored in register 11 2 , the third data sample D 3 stored in register 11 3 , and the fourth and most recent data sample D 4 stored in registers 11 1 and 11 4 . A new data sample D 5 is then received and latched into input register 11 1 during the first machine cycle (Cycle 1). Multiplexers 24 and 28 then provide the respective contents of registers 11 1 and 26 1 (i.e., D 5 and C 1 ) to multiplier 22 . Multiplier 22 outputs the product D 5 C 1 to an adder 25 , which stores the product D 5 C 1 in an accumulation register 29 .
TABLE 1
Register
Start
Cycle 1
Cycle 2
Cycle 3
Cycle 4
11 1
D 4
D 5
D 5
D 5
D 5
11 2
D 2
D 2
D 5
D 4
D 3
11 3
D 3
D 3
D 2
D 5
D 4
11 4
D 4
D 4
D 3
D 2
D 5
11 5
D 1
D 1
D 4
D 3
D 2
Registers 11 2 to 11 5 operate as shift registers. Data sample D 1 is shifted into register 11 2 during the time that data sample D 1 is presented to multiplier 22 . Thus, for the second machine cycle (Cycle 2), each data sample in shift register 11 is similarly shifted, so that data sample D 1 is replaced with data sample D 4 , data sample D 4 is replaced with data sample D 3 , data sample D 3 is replaced with data sample D 2 , and data sample D 2 is replaced with data sample D 5 (see Table 1).
Multiplexer 24 selects the D output D OUT of register 11 while multiplexer 28 selects coefficient C 2 following the foregoing multiply and shift sequence. Multiplier 22 thus supplies the product D 4 C 2 to adder 25 , which sums the product D 4 C 2 with the product D 5 C 1 already in accumulation register 29 and stores the sum (i.e., D 4 C 2 +D 5 C 1 ) in accumulation register 29 . As with data sample D 5 data sample D 4 is shifted into register 11 2 while data sample D 4 is presented to multiplier 22 . Each remaining register 11 3 - 11 5 is similarly updated, so that the contents of registers 11 1 - 11 5 are as depicted above for cycle three of Table 1.
The foregoing multiply, accumulate, and shift process continues until each data/coefficient pair is presented to multiplier 22 and the resulting products are summed in accumulation register 29 and then stored in an output register 14 . Upon completing of the filtering of data sample D 5 , the contents of registers 11 1 - 11 5 are as depicted above for cycle four of Table 1. The filter is then prepared to receive the next data sample D 6 .
Filter implementation 20 requires N clock cycles to filter each data sample, or one clock cycle for each multiply-accumulate operation performed by multiplier 22 and adder 25 . Since many DSP optimized microprocessors can produce the same result in N clock cycles, such an embodiment cannot be used to accelerate the microprocessor.
Some conventional systems employ multiple multiplier/adder pairs operating in parallel to reduce the requisite number of clock cycles and therefore improve speed performance. Unfortunately, such parallel systems are larger, more expensive, and require more power than their sequential counterparts. There is therefore a need for a means of reducing the time required to complete the evaluation of the FIR-filter algorithm without incurring significant increases in power usage, size, and cost.
SUMMARY
The present invention is directed to methods and apparatus for accelerating complex signal-processing tasks, such as FIR filtering. In one embodiment, an FIR-filter accelerator is connected in parallel with a data path in a conventional DSP. The accelerator calculates and maintains a number of partial results based on a selected number of prior data samples. Each time the DSP receives a new data sample for filtering, the DSP makes use of one or more partial results from the accelerator to speed the calculation of the filtered result. The accelerator then recalculates the partial results using the new data sample in preparation for a subsequent data sample.
The filter accelerator can improve the performance of the DSP even if the accelerator hardware operates at a rate slower than that of the DSP. The accelerator can therefore be produced inexpensively by exploiting proven, mass-produced, economical technologies and materials. Moreover, the accelerator can be made relatively small, as the accelerator does not require massively parallel processing means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flowchart 10 of a direct form of a conventional FIR filter.
FIG. 2 depicts a typical hardware implementation 20 of the flow chart of FIG. 1 .
FIGS. 3A-3I are flowcharts depicting the operation of a three-tap FIR filter accelerator in accordance with an embodiment of the invention.
FIG. 4 is a block diagram of an accelerator 41 in accordance with the invention.
FIG. 5 is a flowchart 50 depicting the operation of a FIR filter accelerator in accordance with the present invention.
FIG. 6 is a block diagram of a datapath 60 connected to accelerator 41 of FIG. 4 .
FIGS. 7A-7I are flowcharts depicting the operation of a three-tap FIR filter accelerator in accordance with another embodiment of the invention.
DETAILED DESCRIPTION
FIGS. 3A-3I are flowcharts depicting the operation of a three-tap FIR filter accelerator in accordance with an embodiment of the invention. The subscript of a given data sample D N indicates the relative age of the data sample, the lower the subscript number the older the sample. The filter accelerator conventionally produces a filtered data sample D F by multiplying three consecutive data samples by three respective weighting coefficients C 1 , C 2 , and C 3 . As described below, the filter accelerator presents filtered data D F in just one clock cycle using a single multiplier, providing speed performance without the disadvantages of parallel processing solutions.
Each flowchart in FIGS. 3A-3I depicts the operation of the filter accelerator during a single clock cycle. Referring first to FIG. 3A, a first input data sample D 1 is stored in a data input register 31 . Register 31 presents data sample D 1 to a weighting-coefficient multiplier 32 . Weighting-coefficient multiplier 32 is a single multiplier depicted as including three separate multipliers 32 1 through 32 3 to illustrate that multiplier 32 performs three separate multiplications—one per clock cycle—for each input data sample. Multipliers 32 3 , 32 2 , and 32 1 respectively symbolize the first, second, and third multiplications.
During the first clock cycle, multiplier 32 multiplies data sample D 1 by a weighting coefficient C 3 using multiplier 32 3 . (In each of FIGS. 3A-3I, the active multiplication is highlighted using a multiplier symbol having a solid boundary, whereas the inactive multiplications are contrasted using multiplier symbols with broken boundaries.) Multiplier 32 3 provides a data-sample product D 1 C 3 to an adder 33 1 . This adder adds data-sample product D 3 C 3 with the contents of a register 34 2 and stores the filtered result D F in sum-of-products register 34 1 , the output register of the filter accelerator. The depicted accelerator has three taps, and so when started requires three data samples before producing the first filtered output. Data sample D 1 is assumed to be the first data sample, so the filtered output D F is incomplete.
During the second clock cycle (FIG. 3 B), multiplier 32 multiplies data sample D 1 by a second weighting coefficient C 2 , sums this product D 1 C 2 with the contents of a register 34 3 , and stores the result in a register 34 2 . Register 34 3 is thus far empty, so register 34 2 stores the product D 1 C 2 . In the third clock cycle (FIG. 3 C), multiplier 32 multiplies data sample D 1 by a third weighting coefficient C 1 and stores the resulting product D 1 C 1 in register 34 3 .
FIGS. 3D, 3 E, and 3 F illustrate the receipt and processing of a second input data sample D 2 . Multiplier 32 multiplies data D 2 by coefficient C 3 during the first clock cycle following the receipt of sample D 2 . Adder 33 1 adds the resulting data-sample product D 2 C 3 to the contents of register 34 2 obtained during the processing of the previous data sample D 1 . The resulting sum of products is stored as a filtered result D F in register 34 1 . The filtered result is still incomplete, as a three-tap filter requires three input data samples upon which to base a result.
During the second clock cycle (FIG. 3 E), multiplier 32 multiplies data sample D 2 by coefficient C 2 and adder 33 2 adds the resulting product D 2 C 2 with the contents of a register 34 3 . A second sum-of-products register 34 2 captures the resulting sum of products (D 2 C 2 +D 1 C 1 ). In the third clock cycle (FIG. 3 F), register 34 3 captures the product of data sample D 2 and coefficient C 1 .
FIGS. 3G, 3 H, and 3 I illustrate the receipt of a third input data sample D 3 . The third data sample D 3 is the first for which the three-tap filter has enough data to produce a filtered result. During the first clock cycle after receipt of the third sample D 3 , multiplier 32 multiplies data sample D 3 by coefficient C 3 . Adder 33 1 adds the resulting data-sample product D 3 C 3 to the contents of register 34 2 (D 2 C 2 +D 1 C 1 ) obtained during the processing of the previous data samples D 1 and D 2 . The resulting sum of products is stored as a filtered result D F in register 34 1 . Importantly, the filtered result D F =D 3 C 3 +D 2 C 2 +D 1 C 1 is the first correct filtered result after receiving data sample D 3 , and is available after only one clock cycle. As shown in FIGS. 3H and 3I, registers 34 2 and 34 3 are then updated using data sample D 3 during the second and third clock cycles in the manner described above in connection with FIGS. 3A-3F. The method of FIGS. 3A-3I produces a filtered result before the partial-results in registers 34 2 and 34 3 are updated. The steps illustrated in FIGS. 3G, 3 H, and 3 I are then repeated for each new data sample.
FIG. 4 is a block diagram of a DSP-optimized processor 40 connected to an FIR-filter accelerator 41 that performs the method of FIGS. 3A-3I to produce a filtered output D F in a single clock cycle. Accelerator 41 is a hardware implementation of the flowcharts of FIGS. 3A-3I, like-numbered elements being the same. In addition to the registers depicted in FIGS. 3A-3I, accelerator 41 includes:
1. three coefficient shift registers 42 1 through 42 3 , which contain respective weighting coefficients C 1 through C 3 ;
2. a multiplier 44 that sequentially performs the multiplications represented as weighting-coefficient multipliers 32 1 through 32 3 in FIGS. 3A-3I;
3. an adder 46 (or ALU) that sequentially performs the summations represented by data-sample adders 33 1 and 33 2 in FIGS. 3A-3I;
4. a multiplexer 48 for selecting one or the other of the contents of partial-result registers 34 2 and 34 3 ; and
5. a de-multiplexer 49 for storing the output from adder 46 in a selected one of partial-result registers 34 2 and 34 3 .
Processor 40 presents each new input data sample D x to multiplier 44 via input register 31 . Multiplier 44 then multiplies data sample D x by each of the plurality of weighting coefficients C 1 through C 3 . This is accomplished sequentially by successively shifting weighting coefficients C 3 through C 1 through coefficient shift registers 42 3 through 42 1 to present each, in turn, to multiplier 44 .
As products are made available to adder 46 , adder 46 :
1. adds the first data-sample product, D x C 3 , to the output of partial-result register 34 2 and stores the result in output register 34 1 ;
2. adds the second data-sample product, D x C 2 , to the output of partial-result register 34 3 and stores the result in partial-result register 34 2 ;
3. directs the last data-sample product, D x C 1 , to partial-result register 34 3 ; and
4. pauses, awaiting the next input data sample D (x+1) .
Output register 34 1 contains filtered result D F as soon as the foregoing step one is accomplished; steps two through four can then be accomplished during successive clock cycles while accelerator 41 awaits the next input data sample from processor 40 . Thus, processor 40 can retrieve the result and continue executing instructions with a minimum of delay. Further, this delay does not depend upon the number of input data samples used to calculate the filtered result.
FIG. 5 is a flowchart 50 depicting the operation of a filter accelerator in accordance with an embodiment of the invention. Flowchart 50 is similar to the flowcharts of FIGS. 3A-3I, like-numbered elements being the same; however, where the flowcharts of FIGS. 3A-3I represent a method that accommodates three consecutive input data samples, flowchart 50 represents a method that accommodates N consecutive input data samples. In every case, the filtered result is made available one clock cycle after the data sample of interest is latched into input register 31 . While there is no particular limit to the number of consecutive data samples used in the filter calculation, if the number is too great, the accelerator will not be able to update each partial-result register before receiving the next data sample.
FIG. 6 is a block diagram of a portion of a datapath 60 in a DSP-optimized processor connected to accelerator 41 of FIG. 4 . In this configuration, accelerator 41 speeds the operation of datapath 60 in implementing a four-tap FIR filter.
Datapath 60 includes a multiplier 61 , a pair of multiplexers 62 and 63 , an adder 66 , and an output register 68 . Multiplexers 62 and 63 route data and coefficients around multiplier 61 during processes that do not use accelerator 41 .
To make use of accelerator 41 to filter a sequence of data samples, datapath 60 routes each new input-data sample D 4 to multiplier 61 and to accelerator 41 . Multiplier 61 multiplies input-data sample D 4 by a weighting-coefficient C 4 and presents the resulting product, D 4 C 4 , to adder 66 via multiplexer 62 . Then, before output register 34 1 of accelerator 41 (now a partial-result register) is updated with new results based upon new input-data sample D 4 , adder 66 adds the contents of output register 34 1 (FIG. 4) to the output of multiplier 61 . The resulting sum (D 4 C 4 +D 3 C 3 +D 2 C 2 +D 1 C 1 ) is then shifted into output register 68 and presented at the output of datapath 60 . The partial results in registers 34 2 and 34 3 (FIGS. 3A-3I and 4 ) of accelerator 41 are then updated using data sample D 4 . Datapath 60 is free to perform some other useful work as accelerator 41 updates partial-result registers 34 2 and 34 3 in anticipation of a subsequent data sample.
The combination of datapath 60 and accelerator 41 provides filtered result D F based on data samples D 1 through D 4 in the time required for multiplier 61 and adder 66 to perform a single multiply/accumulate operation. Datapath 60 is therefore able to produce a filtered result based on four data samples in a single machine cycle. Moreover, accelerator 41 can be extended to handle more than three input samples, as shown in FIG. 5, for example.
Because FIR accelerator 41 prepares partial results between data samples, speed and latency differences between datapath 60 and accelerator 41 are of little consequence; therefore, accelerator 41 can have a slower clock speed than datapath 60 , and consequently can be designed to minimize cost. The filter accelerator can improve the performance of the DSP even if the accelerator is slow relative to the DSP. Thus, accelerator 41 can be implemented in hardware or software using any number of technologies, including programmable logic devices and application-specific integrated circuits. Moreover, the reduced speed sensitivity of the accelerator allows the accelerator to be produced inexpensively by exploiting proven, mass-produced, economical technologies and materials. In another embodiment, accelerator 41 can be time-shared among multiple DSPs, thereby providing additional savings in size, cost, and complexity.
FIGS. 7A-7I are flowcharts depicting the operation of a filter accelerator in accordance with another embodiment of the invention. The depicted accelerator includes three taps for simplicity, but can be adapted for use with more or fewer taps. As in previous examples, the subscript of a given data sample D N indicates the relative age of the data sample, the lower the subscript number the older the sample. The filter accelerator conventionally produces a filtered data sample D F by multiplying three consecutive data samples by three respective weighting coefficients C 1 , C 2 , and C 3 . The filter accelerator presents filtered data D F in just one clock cycle using a single multiplier.
Each flowchart in FIGS. 7A-7I depicts the operation of the filter accelerator during a single clock cycle. Referring first to FIG. 7A, a first input data sample D 1 is stored in a data input register 70 . Register 70 presents data sample D 1 to a weighting-coefficient multiplier 72 . Weighting-coefficient multiplier 72 is a single multiplier depicted as including three separate multipliers 72 1 through 72 3 to illustrate that multiplier 72 performs three separate multiplications—one per clock cycle—for each input data sample. Multipliers 72 1 , 72 2 , and 72 3 respectively symbolize the first, second, and third multiplications.
During the first clock cycle, multiplier 72 multiplies data sample D 1 by a weighting coefficient C 3 using multiplier 72 1 . (In each of FIGS. 7A-7L, the active multiplication is highlighted using a multiplier symbol 72 X having a solid boundary, whereas the inactive multiplications are contrasted using multiplier symbols 72 X with broken boundaries.) Multiplier 72 1 provides a data-sample product D 1 C 3 to an adder 73 1 . This adder adds data-sample product D 1 C 3 with the contents of a partial-result register 74 2 and stores the filtered result D F in sum-of-products register 74 1 , the output register of the filter accelerator. The depicted accelerator has three taps, and so when started requires three data samples before producing the first filtered output. Data sample D 1 is assumed to be the first data sample, so the filtered output D F is incomplete.
During the second clock cycle (FIG. 7 B), multiplier 72 multiplies data sample D 1 by a second weighting coefficient C 2 and stores the product D 1 C 2 in a partial-result register 74 2 . In the third clock cycle (FIG. 7 C), multiplier 72 multiplies the contents of a data register 71 by a third weighting coefficient C 1 . In the example, data sample D 1 is the first data sample. Consequently, register 71 is empty before receipt of sample D 2 , the second data sample. The resulting product from multiplier 72 3 is therefore 0(C 1 ), or zero. An adder 73 2 adds this zero to the contents of register 74 2 and stores the resulting sum back in register 74 2 . The sum initially stored in register 74 2 is therefore D 1 C 2 +0(C 1 ), or D 1 C 2 . Adders 73 1 and 73 2 are depicted as separate for illustrative purposes, but can be implemented using a single adder.
FIGS. 7D, 7 E, and 7 F illustrate the receipt and processing of a second input data sample D 2 . The previous data sample D 1 shifts into register 71 as data sample D 2 shifts into register 70 . Multiplier 72 1 then multiplies data sample D 2 by coefficient C 3 during the first clock cycle following the receipt of sample D 2 . Adder 73 1 adds the resulting data-sample product D 2 C 3 to the contents of register 74 2 obtained during the processing of the previous data sample D 1 . The resulting sum of products is stored as a filtered result D F in register 74 1 . The filtered result is still incomplete, as the three-tap filter requires three input data samples upon which to base a correct result.
During the second clock cycle (FIG. 7 E), multiplier 72 2 multiplies data sample D 2 by coefficient C 2 . Adder 73 2 stores the resulting product D 2 C 2 in partial-result register 74 2 . In the third clock cycle (FIG. 7 F), multiplier 72 3 multiplies data sample D 1 by coefficient C 1 , and adder 73 2 sums the resulting product D 1 C 1 with the product D 2 C 2 in partial-result register 74 2 . The resulting sum of products (D 1 C 1 +D 2 C 2 ) is stored in partial-result register 74 2 .
FIGS. 7G, 7 H, and 7 I illustrate the receipt of a third input data sample D 3 . The third data sample D 3 is the first for which the three-tap filter has enough data to produce a correct filtered result. During the first clock cycle after receipt of the third sample D 3 , multiplier 72 1 multiplies data sample D 3 by coefficient C 3 . Adder 73 1 adds the resulting data-sample product D 3 C 3 to the contents of register 74 2 (D 2 C 2 +D 1 C 1 ) obtained during the processing of the previous data samples D 1 and D 2 . The resulting sum of products is stored as a filtered result D F in register 74 1 . Importantly, the filtered result D F =D 1 C 1 +D 2 C 2 +D 3 C 3 is the first correct filtered result produced from the input data samples, and is available after only one clock cycle from receipt of data sample D 3 . As shown in FIGS. 7H and 7I, register 74 2 is then updated using data samples D 2 and D 3 during the second and third clock cycles in the manner described above in connection with FIGS. 7A-7F. The method of FIGS. 7A-7I thus produces a filtered result before the partial-results in registers 74 2 and 74 3 are updated. The steps illustrated in FIG. 7G, 7 H, and 7 I are then repeated for each new data sample.
In typical filters, the receipt of a new data sample triggers the calculation of a filtered result. In contrast, each of the filters and filter accelerators in accordance with the invention begin calculating the filtered result of the next data sample before the next sample arrives. This advance preparation saves valuable processing time.
As mentioned previously, the accelerator depicted in FIGS. 7A-7I includes three taps for simplicity, but can be adapted for use with more or fewer taps. For example, each additional tap can employ an additional register connected in series with register 71 and a multiplier 72 N connected between the output of the additional register and an input of adder 73 2 .
While the present invention has been described in connection with specific embodiments, variations of these embodiments will be obvious to those of ordinary skill in the art. For example, application of the invention is not limited to FIR filters, but may be extended for use with any signal-processing algorithm that depends upon a single final data point to produce a processed result. Therefore, the spirit and scope of the appended claims should not be limited to the foregoing description.
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A method and apparatus to accelerate the evaluation of complex, computationally intense digital signal processing algorithms is disclosed. In one embodiment, a filter accelerator is connected in parallel with a conventional digital signal processor (DSP). The accelerator enhances the speed at which the DSP performs some filtering operations by calculating and maintaining a number of partial results based on a selected number of prior data samples. Each time the DSP receives a new data sample for filtering, the DSP makes use of one or more partial results from the accelerator to speed the calculation of the filtered result. Receipt of the new data sample causes the accelerator to recalculate the partial results, this time using the new data sample. The accelerator thus prepares for receipt of the subsequent data sample, freeing the DSP to perform other operations.
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TECHNICAL FIELD OF THE INVENTION
The present invention relates to novel, improved methods and systems for so damping impact-generated vibrations as to keep those vibrations from discomforting or paining the wielder of an implement in which the vibration originated.
DEFINITION
The term "implement" as employed herein is intended to encompass wielded devices designed to impart and receive impacts including but not limited to: golf clubs, baseball and softball bats, tennis rackets, and hammers.
BACKGROUND OF THE INVENTION
It is common for the vibrations set up in an implement by impact to sting the wielder's hands. This stinging can lead to flinching, an altered grip, and other phenomena which adversely affect a player's performance.
The vibrations can also cause serious injury. For example, the stiff graphite and other high tech handles of modern tennis rackets vibrate at high frequencies, and the result is a higher incidence of debilitating tennis elbow.
Others have attempted to solve the problems attributable to impact-generated vibrations with vibration dampers in or attached to the handle of an implement, see U.S. Pat. No. 3,941,380 issued Mar. 2, 1976 to Lacoste. One drawback of this prior art approach is that the feel of the implement upon impact is deader. This dead feel adversely affects the wielder's performance. Another drawback of this prior art approach to offsetting the effect of impact-generated vibrations is that they act too slowly, and the damage is done before the impact is damped.
SUMMARY OF THE INVENTION
There have now been invented and disclosed herein certain new and novel vibration damping systems which have the advantage over those heretofore proposed that they act almost instantaneously and therefore effectively keep unwanted vibrations from being transmitted to the hands of an implement wielder. Instead the energy is advantageously imparted to the object struck by the implement. At the same time, the modus operandi of these novel systems is such that the wielder is unaware of any adverse change in the feel of the implement upon impact.
The novel vibration damping systems of the present invention are fabricated from a soft viscoelastic polymer and have a mushroom-like configuration provided by a head and an integral stem. The vibration damper is attached to or installed in the handle of an implement which can advantageously be subjected to vibration damping. The head and stem of the system are so configured and dimensioned that: (1) the stem can vibrate or oscillate generally normal to the longitudinal axis of the implement handle in any radial direction, and (2) peripheral portions of the damper head can oscillate in directions generally parallel to that axis at any location around the circumference of the damper head.
Vibration dampers employing the principles of the present invention have the advantage that harmful vibrations are damped by the dissipation of energy before they can be transmitted to the wielder of the implement. This is particularly important when the impact occurs off center or otherwise outside of the sweet spot of the implement as it is impacts in those locations that typically generate the most detrimental vibrations. Or, from another viewpoint, the damping devices disclosed herein have the important advantage that they in effect significantly increase the sweet spot areas of the implements to which they are attached.
The novel vibration damping devices disclosed herein also have the advantage that they effect to only a minimal extent the natural resonance frequencies of the implements with which they are employed. This is important. The dead and other strange, performance affecting feels attributable to the use of damping devices which do have a significant effect on natural resonance frequencies--for example, those disclosed in the above-cited U.S. Pat. No. 3,941,380--are avoided.
Another important advantage of the novel dampers disclosed herein is that they are light and small enough that, even if exposed, they do not interfere with the swing of the implements with which they are associated. The damping devices are simple and relatively easy and inexpensive to manufacture. The devices also have the advantage of being versatile in that they can be used to advantage to dampen deleterious vibrations set up in a wide variety of implements.
The objects, features, and advantages of the invention will be apparent to the reader from the foregoing and the appended claims and as the ensuing detailed description and discussion of the invention proceeds in conjunction with the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of an energy dissipating, vibration damping device constructed in accord with and embodying the principles of the present invention;
FIG. 2 is a section through the handle end of a wooden bat equipped with an energy dissipating device as illustrated in FIG. 1;
FIG. 3 is an exploded section through the handle end of a hollow bat equipped with a second form of energy dissipating device embodying the principles of the present invention;
FIG. 4 is a section through the handle end of a hollow bat equipped with a third form of energy dissipating device embodying the principles of the present invention;
FIG. 5 is a view of the butt end of a tennis racket equipped with an energy dissipating device embodying the principles of the present invention;
FIG. 6 and 7 are sections through the butt ends of tennis rackets equipped with two other forms of energy dissipating devices employing the principles of the present invention;
FIG. 8 is a section through the grip end of a golf club equipped with an energy dissipating device embodying the principles of the invention;
FIG. 9 is a view showing the movements made by a device as depicted in FIG. 1 in the course of dissipating energy imparted to a bat equipped with the device;
FIG. 10 is a graph showing the decay of vibrations set up in a conventional, wooden bat by an impact on the bat;
FIG. 11 is a graph of the character presented as FIG. 10 showing the significant and unexpectedly faster rate-of-decay of the impact-generated vibrations set up in a wooden bat equipped with an accessory embodying the principles of the present invention;
FIG. 12 is a graph showing the decay of vibrations set up in a conventional, hollow aluminum bat by an impact on the bat;
FIG. 13 is a graph of the character presented as FIG. 10 showing the significant and unexpectedly faster rate-of-decay of the impact-generated vibrations set up in a hollow aluminum bat equipped with an accessory embodying the principles of the present invention;
FIG. 14 is a graph showing the decay of vibrations set up in a conventional tennis racket with a graphite handle by an impact on the racket;
FIG. 15 is a graph of the character presented as FIG. 10 showing the decay of vibrations set up by an impact on a racket of the same type but equipped with a prior art damping device; and
FIG. 16 is a graph like those presented in FIGS. 14 and 15 but showing the significant and unexpectedly faster rate-of-decay of the vibrations set up in a like tennis racket equipped with a vibration damping accessory embodying the principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1 depicts a vibration damping device 20 embodying the principles of the present invention; and FIG. 2 depicts a solid, wooden bat 22 of the type used in baseball and softball. This bat is equipped with vibration damping device 20. In this embodiment of the invention, vibration damping device 20 is attached to the exposed end 24 of the bat handle 26 with an appropriate adhesive 28 such as Super Glue or Adcam 728.
Vibration damping device 20 has a mushroom-like configuration and a T-like cross-section defined by a cylindrical head 30 with an annular, depending, peripheral lip 31 and an integral, also cylindrical stem 32. Vibration damping device 20 is assembled to bat handle 26 with the exposed end 34 of stem 32 adjacent and bonded to the exposed end 24 of bat handle 26. The longitudinal centerline 36 of the vibration damping device is coincident with the longitudinal axis 38 of bat 22. Vibration damping device stem 32 consequently extends in the same direction as the bat, and head 30 is oriented normally to longitudinal centerline 36 of the bat.
Vibration damping device 20 is fabricated from a soft, viscoelastic material; i.e., a viscoelastic material with a Shore A hardness in the range of 3 to 20. The preferred elastomer is NAVCOM, a soft, amphorous, rubberlike viscoelastic material available from Vibration Technology Incorporated, Redmond, Wash. NAVCOM contains a mixture of chloroprene and butyl polymers and has the following physical properties:
______________________________________Shore A hardness: 17-90 Com- Ultimate Tensile pressionEnvi- Shore Elongation, Strength Set Specificronment A (Percent) (PSI) (Percent) Gravity______________________________________ 7 1,075 373 6.01 1.014 12 900 643 7.3 1.025 20 835 1,069 6.9 1.063 30 1,056 1,621 4.0 1.074 40 326 1,453 N/A 1.185 90 175 2,440 N/A 1.379Oven aged 7 N/A N/A 56.3 --for 12 -- -- 31.1 --70 hrs at 20 -- -- 30.8 --212 ± 5° F. 40 -- -- 22.4 -- 90 -- -- 18.6 --______________________________________
______________________________________Resilience: At room temperature - Medium At high temperature - Fairly highHeat-resistance GoodOutdoor aging resistance: ExcellentLow temp flexibility: GoodAbrasion resistance: GoodFlex life: GoodSolvent resistance:Hydrocarbons - Fair to goodOxygenated - Fair to goodAir permeability: Low to moderateMoisture resistance: FairUseful operating -40° to 250° F.temperature:______________________________________
Also important is the ratio between the diameter d of vibration damping device head 30 and the length 1 of the relatively short stem 32. For vibration damping device to function effectively, it is essential that the ratio d:1 be between 5:1 and 1:1.
The illustrated, exemplary vibration damping device 20 is fabricated from the preferred NAVCOM material and has: a head 30 which is 1.6 inch in diameter and 0.25 inch thick, a stem 32 which is 0.178 inch long and 0.5 inch in diameter, and a weight of 4 grams.
The fabricating of vibration damping device 20 from a viscoelastic material with a hardness and the relative proportions specified above produces a device which effectively and rapidly dampens vibrations when bat 22 strikes a ball, particularly if the ball is not struck on the "sweet spot" of the bat and the familiar, stinging sensation is consequently felt. The vibration damping effect is attributable to the dissipation of the energy imparted to bat 22 upon impact by the novel pattern of vibrations thereupon set up in vibration damping device 20 (see FIG. 9).
The stem 32 of vibration damping device 20 can vibrate in directions generally normal to longitudinal axes 36/38 as shown by arrows 40 in any and all directions around the circumference of the stem. At the same time, the peripheral edge portion 42 of vibration damping device stem 30 can vibrate around the circumference of the head in directions generally paralleling axes 36/38 as indicated by arrows 44. This pattern of oscillatory movement is uniquely different from that of prior art vibration dampers such as the pendulum-like devices disclosed in the in the '380 patent and significantly contributes to the superiority of the novel vibration devices of the present invention.
The effectiveness of vibration damping device 20 was confirmed in tests in which bat 22 was suspended and then impacted. Vibrations were detected with a piezoelectric pickup which had a mass of less than two grams and therefore had a negligible effect on the vibrations set up in bat 22. The data acquired by the piezoelectric pickup was processed through a DSP 16 data acquisition system comprising a digital spectrum analyzer and an oscilloscope and employing modified hypersignal software.
FIG. 10 shows that large magnitude vibrations persisted in the undamped bat 22 for a period of 100 milliseconds or longer and that vibrations of significant magnitude were still present after a period of 500 milliseconds. In contrast, the large magnitude vibrations in the bat equipped with vibration damping device 22 were gone after a period of 10 milliseconds, and vibrations of the magnitude remaining in the undamped bat after the 100 millisecond test period had disappeared after approximately 25 milliseconds.
The damping of the large magnitude vibrations in the confirmed 10 millisecond time period is significant. This eliminates the stinging and other unpleasant sensations felt by the user, especially if bat 22 meets a ball outside of the bat's sweet spot. The result is the elimination or at least drastic reduction of the fatigue, flinching, and other movements which make the batter less effective; and of the possibility of injury is minimized. From another viewpoint, vibration damping device 20 has the advantage that it significantly and advantageously increases the area of the bat's sweet spot, again contributing to batting efficiency.
As pointed out above, an unlimited variety of devices or implements subjected to impact may advantageously be equipped with vibration damping devices employing the principles of the present invention. One of these is of course the wooden bat 22 just discussed.
Another is the widely used, typically aluminum, hollow bat employed in softball and baseball. FIG. 3 depicts a bat 50 of that character as equipped with a device 52 embodying the principles of the present invention for damping vibrations set up by an impact upon bat 50. The bat shown in FIG. 3 has a hollow handle 54, and vibration damping device 52 is installed in the cavity 56 at the exposed end 57 of the handle.
Vibration damping device 52 is much like the device 20 of the same character discussed above. It is fabricated of a soft, viscoelastic material such as a NAVCOM; and it has a head 58 and stem 59 with a d:1 ratio in the range specified above.
In this embodiment of the invention, a fitting 60 is installed in the hollow handle 54 of bat 50; and vibration damping device 52 is fixed to that fitting as by the illustrated screw 61.
Fitting 60 has a trapezoidal section. That section is defined by: (a) a side wall 62 with dimensions and a configuration complementing those of bat handle 54; and (b) a flat, laterally extending, integral support 63 with a centrally located, drilled and tapped, through bore 64. Typically, fitting 60 is press fitted into bat handle 54 and retained in place by friction or dimensioned so that the insert can be retained in place by an appropriate adhesive or in any other suitable manner.
Vibration damping device 52 is installed in the handle end cavity 56 with: (a) the exposed end 66 of stem 59 seated on the laterally extending component 63 of fitting 60, and (b) a central bore 68 through vibration damping device 52 aligned with the threaded aperture 64 in fitting 60. Screw 61 is then displaced through a central opening 70 in a washerlike reinforcement 72 toward the exposed end 66 of vibration damping device stem 59 and threaded through the aperture 64 in fitting 60 to secure vibration damping device 52 in place.
The assembly is completed by attaching a cover 74 to the handle 54 of bat 50 to cover the opening 76 in the exposed end 57 of the bat handle. Threads, an adhesive, friction, or any other appropriate approach may be employed to hold cap 74 in place.
The results of hollow bat time analyses conducted as described above are shown graphically in FIGS. 12 and 13. Larger magnitude vibrations were damped in less than 12 milliseconds in the bat as equipped with the device 52 shown in FIG. 3 whereas they persisted for over three times that long in the undamped bat. Vibrations of significant magnitude persisted over the 100-millisecond duration of the test in the undamped bat but for less than 40 milliseconds in the damper-equipped bat 50. Again, therefore, vibration damping in accord with the principles of the present invention would minimize, if not entirely eliminate, stinging and other unpleasant sensations; reduce fatigue and prevent injury; and make batters more effective by de facto increasing the sweet spot of the bat.
An alternative vibration damper for hollow implements such as softball and baseball bats is depicted in FIG. 4 and identified by reference character 80. In this embodiment of the invention, the vibration damping device 80 is configured and dimensioned like the vibration damping device 52 shown in FIG. 3 but without the central aperture formed in the latter. The vibration damping device is bonded with an appropriate adhesive or in any other suitable manner to a spade-sectioned fitting 82. This fitting has a longitudinally extending stem 84 of essentially the same diameter as vibration damping device stem 59, and it is the exposed ends 66 and 86 of the two stems 59 and 84 which are bonded together.
Fitting 82 also has an integral, main body element 88 of circular configuration with a tapered, conical nose section 90. Nose section 90 facilitates the movement of the assembled vibration damper 80 and fitting 82 in the direction indicated by arrow 92 in FIG. 4 to install the vibration damper in the depicted location in the hollow handle 54 of bat 50. Otherwise, fitting 82 has an integral segment 93 which, like side wall 62 of the FIG. 3 fitting 60, is dimensioned and configured for retention in bat handle 54 by friction or an adhesive or in any other desired manner.
Fitting 82 will typically be made of a harder material than vibration damping device 80 so that the latter will vibrate in the patterns discussed above and shown in FIG. 9.
As in the FIG. 3 application of the invention, the opening 76 in the exposed end 57 of bat handle 54 is covered by a cap 74 after the assembly of vibration damping device 80 and fitting 82 is press fitted or otherwise installed in the bat handle.
Referring still to the drawing, FIG. 5 depicts a tennis racket 100 with a handle 102 having an exposed end portion 104 surrounded by a conventional cup-like grip 106 typically fabricated from polyurethane. A vibration damping device of the character discussed above and illustrated in FIG. 2 and identified by the same reference character 20 is adhesively bonded or otherwise fixed to the end surface 108 of grip 106. Device 20 is provided to dampen vibrations set up in handle 102 when racket 100 strikes a tennis ball.
FIGS. 14, 15, and 16 show, in graphical form, the results of time analyses of a graphite racket with: (a) no damping device (FIG. 14); (b) a damping device as disclosed in above-discussed U.S. Pat. No. 3,941,380; and (c) damping device 20 adhesively bonded to the exposed end surface 108 of the racket. Both devices proved to have vibration damping capabilities (compare FIGS. 15 and 16 with FIG. 14). However, a comparison of FIGS. 14, 15, and 16 makes it apparent that the damping device 20 employing the principles of the present invention damped large amplitude vibrations in almost one-third of the time required for the prior art damping device to be effective with these large magnitude vibrations being damped in less than 8 milliseconds. This translates directly into major improvements into terms of: elimination of stinging and other unpleasant sensations as well as fatigue, in the prevention of injury, and in improved performance by virtue of the de facto increase in the size of the tennis racket's sweet spot.
FIG. 6 depicts yet another specie of the present invention in which impact-attributable vibrations set up in the handle 120 of a tennis racket 122 are damped with a device embodying the principles of the present invention. The particular damping device utilized in this application of the invention generally duplicates the damping device 52 depicted in FIG. 3.
A longitudinal extending cavity 124 opens onto the exposed end surface 126 of tennis racket handle 120. Vibration damping device 52 is installed in cavity 124 with the exposed end 66 of the damping device stem 59 firmly contacting racket handle 120 at the inner end 128 of the cavity.
In this application of the invention, the screw 61 of the damping device is a conventional wood screw. It is threaded into handle 120 to hold the damping device in place against the tennis racket handle. A grip 106 like that illustrated in FIG. 5 is then installed on the exposed handle end 126 to cover the open end 130 of the damping device-receiving recess 124 and thereby complete the assembly process.
Another, albeit possibly less efficient, arrangement for damping impact-generated vibrations set up in the handle 120 of tennis racket 120 and employing a vibration damper 20 as depicted in FIGS. 1 and 2 is illustrated in FIG. 7. In this case, the vibration damping device is fixed by the illustrated band of adhesive 140 to a relatively rigid, cup-shaped damping device support/grip 144.
Grip 144 is typically fabricated from a material such as vinyl. It has a side wall segment 146 which surrounds the free or exposed end segment 148 of racket handle 120. It also has an integral, laterally extending segment 150 which spans the open end 130 of cavity 124 and has a central pedestal 152. As shown in FIG. 7, adhesive 140 fastens the exposed end 34 of vibration damping device stem 32 to pedestal 152 with the head 30 of the vibration damping device facing the inner end 128 of cavity 124.
Referring now to FIGS. 4, 6, and 7, it is important that there be a clearance gap 153 (FIG. 4), 154 (FIG. 6), or 155 (FIG. 7) between the periphery 156 (FIG. 4), 157 (FIG. 6), or 158 (FIG. 7) of the vibration damping device head 58 or 30 and the side 159 or 160 of the cavity 56 or 124 in which the vibration damping device is installed. It is also essential that this gap extend around the entire circumference of the damping device head. This is required so that the stem of the involved damping device can oscillate or move in the arrow 40 directions (see FIG. 9) and so that the marginal portions of the damping device heads can oscillate in the arrow 44 directions. Both patterns of movement are required for the damping devices to function effectively.
The golf club 170 depicted in FIG. 8 is another implement which can advantageously be equipped with a device employing the principles of the present invention to rapidly dampen large magnitude vibrations with the significant and advantageous results discussed above. Golf club 170 has a conventional, hollow handle 172. The vibration damping device installed in this handle at its exposed or free end 174 is identified by reference character 176. Other major components of the vibration damper-equipped golf club 170 include a conventional grip 178, a grip support 180 which also surrounds and houses vibration damping device 176, and an internally threaded cap or cover 182 at the exposed end 184 of the grip support.
The vibration damper 176 illustrated in FIG. 8 resembles the vibration damper/support assembly 80/82 depicted in FIG. 4. It has: (a) a handle gripping damper support 186 with a tapered or pointed, installation-facilitating nose 188; and (b) an integral damper 190 of mushroom-like configuration. The damper part of the device has a circular head 192 and a stem 194. In the illustrated embodiment of the invention, stem 194 replaces the two separate stems 59 and 84 of the damper/support system shown in FIG. 4.
The integral damper component 190 also has a second, stem 196 longitudinally aligned with stem 194. Stem 196 is capped by a second, laterally extending, circular head 198 disposed in spaced, parallel relationship to head 192. Stems 194 and 196 are both dimensioned and configured for oscillation in the arrow 40 directions (see FIG. 9). Vibration damper heads 192 and 198 are dimensioned and configured for oscillation in the arrow 44 directions. This provision of multiple, oscillatable heads and stems makes vibration damper component 190 particularly efficient and effective.
Vibration damper device 176 is assembled to the hollow shaft 172 of golf club 170 by displacing it in the arrow 200 direction. This displacement is continued until support component 186 is seated in the bore 202 through shaft 172 in longitudinally spaced relationship to the exposed end 174 of the shaft with the heads 192 and 198 of the vibration damper component 190 located beyond that shaft end. As discussed in conjunction with the FIG. 4 embodiment of the invention, friction, an adhesive, or any other appropriate mechanism can be employed to retain support component 186 in place.
The assembling of the vibration damper device 176 to the hollow golf club shaft 172 is followed by the installation of grip support 180. This component, which is fabricated of a relatively stiff material such as sheet steel or nylong, has a necked down segment 206 configured and dimensioned to complement the inner surface 208 of the bore 202 through golf club shaft 172. Grip support 180 also has: (a) an integral, laterally extending flange segment 212 which abuts the outer end 174 of golf club shaft 172; and (b) a second, also longitudinally extending and integral, damper housing segment 214 which protrudes beyond the exposed end 174 of the golf club shaft. Integral segment 214 has an outer diameter matching that of the golf club shaft 172, the outer surface 216 of segment 214 consequently constituting an extension of the outer surface 218 of the shaft. This like diameter extension of hollow shaft 172 afforded by the segment 214 of grip support 180 allows grip 178 to transition smoothly from the shaft to the grip support, making the grip "feel right" to the golfer.
As in the FIGS. 4, 6, and 7 embodiments of the invention, an annular gap 220 is provided between the peripheries 222 and 224 of damping device heads 192 and 198 and the inner, cylindrical surface 226 of support segment 214. This accommodates the FIG. 9 depicted patterns of oscillation of the heads and damping component stems 194 and 196.
The assembly process is completed by the installation of cover 182 over the exposed, open end 228 of grip support segment 214. The illustrated, exemplary cover 182 has a laterally extending, domed segment 230 and an internally threaded, cylindrical side wall segment 232. Cover 182 is screwed onto the externally threaded, free end segment 234 of grip support segment 214 until the exposed end 236 of cover side wall 232 reaches the exposed end 238 of grip 178 and the domed segment 230 of the cap is seated on the exposed end 184 of the grip support segment 214.
The invention may be embodied in many forms without departing from the spirit or essential characteristics of the invention. For example, devices with even more than two stems and heads can be employed; and it is not necessary that the device be located at the end of the implement handle. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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Small, effective, lightweight, vibration damping devices for implements which are subject to impact. These devices have a head and a stem and are fabricated from a soft elastomeric material. The stem is capable of oscillating over a 360° span in directions generally normal to the longitudinal axis of the device. The peripheral part of the head can oscillate around its circumference in directions generally paralleling that axis.
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BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The present invention pertains to a lubricant retention assembly employed with an electric motor that has a self-contained lubricant reservoir. More specifically, the present invention pertains to a thrust collar mounted on the motor shaft and a bearing cap surrounding the thrust collar, where the thrust collar has an annular flange that throws lubricant leaking along the shaft radially outwardly toward the bearing cap and the bearing cap has an angled interior surface that deflects the lubricant thrown by the annular flange into the motor interior and toward the lubricant reservoir. In addition, a thrust washer is provided on the shaft adjacent the thrust collar for preventing lubricant leakage along the shaft between the interface of the shaft and thrust collar. The thrust washer and thrust collar have complementary configurations that maintain the thrust washer in position on the shaft adjacent the thrust collar.
[0003] (2) Description of the Related Art
[0004] In most motor constructions having rotating drive shafts, proper lubrication of the drive shaft and the bearing surfaces or bearing assemblies supporting the shaft is essential for insuring a prolonged operating life and quiet operation of the motor. Some larger motors are constructed with their own lubrication circuits where a pump pumps lubricant from a reservoir to the shaft bearing assemblies and the lubricant is then directed back to the reservoir. The internal combustion motors of automobiles are examples of these types of motors. Any lubricant lost from the motor over time due to leakage past the bearing assemblies supporting the motor shaft can be replenished by supplying additional lubricant to the motor reservoir from a separate source. Because the lubricant can be replenished with periodic maintenance of the motor, the occasional loss of lubricant or loss of lubricant over time does not significantly detract from the operating life of the motor.
[0005] However, this is not the case with smaller motors, for example electric motors used in electric household appliances like dishwashers, clothes washers and clothes dryers. These types of motors are contained in the enclosures of the appliance and are inaccessible for replenishing lubricant lost due to leakage. The lubrication reservoir of these types of motors is self-contained and cannot be replenished. The motor shafts for small motor constructions are usually not supported for rotation by ball bearing or roller bearing assemblies, but by sleeve bearings or porous sintered metal bearings where bearing surfaces support the shafts for rotation. Loss of lubricant from these types of motors can cause the bearings to fail and can have serious consequences on the motor's operational life.
[0006] One of the major causes for sleeve bearing failures is loss of oil out of the bearing/lubrication system. An example of a conventional bearing/lubrication system in appliance motor designs is shown in FIG. 1. The system shown in FIG. 1 is known in the prior art, and therefore only a partial view of the motor is shown.
[0007] [0007]FIG. 1 shows a porous powdered metal or babbitt metal type bearing ( 10 ) supporting the motor shaft ( 12 ) for rotation in an end shield ( 14 ) of the motor. The center axis A-A of the shaft ( 12 ) defines mutually perpendicular axial and radial directions. A cooling fan ( 16 ) is shown mounted on the shaft ( 12 ) to the right of the bearing assembly shown in FIG. 1. The interior of the motor is to the right of the end shield in FIG. 1. The shaft ( 12 ) extends through a cylindrical collar ( 18 ) of the motor end shield that surrounds the end shield shaft opening ( 20 ). The bearing ( 10 ) is held in the shaft opening ( 20 ) by its engagement with bearing seat surfaces ( 22 ) of the end shield on one side of the bearing and a bearing retainer ( 24 ) on the opposite side of the bearing. The typical bearing retainer ( 24 ) is constructed as a stamped metal disc ( 26 ) with a peripheral rim ( 28 ) that is press-fit into the end shield collar ( 18 ). A plurality of resilient fingers ( 30 ) project radially inwardly from the disk ( 26 ) and engage against the bearing ( 10 ) and hold the bearing to the bearing seat surfaces ( 22 ).
[0008] The typical bearing lubricant feeding and return system comprises a lubricating oil, felt or other fibrous material ( 32 ) injected with the oil, a thrust collar/oil slinger ( 34 ) and a bearing cap ( 36 ).
[0009] As seen in FIG. 1, the thrust collar/oil slinger ( 34 ) is mounted in a press-fit engagement on the shaft ( 12 ). A rubber washer ( 38 ) and a metal washer ( 40 ) are positioned between the collar ( 34 ) and the bearing ( 10 ). The engagement of the rubber washer ( 38 ) around the shaft provides a seal around the shaft surface that minimizes oil from leaking out of the motor interior along the interface between the shaft and the interior bore of the thrust collar ( 34 ). The metal washer ( 40 ) provides a sliding surface between the rubber washer ( 38 ) and the bearing ( 10 ) that prevents wear of the rubber washer on rotation of the shaft.
[0010] The bearing cap ( 36 ) is typically stamped from sheet metal and is formed with a resilient annular outer wall ( 42 ) that is press-fit into the end shield collar ( 18 ) surrounding the shaft opening ( 20 ). A cylindrical side wall ( 44 ) extends axially from the bearing cap outer wall ( 42 ) to a circular end wall ( 46 ) of the bearing cap. The bearing cap end wall ( 46 ) extends radially inwardly from the bearing cap side wall ( 44 ) toward the motor shaft ( 12 ) and terminates at an axially inwardly projecting lip ( 48 ) of the cap. The cap lip ( 48 ) is spaced radially outwardly from the fan ( 16 ) and shaft ( 12 ) leaving a clearance area ( 50 ) between the cap lip ( 48 ) and the fan ( 16 ) and shaft ( 12 ).
[0011] The area axially between the bearing retainer disk ( 26 ) and the bearing cap end wall ( 46 ) and radially outside the dashed line B-B shown in FIG. 1 is typically occupied by the lubricant-permeated fibrous material. This material is not shown in FIG. 1 to avoid obscuring other component parts of the bearing lubrication system.
[0012] In the intended operation of the prior art bearing lubrication system shown in FIG. 1, any lubricant advancing along the shaft ( 12 ) would be restricted from passing through the interface of the thrust collar/oil slinger ( 34 ) and the shaft by the rubber washer ( 38 ). The washer ( 38 ) is typically stretched as it is mounted on the shaft ( 12 ) and is in a tight engagement around the shaft, preventing any lubricant from advancing beyond the washer out of the motor. However, rotation of the shaft ( 12 ) also causes lubricant that is advanced along the shaft to move radially outwardly over the metal washer ( 40 ) and the thrust collar/oil slinger ( 34 ). Any lubricant that travels radially outwardly over the surfaces of the metal washer ( 30 ) is thrown from the peripheral edge of the metal washer into the fibrous material ( 32 ) that absorbs the lubricant. The material ( 32 ) wicks the lubricant back to the bearing ( 10 ). The lubricant soaks through the porous bearing to its center bore, re-lubricating the rotating engagement of the shaft ( 12 ) with the bearing ( 10 ). Any lubricant that travels radially outwardly along the rubber washer ( 38 ) is transferred to either the metal washer ( 40 ) or the thrust collar/oil slinger ( 34 ) which have greater radial dimensions than the rubber washer. Any lubricant that travels radially outwardly along the thrust collar/oil slinger ( 34 ) is thrown radially off of an annular rim ( 54 ) on the side of the thrust collar or off of the outer peripheral edge ( 56 ) of the thrust collar to the fibrous material ( 34 ). This lubricant is then wicked through the material ( 32 ) back to the porous bearing ( 10 ) that absorbs the lubricant and again transfers the lubricant to the rotating engagement of the shaft ( 12 ) with the bearing ( 10 ).
[0013] The bearing lubrication system described above and shown in FIG. 1 has been found to be disadvantaged in that lubricant thrown radially off the spinning thrust collar will at times impact against the interior surface of the fibrous material ( 32 ) represented by the dashed lines B-B and splash back onto the surface of the thrust collar ( 58 ) outside of or to the right of the thrust collar peripheral edge ( 56 ). When the motor is stopped or running, oil that has splashed onto the thrust collar outer surface ( 58 ) can advance along the surface of the fan hub ( 60 ) reaching the fan blades ( 62 ). The next time the motor is activated, the lubricant that reaches the fan hub ( 60 ) and fan blades ( 62 ) will fly off the blades, resulting in a loss of lubricant from the lubricant reservoir of the motor. In addition, when motors having a bearing lubrication system such as that shown in FIG. 1 are employed in a clothes dryer, lint can collect in the opening or clearance ( 50 ) between the bearing cap lip ( 48 ) and the fan ( 16 ) and soak up oil, causing additional loss of lubricant from the motor lubricant reservoir. Over time, the loss of oil can result in failing of the motor bearings requiring repair of the motor and the appliance.
[0014] What is needed to overcome the above shortcomings of the prior art bearing lubrication system is a system that reliably retains lubricant in the self-contained lubricant reservoir of an electric motor.
SUMMARY OF THE INVENTION
[0015] The lubricant retention assembly of the invention overcomes the shortcomings of the prior art bearing lubrication system by providing a thrust collar and a bearing cap that are designed to function together to reliably return any lubricant that reaches the thrust collar to the oil-permeated fibrous material of the self-contained lubricant reservoir of the motor. In addition to the novel constructions of the thrust collar and bearing cap, the bearing lubrication system of the invention also comprises a rubber washer of novel construction that is complementary to the construction of the thrust collar and a novel application of the fibrous material impregnated with the lubricant that forms the lubricant reservoir of the invention.
[0016] The thrust collar and thrust washer of the invention are mounted on the motor shaft in basically the same positions as the thrust collar and thrust washer of the prior art, and the bearing cap of the invention is mounted in the end shield collar surrounding the shaft opening of the end shield in basically the same position as the bearing cap of the prior art.
[0017] The thrust collar has a cylindrical hub that is mounted on the shaft. The collar hub has a center bore surrounded by a cylindrical interior surface of the hub. The hub interior surface is dimensioned so that the thrust collar will fit in a friction engagement on the exterior surface of the shaft for rotation of the collar with the shaft. The thrust collar hub also has a cylindrical exterior surface that extends between axially opposite first and second annular end surfaces of the thrust collar. The first annular end surface of the collar hub faces toward the bearing of the motor shaft. This first end surface of the collar hub is beveled so that it extends axially over the shaft as it extends from the interior surface of the collar hub to the exterior surface of the collar hub. The opposite, second annular end surface of the hub has an annular flange that extends radially outwardly from the hub. As the annular flange extends radially away from the collar hub, it also extends axially over the hub exterior surface, giving the flange a conical shape. The flange extends radially outwardly to a peripheral end surface of the flange that is parallel to the center axis of the motor shaft and extends around the hub exterior surface.
[0018] The bearing cap is mounted to the end shield collar surrounding the shaft opening of the end shield. The bearing cap has an annular side wall that extends axially away from the end shield collar and the bearing and radially toward the thrust collar mounted on the shaft. The cap side wall extends radially inwardly to an inner edge of the cap that extends around the annular flange of the thrust collar on an axially opposite side of the flange peripheral end surface from the bearing.
[0019] In the bearing lubrication system of the invention, the fibrous material permeated with the lubricant is packed in the end shield collar against the bearing retainer and surrounding the bearing. However, the fibrous material does not extend axially beyond the end of the bearing and does not enter into the area surrounded by the bearing cap as was done in the prior art.
[0020] The conventional rubber washer of the prior art is replaced in the bearing lubrication system of the invention with a resilient o-ring. The o-ring is slightly stretched as it is positioned on the shaft in the same position as the prior art rubber washer, between the metal washer and the first annular end surface of the thrust collar. The circular cross section of the o-ring thrust washer provides an improved lubricant seal that prevents lubricant from passing along the shaft exterior surface and between the interface of the shaft and the interior surface of the o-ring thrust washer. In addition, with the reduced exterior diameter dimension of the thrust collar hub, a conventional rubber washer would be prone to stretching away from the shaft and moving onto the thrust collar hub due to any relative rotation between the thrust collar and metal washer and/or due to a high thrust impact or a high thrust load on the shaft. With the rubber washer moved onto the thrust collar hub, it is ineffective in stopping lubricant leakage along the shaft and also creates axial end play of the shaft. The circular cross section of the o-ring thrust washer seats inside a conical or frustum shaped recess formed by the beveled first annular end surface of the thrust collar hub. Because the first annular end surface of the thrust collar hub extends over a portion of the o-ring as the end surface extends from the interior bore surface of the hub to the exterior surface of the hub, the annular end surface prevents the o-ring from expanding or stretching outwardly from the shaft surface due to any relative rotation between the thrust collar and the bearing and/or due to a high thrust impact or a high thrust load on the shaft, and thereby prevents the o-ring thrust washer from leaving the shaft surface and moving onto the hub of the thrust collar.
[0021] Thus, with the thrust collar of the invention mounted on the motor shaft and the bearing cap of the invention surrounding the thrust collar, any lubricant that leaks along the shaft to the thrust collar will be thrown from the thrust collar flange toward the angled interior surface of the cap side wall and will be deflected by the cap side wall back into the motor interior toward the fibrous material of the lubricant reservoir. In addition, with the o-ring thrust washer of the invention mounted on the shaft lubricant leakage between the interface of the shaft and the thrust collar, the beveled annular end surface of the thrust collar hub will prevent the o-ring thrust washer from moving from its position on the shaft onto the hub of the thrust collar.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Further features of the invention are revealed in the following detailed description of the preferred embodiment of the invention and in the drawing figures wherein:
[0023] [0023]FIG. 1 is a partial sectioned view of a motor end shield and shaft of the prior art bearing lubrication system; and
[0024] [0024]FIG. 2 is a partial sectioned view of the same motor end shield and shaft of FIG. 1 and also showing the bearing lubrication system of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] As stated earlier, the lubricant retention assembly of the invention overcomes the shortcomings of the prior art bearing lubrication system by providing a thrust collar ( 70 ) and a bearing cap ( 72 ) that are designed to function together to reliably return any lubricant that reaches the thrust collar to the oil permeated fibrous material ( 74 ) of the self contained lubricant reservoir of the motor. In addition to the novel constructions of the thrust collar ( 70 ) and bearing cap ( 72 ), the bearing lubrication system of the invention also comprises a rubber washer ( 76 ) of novel construction that is complementary to the construction of the thrust collar as well as a novel application of the lubricant permeated fibrous material ( 74 ) that forms the lubricant reservoir of the invention. Because the lubricant retention assembly of the invention is an improvement over the prior art bearing lubrication system described earlier, the assembly of the invention will be described and explained using the same operative environment of FIG. 1 that employed in describing the prior art bearing lubrication system. The component parts of the motor referred to in describing the prior art bearing lubrication system shown in FIG. 1 make up the illustrated environment of the lubrication retention assembly of the invention shown in FIG. 2 and are identified by the same reference numbers shown in FIG. 1.
[0026] The thrust collar ( 70 ) of the invention is preferably constructed of a plastic material, but may be constructed of other types of materials. The thrust collar ( 70 ) is basically comprised of a cylindrical hub ( 80 ) and an annular flange ( 82 ) projecting radially outwardly from one end of the hub. The collar hub ( 80 ) has a cylindrical exterior surface ( 84 ) and a cylindrical interior surface ( 86 ). The hub interior surface ( 86 ) surrounds a center bore ( 88 ) of the hub and has an interior diameter dimension that allows the hub to be slipped on the shaft ( 12 ) in an interference fit or friction fit between the hub ( 80 ) and shaft ( 12 ) that causes the thrust collar ( 70 ) to rotate with the shaft ( 12 ). The thrust collar hub ( 80 ) has an axial length between opposite first ( 88 ) and second ( 90 ) annular end surfaces of the thrust collar. The first annular end surface ( 88 ) faces toward the bearing ( 10 ) and the motor end shield ( 14 ) and the opposite second annular end surface ( 90 ) faces away from the bearing and end shield. The first annular end surface ( 88 ) of the hub is beveled so that it extends radially away from the shaft ( 12 ) and axially over the shaft ( 12 ) as it extends from the thrust collar hub interior surface ( 86 ) to the thrust collar hub exterior surface ( 84 ). The beveled configuration of the first annular end surface ( 88 ) defines a conical or frustum shaped recessed area ( 92 ) within the first annular end surface ( 88 ).
[0027] The opposite, second annular end surface ( 90 ) of the hub is a flat surface that is perpendicular to the shaft center axis and extends radially outwardly and merges with the thrust collar annular flange ( 82 ). As the annular flange ( 82 ) extends radially outwardly from the thrust collar hub exterior surface ( 84 ) it gradually angles over the exterior surface ( 84 ), giving the flange ( 82 ) a conical shape. The flange has opposite interior ( 94 ) and exterior ( 96 ) surfaces that both extend axially over the thrust collar hub exterior surface ( 84 ) as they extend radially away from the thrust collar hub ( 80 ). The flange interior ( 94 ) and exterior ( 96 ) surfaces extend radially away from the thrust collar hub ( 80 ) to a peripheral end surface ( 98 ) of the flange. The flange peripheral end surface ( 98 ) is parallel to the center axis of the motor shaft and extends around the hub exterior surface ( 84 ). The flat peripheral end surface ( 98 ) of the flange merges with the angled interior surface ( 94 ) of the flange and forms a sharp annular corner or edge ( 100 ) on the flange that promotes oil droplet formation.
[0028] The bearing cap ( 72 ) is stamped from metal as is the bearing cap ( 36 ) of the prior art. Other types of materials could also be used in constructing the bearing cap. The bearing cap ( 72 ) of the invention is formed with a rim ( 102 ) at its outer perimeter that is dimensioned to be press fit into the end shield collar ( 18 ) in attaching the bearing cap ( 72 ) over the shaft opening ( 20 ) of the end shield collar ( 18 ). An annular bend ( 104 ) formed in the bearing cap connects the outer rim ( 102 ) of the cap with an annular side wall ( 106 ) of the bearing cap. The bearing cap side wall ( 106 ) has opposite exterior ( 108 ) and interior ( 110 ) surfaces that both extend radially inwardly as the side wall extends from the cap outer rim ( 102 ) toward the shaft ( 12 ). As seen in FIG. 2, the bearing cap side wall ( 106 ) extends axially away from the end shield collar ( 18 ) and axially away from the bearing ( 10 ) as it extends radially inwardly toward the thrust collar ( 34 ) mounted on the motor shaft ( 12 ). This gives the side wall ( 106 ) a conical shape. The bearing cap side wall ( 106 ) extends radially inwardly to an inner annular bend ( 112 ) formed in the cap that curves inside the side wall interior surface ( 110 ) to an inner annular edge ( 114 ) of the cap. The edge ( 114 ) of the cap side wall extends completely around the thrust collar flange ( 82 ) on an axially opposite side of the flange peripheral end surface ( 98 ) from the shaft bearing ( 10 ). As seen in FIG. 2, the side wall inner edge ( 114 ) is dimensioned to provide only a minimum amount of clearance for passage of the thrust collar annular flange ( 82 ) through the opening defined by the bearing cap sidewall inner edge ( 114 ).
[0029] In the bearing lubrication system of the invention, the fibrous material permeated with the lubricant ( 116 ) is packed in the end shield collar ( 18 ) against the bearing retainer ( 24 ) and surrounding the bearing ( 10 ), but does not extend into the area surrounded by the bearing cap side wall ( 106 ) as was done in the prior art bearing lubrication system. Instead, the lubricant permeated fibrous material ( 116 ) is packed into the end shield collar ( 18 ) surrounding the bearing ( 10 ) and does not extend axially beyond the bearing or beyond the dashed line C-C shown in FIG. 2 in the preferred embodiment of the invention.
[0030] In the bearing lubrication system of the invention, the conventional rubber washer of the prior art is replaced with a resilient washer having at least a portion dimensioned to fit into the recess at the thrust collar first end surface, preferably an o-ring ( 76 ). The o-ring thrust washer ( 76 ) has an interior diameter dimension that is slightly smaller than the exterior diameter dimension of the shaft ( 12 ), resulting in the o-ring being stretched slightly as it is positioned on the shaft in the same position as the prior art rubber washer, i.e. between the metal washer ( 40 ) and the first annular end surface ( 88 ) of the thrust collar. The o-ring ( 76 ) also has an exterior diameter dimension that is slightly smaller than the exterior diameter dimension of the thrust collar hub exterior surface ( 84 ). The circular cross section of the o-ring thrust washer ( 76 ) provides an improved lubricant seal that prevents lubricant from passing along the exterior surface of the shaft ( 12 ) and between the interface of the shaft ( 12 ) and the interior of the o-ring thrust washer ( 76 ). The dimensioning of the o-ring thrust washer ( 76 ) also allows it to be received at least partially in the frustum shaped recessed area ( 92 ) surrounded by the first annular surface ( 88 ) of the thrust collar. As explained earlier, the reduced exterior diameter dimension of the thrust collar hub ( 80 ) could lead to the conventional rubber washer stretching away from the shaft ( 12 ) and moving onto the thrust collar hub due to any relative rotation between the thrust collar and the metal washer and/or due to a high thrust impact or a high thrust load on the shaft. With the rubber washer moved onto the thrust collar hub, it would be ineffective in stopping lubricant leakage along the shaft. The circular cross section of the o-ring thrust washer ( 76 ) and its dimensioning seat the o-ring inside the conical or frustum shaped recess ( 92 ) formed by the beveled first annular end surface ( 88 ) of the thrust collar hub. A portion of the hub first annular end surface ( 88 ) extends axially over the o-ring thrust washer ( 76 ) and thereby prevents the thrust washer from stretching away from the shaft ( 12 ) and moving onto the thrust collar hub ( 80 ).
[0031] In operation of the lubricant retention assembly of the invention, as the shaft ( 12 ) rotates, the tight, stretched engagement of the o-ring thrust washer ( 76 ) around the shaft prevents any leakage of lubricant along the shaft beyond the o-ring ( 76 ) where it could potentially pass through the interface between the thrust collar ( 70 ) and the shaft and reach the fan ( 16 ) where the lubricant would be thrown from the motor. Any lubricant that reaches the exterior surface ( 84 ) of the thrust collar hub and moves away from the motor interior to the thrust collar annular flange ( 82 ) will be cause to move across the flange interior surface ( 86 ) by rotation of the thrust collar. The lubricant moving over the flange interior surface ( 86 ) will reach the flange peripheral edge corner ( 100 ). The sharp annular corner ( 100 ) between the flange interior surface ( 86 ) and the flange peripheral end surface ( 98 ) causes lubricant droplets to be thrown radially off of the edge corner ( 100 ) toward the interior surface ( 110 ) of the bearing cap annular side wall ( 106 ). The lubricant droplets thrown from the thrust collar ( 80 ) impact against the bearing cap side wall interior surface ( 110 ) and are deflected axially inwardly toward the fibrous material ( 116 ) packed around the bearing ( 10 ). Thus, the problem of splashing lubricant impacting with the fibrous material being deflected outside the bearing cap of the prior art is eliminated. The close tolerance between the bearing cap side wall inner edge ( 114 ) and the thrust collar flange peripheral surface ( 98 ) ensures that no lubricant is deflected from the bearing cap ( 72 ) outside the bearing cap and the thrust collar flange ( 82 ) where it would be lost from the lubricant reservoir.
[0032] While the present invention has been described by reference to a specific embodiment, it should be understood that modifications and variations of the invention may be constructed without departing from the scope of the invention defined in the following claims.
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A lubricant retention assembly is employed with an electric motor to prevent the loss of lubricant from a self contained lubricant reservoir of the motor. The lubricant retention assembly includes a thrust collar mounted on the motor shaft and a bearing cap surrounding the thrust collar, where the thrust collar has an annular flange that throws lubricant leaking along the shaft radially outwardly toward the bearing cap. The bearing cap has an angled interior surface that deflects the lubricant thrown from the annular flange of the thrust collar back into the motor interior and toward the lubricant reservoir. A thrust washer is also provided on the shaft adjacent the thrust collar and prevents lubricant leakage along the shaft between the interface of the shaft and the thrust collar. The thrust washer and thrust collar have complementary configurations that maintain the thrust washer in position on the shaft adjacent the thrust collar.
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BACKGROUND OF THE INVENTION
The present invention relates to an optical amplifier for optical communications, and more particularly, to a multi-stage fiber amplifier in which the total available pump power, which is supplied from a single source, is optimally divided between the stages to provide maximum gain and minimum noise for a given spectral response.
High output power amplifiers are required for many applications, including, for example, multi-wavelength systems. One of the key performance characteristics of an amplifier is its output power, which is largely governed by how efficiently the pump light is converted into signal light.
FIG. 1 schematically illustrates that at the input of gain fiber 10 both the signal and the spontaneous emission (SE) are available to be amplified. The amount of SE that is amplified must be reduced relative to the amount of signal that is amplified so that signal amplification dominates in the utilization of pump power. The size of the signal is typically set by the system link loss and therefore cannot be increased. The amount of amplified spontaneous emission (ASE) could be reduced by reducing the total pump power. However, there would then be less pump power available for conversion to signal power. Since the erbium-doped fiber amplifier has utility in communication systems operating at 1550 nm, that fiber amplifier is specifically discussed herein by way of example. The invention also applies to fiber amplifiers containing gain ions other than erbium, since ASE also diverts pump power from the signal in amplifiers utilizing gain ions other than erbium. As shown by curve 18 of FIG. 2, the gain spectrum of a highly inverted erbium-aluminum-doped germania silicate fiber amplifier has a peak around 1532 nm and a broad band with reduced gain to about 1560 nm. Some prior art fiber amplifiers included means for reducing the 1532 nm peak to prevent the occurrence of such disadvantageous operation as wavelength dependent gain or gain (with concomitant noise) at unwanted wavelengths. The resultant gain spectrum might be as represented by curve 19, for example.
In one such fiber amplifier, a filter such as a fiber containing ions that absorb at the ASE wavelength is connected between two sections of gain fiber. The ASE is filtered from the output of the first gain fiber section by the ASE-absorbing fiber, and the resultant signal light is amplified by the second gain fiber section. Both the signal and pump light are introduced into the first gain fiber section, and the remnant pump light at the output of the first gain fiber section is used to pump the second gain fiber section. The lengths of gain fiber at both ends of the filter determine the amplifier gain and spectral response.
A modification of the above-described amplifier is described in the publication, R. I. Laming et al. "High-Sensitivity Two-Stage Erbium-Doped Fiber Preamplifier at 10 Gb/s", IEEE Photonics Technology Letters, vol. 4, No. 12, December 1992, pp. 1348-1340. In the fiber amplifier disclosed in that publication, the ASE absorbing fiber of the above-described amplifier is replaced by a 1536 nm isolator for suppressing the backward-traveling ASE. Since the isolator has a very high loss at the 980 nm pump wavelength, two wavelength division multiplexer (WDM) couplers are included in the circuit to provide a low-loss pump power bypass around the isolator.
Another fiber amplifier having ASE filtering is described in the publication "High Gain Two-Stage Amplification with Erbium-Doped Fibre Amplifier" by H. Masuda et al., Electronics Letters, 10 May 1990, vol. 26, No. 10, pp. 661-662. The ASE filter is connected between two fiber amplifier stages. Separate pump sources are connected to the two stages, the second stage being double pumped from two separate sources, whereby it receives more pump power than the first stage. The signal is amplified by the first fiber amplifier stage. The ASE wavelengths in the output of that amplifier are filtered, and the resultant signal is connected to the second amplifier stage. Since the input signal is relatively small, much of the pump power will be converted to ASE in the first stage. With the ASE filter in place, this ASE optical power is lost, as it does not reach the second stage. Therefore, in this type of configuration, the amount of power converted to ASE is minimized by reducing the ASE build up in the first stage by limiting the amount of pump power supplied to the first stage. In this kind of fiber amplifier, the pump conversion is enhanced, but a large number of pump sources is required.
U.S. Pat. No. 5,050,949 also teaches a two-stage fiber amplifier in which unequal pump power is supplied to each of the two stages. The gain spectrums of the two gain fibers are made different by selecting gain fibers having different host glasses and/or different gain ions. Since the gain spectrums of the two stages are different, signal gain equalization is achieved, rather than optimization of pump power conversion.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a multi-stage fiber amplifier in which pump power from a single source is unequally coupled to the two stages in such a manner that output power is optimized for a given spectral response. Another object is to provide a fiber amplifier that overcomes the disadvantages of prior art devices.
Briefly, the present invention relates to a fiber amplifier comprising first and second fiber amplifier stages, the output spectrum from the first stage including a first band of wavelengths that is primarily attributable to ASE. The first and second stages are connected by means including a filter for attenuating the first band of wavelengths. Distribution means connects pump light from a source to the first and second stages such that less than half of the pump power is converted to signal and amplified spontaneous emission in the first amplifier stage.
In one embodiment the pump source consists of a pair of light sources connected to a coupler that splits the power equally to two output legs. All of the pump power from the second coupler output leg is supplied to the second stage. A portion of the pump power from the second coupler output leg is converted in the first stage to amplified signal and ASE, and the remainder of the power from that leg is supplied to the second stage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a gain fiber.
FIG. 2 is a graph showing the gain spectrum of an erbium-aluminum-doped germania silicate fiber amplifier.
FIG. 3 is a schematic illustration of a fiber amplifier in accordance with the present invention.
FIG. 4 is a schematic illustration showing division of pump power.
FIGS. 5, 6 and 7 are schematic illustrations of embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
To maximize the pump-to-signal conversion efficiency, the amount of light converted to ASE should be minimized. In accordance with this invention, pump power from a single source is divided such that pump power consumption is reduced in the primary stage of the amplifier, thus reducing the power converted to ASE. Excess pump power is directed to a later stage in the amplifier where the signal will be larger and better conversion efficiency can be attained.
A basic schematic diagram of the invention is shown in FIG. 3. The amplifier comprises a primary stage 31 which is connected to a secondary stage 32 by an ASE filter 33. ASE filter 33, as well as the ASE filters of later described amplifiers, can be one that diverts light between 1530-1540 nm to an output telemetry port. It is in this spectral region that the peak of ASE emission is found for a fully inverted amplifier. A given pump budget is available from pump source 34. A given amount x of the available pump power is supplied to stage 31, wherein x is less than 50%. The remaining (1-x) of the available power is supplied to stage 32. The value of x is typically between about 10% and 49%. At values below 10%, the noise performance is seriously degraded. There is obviously not much improvement in efficiency of pump-to-signal conversion when x is 49%. The value of x is thus often selected to be between about 20% and 30%. To determine the value of x for a given amplifier, the amount of amplifier noise that can be tolerated in the system is initially determined. The gain is then optimized for that noise performance by appropriately apportioning the pump power budget to the first and second amplifier stages.
As shown in FIG. 4, the pump source may be a laser diode 37 connected to stages 1 and 2 by a coupler 38 that splits the pump power such that, at the pump wavelength, less than half (e.g. 25%) of the power is supplied to stage 1, The remainder of the pump power being directed to the second stage. This configuration requires few components, but it does not provide the amplifier with the soft fail function which will be described in the remaining embodiments.
FIG. 5 illustrates a multi-stage fiber amplifier that is pumped by a single source which divides the pump power between the stages so that the amplifier achieves efficient pump power-to-signal conversion efficiency. Laser diodes 41 and 42 of source 40 are connected to a 3 dB coupler 43 which provides equal amounts of pump power to 3 dB coupler 44 and wavelength division multiplexer (WDM) coupler 45. The gain of the amplifier will drop by no more than 3 dB if one of the sources fails, because to the use of coupler 43 in the pump source. Without this soft fail architecture, the gain will drop by more than 3 dB when one of the pump diodes fails. Coupler 44 provides equal amounts of pump power to WDM couplers 46 and 47. The signal of wavelength λ s , which is applied to coupler 46, is amplified by first fiber amplifier stage 48. The amplified signal is connected to gain fiber 54 by pump filter 50, ASE filter 51, isolator 52 and WDM coupler 47. Pump filter 50 is employed when ASE filter 51 is of the type whose performance is degraded by pump light. The amplified signal from gain fiber 54 is connected to gain fiber 56 by WDM coupler 45. The pump-to-signal conversion efficiency is improved in this embodiment by employing only 25% of the pump power in the first stage 47, and supplying 75% of the pump power to the stage including gain fibers 54 and 56, which is located after ASE filter 51. Isolators 49, 52 and 53 suppress reflection noise. An optional pump filter 55 protects downstream elements from pump light that might be deleterious thereto.
Comparison Amplifier 1 was constructed to evaluate the performance of the amplifier of FIG. 5. Comparison Amplifier 1 was similar to the amplifier of FIG. 5 except that the second stage consisted of a single gain fiber and the pump power was supplied to the two stages directly from source 40, i.e. each stage received 50% of the available power. The output power of the amplifier constructed in accordance with FIG. 5 was more than 1.5 dB larger than the output power of Comparison Amplifier 1.
An accurate numerical model was constructed for the amplifier of FIG. 5 and for Comparison Amplifier 1. It showed that the output power of an amplifier constructed in accordance with FIG. 5 would have 1.4 dB greater output power than Comparative Amplifier 1 at equivalent noise and gain spectrum.
In FIG. 6 laser diodes 61 and 62 are connected to a 3 dB coupler 63 which provides equal amounts of pump power to WDM couplers 64 and 65. The signal of wavelength λ s , which is applied to coupler 64, is amplified by a first fiber amplifier stage comprising gain fiber 67. The amplified signal is connected to gain fiber 68 by WDM coupler 70, ASE filter 71, isolator 72 and WDM coupler 74. The length of first stage gain fiber 67 is insufficient to convert all of the pump power supplied thereto by couplers 63 and 64 to signal and ASE. Gain fiber 67 might absorb only 50% of the pump power, for example. The remnant pump power from gain fiber 67 is connected to coupler 74 by coupler 70; this pump power pumps gain fiber 68 in the forward direction. Gain fiber 68 is also pumped in the reverse direction by the pump power supplied to it from coupler 65. The amplified signal is coupled from gain fiber 68 to output fiber 75 by WDM coupler 65 and isolator 76. If, as suggested above, gain fiber 67 absorbs only 50% of the pump power supplied to it, then gain fiber 67 utilizes essentially 25% of the available pump power budget from source 60, and gain fiber 68 utilizes essentially 75% of the available pump power budget from source 60. As discussed above, this division of pump power improves the pump-to-signal conversion efficiency.
Due to the finite signal crosstalk of WDM couplers 70 and 74, some signal light leaks into the pump path a. This signal will be out of synchronization with the principle signal from path b where the paths rejoin at coupler 74 due to inevitable small differences in path length between the two paths. This unsynchronized signal will be a source of added noise. It has been calculated that with WDM couplers 70 and 74 having 15 dB crosstalk at the signal wavelength, this 30 dB attenuated signal will degrade the noise figure by as much as 26 dB, when the path lengths differ by more than the source coherence length. To block this secondary signal path, which would ordinarily occur through pump path a, a signal attenuating fiber 73 is added to path a. It has been calculated that 60 dB signal attenuation in path a would eliminate this additional source of noise. If the gain fibers were erbium-doped, the filtering function could easily be obtained with one meter of praseodymium-doped fiber, for example.
FIG. 7 shows an alternate design for the second stage 66 of FIG. 6. Gain fiber 68 is replaced by two gain fibers 81 and 82. Connecting fibers a, b and c, which enter second stage 66 of FIG. 6, are also shown in FIG. 7. Gain fiber 81 is pumped in the forward direction by pump power supplied thereto via connecting fiber a and WDM coupler 74'. The pump power from connecting fiber c and the amplified signal from gain fiber 81 are coupled to gain fiber 82 by WDM coupler 84, whereby gain fiber 82 is also forward pumped. The amplified output is connected to output fiber 86 by pump filter 87 and isolator 88.
An accurate numerical model was also constructed for the amplifier of FIG. 7. It showed that the output power of an amplifier constructed as in FIG. 7 would have 1.9 dB greater output power than Comparative Amplifier 1 at equivalent noise and gain spectrum.
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The present invention relates to a multi-stage fiber amplifier in which the first and stages are connected by means including a filter for attenuating the amplified spontaneous emission. The pump source consists of a pair of light sources that are connected to a coupler that splits the power equally to two output legs. All of the pump power from the second coupler output leg is supplied to the second stage. A portion of the pump power from the second coupler output leg is converted in the first stage to amplified signal and amplified spontaneous emission, and the remainder of the power from that leg is supplied to the second stage.
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CROSS REFERENCE TO RELATED APPLICATIONS
This Patent Application is a Continuation of International Patent Application No. PCT/EP2007/061264 filed on Oct. 22, 2007, entitled, “METHOD AND APPARATUS FOR CRIMPING A MULTIFILAMENT THREAD”, the contents and teachings of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
Embodiments of the invention relate to methods for crimping a multifilament thread as well as devices for carrying out such methods.
BACKGROUND
It is generally known to initially extrude a plurality of restiform filaments from a thermoplastic melt during the production of crimped synthetic threads. The filament bundle is combined after cooling to form a smooth multifilament thread. In order to produce crimping in the individual filament strands, the multifilament thread is compressed into a thread plug. For this purpose, the filaments of the thread are preferably conveyed through a hot fluid, and deformed into loops and arcs at the surface of the thread plug. In order to fix the crimping forming in the filaments, the thread plug is thermally treated. In the case where the thread plug formation occurs by hot fluid, the thread plug heated in this manner is subsequently cooled. For this purpose the thread plug is guided at the circumference of a processing drum. The processing drum is driven in a rotating manner so that the dwell time for cooling the thread plug is determined substantially by both the circumferential speed of the processing drum, and by the degree of the wraparounds of the thread plug at the circumference of the processing drum. Since the circumferential speed of the processing drum is determined by processing speeds and can be modified only to a limited degree, the intensive cooling may be achieved only by respective wraparounds of the thread plug at the processing drum.
A method and a device are known from DE 38 00 773 C2, which discloses that the thread plug is guided in multiple wraparounds at the circumference of the processing drum. For this purpose the wraparounds of the thread plug are guided in a direct side-by-side manner at the circumference of the processing drum, such that reciprocal influences of the individual filaments of the thread plug are inevitable.
SUMMARY
A loose connection of the filaments within the thread plug can result in individual filaments getting stuck to each other in the adjacent wraparounds of the thread plug at the circumference of the processing drum, particularly in the case of thread plugs having a respectively low thread plug density. Such sticking together has an adverse effect, especially during the unraveling of the thread plug into a crimped thread, such that irregularities occur at the crimped thread, which are particularly evident in a fluctuating thread tension during the unraveling of the crimped thread. Such thread tension fluctuations have a very adverse effect, especially on the after-treatment of the thread, such as by twirling.
Embodiments of the present invention are therefore directed to further improve a method and a device for crimping a generic, multifilament thread such that it enables a safe and even unraveling of the thread plug into a crimped thread after thermal treatment of the thread plug having multiple side-by-side wraparounds at the circumference of a processing drum.
Embodiments of the invention include guiding the thread at a slant from the unraveling area of the thread such that an increasing axial space appears between the thread and the thread plug on the circumference of the processing drum during increasing wraparounds of the thread on the circumference of the processing drum.
It has been surprisingly found that the individual filament strands have no substantial differences in composition and crimping even with a non-linear transition of the thread plug into the crimped thread. However, even the filament strands that are stuck to the adjacent wraparound of the thread plug are integrated into the filament connection of the crimped thread without any irregularities during the unraveling, due to the removal of the crimped thread from the thread plug end at a slant. Due to the course of the crimped thread facing away from the wraparounds of the thread plug on the processing drum, different actions of forces are created in the unraveling area between in inner side of the thread plug, which directly faces the adjacent wraparounds of the thread plug, and an outer side of the thread plug for forming the thread. In this manner, particularly the partial areas of the filament strands placed in the inner area of the thread plug are drawn more intensely than the partial areas placed in the outer area, which substantially facilitates the unraveling of possible individual overlapping locations between the individual wraparounds of the thread plug at the circumference of the processing drum. In this regard the thread plug can be evenly transferred into the crimped thread.
In order to obtain conditions in guiding the thread and the unraveling of the thread plug that are as stable and even as possible, a further improvement of one embodiment of the invention of guiding the thread into an unraveling groove at the circumference of the processing drum after unraveling of the thread plug has proven particularly successful. In this manner reproducible and even operating conditions and straight grains can be achieved.
As a function of the thickness of the thread plug, which has a direct effect on the reciprocal influencing of the thread plug wraparounds at the circumference of the processing drum, different straight grains may be selected during the unraveling of the thread plug. However, it has been shown that the thread should be guided at the circumference of the processing drum at a gradient angle, if possible, which exceeds an angle of 10°. Depending on the looseness of the thread plug the gradient angle may be increased, where maximum gradient angles of 80° should not be exceeded.
It is of particular importance for the after-treatment of the crimped thread that a sufficient thread tension is created at the thread. For this purpose, one embodiment of the invention advantageously provides a further improvement in that the thread is guided between the unraveling area and a removal area across a wraparound area at the circumference of the processing drum, which includes a circumferential angle of at least 45°. In this manner the only minimal tensile forces required for unraveling the thread plug as opposed to the thread tensile forces required for the after-treatment can be realized. For example, no substantial tensile force acting upon the thread is desired in the unraveling area of the thread plug. The thread tensile force required for the after-treatment of the crimped thread could be, for example, 100 cN.
It has been proven particularly successful for the after-treatment, if the crimped thread is twirled into a spool before wrapping, and is twirled after removal from the processing drum by a twirling unit. In this manner the bond of the crimped filaments may be advantageously improved in the thread connection for further processing.
In order to be able to carry out the forming of the thread plug and the thermal treatment of the thread plug at a flexibility that is as high as possible, one embodiment of the method variation has proven particularly successful, in which the thread plug is conveyed by a conveyor device for the unraveling on the circumference of the processing drum, where the conveyor device and the processing drum are driven independently of one another. The thickness and the guide speed of the thread plug can be adjusted both via the conveyor device and via the processing drum.
A device is provided in order to carry out the embodiments of the method of the invention. The device according to embodiments of the invention includes a guiding apparatus for guiding the crimped thread at the circumference of the processing drum at a slant from the unraveling area of the thread plug such that an increasing axial space appears between the thread and the thread plug on the circumference of the processing drum during increasing wraparounds of the thread on the circumference of the processing drum.
Such a guiding apparatus may be formed directly at the circumference of the processing drum. However, it is also possible to embody the apparatus at a distance to the circumference of the processing drum.
It has proven particularly advantageous to form the guiding apparatus via a cast-off groove at the circumference of the processing drum. The cast-off groove is arranged at an axial offset to a guideway receiving the thread plug at the circumference of the processing drum such that a crimped thread guided from the unraveling area of the thread plug at a slant can be directly inserted into the cast-off groove. This results in very stable and reproducible operating conditions and thread guides at the circumference of the processing drum during the unraveling of the thread plug.
For the purpose of the thread guide of the crimped thread at the circumference of the processing drum one embodiment of the device according to the invention has proven particularly advantageous in which a diameter step is embodied at the circumference of the processing drum between the cast-off groove and the guideway. For this purpose the thread is guided across the diameter step at the circumference of the processing drum. In this manner, gradient angles can be realized in the straight grain, which are possible in a range of between 10° and 80°.
In order to be able to guide the crimped thread in the cast-off groove at a defined wraparound, a thread guide is preferably connected downstream of the processing drum, which tensions a guide plane with the cast-off groove. For this purpose a wraparound can be realized depending on the position of the thread guide, which preferably includes at least one circumferential angle of 45° at the circumference of the processing drum.
Since texturing apparatus having compression chambers, being vertically aligned, are usually utilized for forming thread plugs, a further improvement of the device according to one embodiment of the invention is preferably used, in which a supply unit is arranged between the texturing apparatus and the processing drum in order to obtain a transition of the thread plug from the texturing apparatus to the circumference of the processing drum that is as gentle as possible. In this manner the thread plug thicknesses preadjusted in the compression chamber may be left substantially unchanged. The transition toward the circumference of the processing drum is preferably embodied at an acute angle, or tangentially, such that the thread plug may be guided without any substantial supply.
For this purpose, the supply unit is formed by a guide mechanism and a conveyor device, which are combined into a conveyor gap such that the thread plug is conveyed along a slideway formed by the guide mechanism via the engagement of the conveyor device. For this purpose the supply and a conveying of the thread plug can be advantageously combined with little deformation. A defined and controllable discharge speed of the thread plug from the texturing apparatus is possible by the conveyor device such that a constant building up of the thread plug is ensured.
In order to realize multiple wraparounds in a substantially elongated and straight line unraveling of the thread plug at the circumference of the processing drum the embodiments of the invention preferably provide a control member that is arranged in the pivoting direction of the processing drum, at a short distance in front of the guide mechanism, such that the thread plug may be displaced by the control member after a single wraparound at the circumference of the processing drum. In this manner compact guides of the thread plug can be realized at the guideway in the processing drum.
The cooling of the thread plug at the circumference of the processing drum for the thermal treatment is preferably carried out by ambient air. For this purpose the circumference of the processing drum is embodied by a gas permeable guide casing, where low pressure acting upon the environment in the interior of the processing drum is created by a suction device. In this manner, a uniform cooling air flow can be created for flowing through the thread plug at the circumference of the processing drum. As an alternative, or in addition, conditioning of the air or of the thread plug may also be carried out. It is possible to utilize cold air, or to wet the thread plug using a fluid, such as water.
The device according to embodiments of the invention is preferably utilized in a spinning process, in which the crimped thread at the end of the spinning process is wound on a spool. For this purpose it is of particular advantage if an additional twirling of the crimped filaments is carried out before winding. For this purpose a twirling unit is connected downstream of the processing drum, by way of which the filaments of the multifilament crimped thread are twirled after crimping. Multifilament threads or composite threads, such as BCF threads, can be produced within the spinning process. In case of composite threads, such as the so-called tricolor thread, which is formed of three individual partial threads, the thread plug can be created by combining all three partial threads.
Regardless of the composition of the synthetic thread, a conveyor nozzles combined with a compression chamber has been proven as particularly suited as the texturing apparatus. The conveyor nozzle is connected to a compressed air source, and the compressed air is supplied to the conveyor nozzle preferably heated such that a heating of the filaments may take place simultaneously in addition to the conveying of the filaments.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments of the invention is described in further detail below based on some example embodiments of the device according to the invention for carrying out the method according to the invention with reference to the attached figures.
They show:
FIG. 1 a schematic cross-sectional view of a first example embodiment of the device according to the invention for carrying out the method according to the invention;
FIG. 2 a schematic side view of the example embodiment of the device according to the invention in FIG. 1 ;
FIG. 3 a schematic rear view of the example embodiment of the device according to the invention in FIG. 1 ; and
FIG. 4 a schematic side view of a further example embodiment of the device according to the invention.
DETAILED DESCRIPTION
FIG. 1 , FIG. 2 , and FIG. 3 schematically show a first example embodiment of the device according to the present invention for carrying out the method of the present invention for crimping a multifilament thread in multiple views. FIG. 1 schematically shows the device in one view, and FIG. 2 in a side view. FIG. 3 shows the rear view of the example embodiment. Insofar as no reference is made to one of the figures, the following description applies to both figures.
The device, which could be integrated, for example, into a spinning process for the production of a BCF thread, has a texturing apparatus 1 in order to compress a running multifilament thread 8 into a thread plug 9 . However, depending on the percentage, the thread 8 could also be formed from one filament bundle, or from multiple filament bundles of multiple partial threads. In this example embodiment, the texturing apparatus 1 is formed by a conveyor nozzle 2 and an adjoining compression chamber 4 , as known from WO 03/004743. In this regard express reference is made to WO 03/004743 which is incorporated herein by reference, such that only a short description shall suffice at this point.
The conveyor nozzle 2 has a center thread channel 6 , into which a conveyor fluid is introduced. For this purpose the conveyor nozzle 2 is connected to a compressed air source via a fluid connection 3 . The conveyor fluid introduced into the thread channel 6 , which is preferably formed by compressed air, is heated before the introduction into the conveyor nozzle 2 . The multifilament thread 8 , which was previously formed from a plurality of extruded filaments, is suctioned into the conveyor nozzle 2 by the compressed air entering into the thread channel 6 under pressure, and conveyed along the thread channel 6 .
The compression chamber 4 has a plug channel 7 in an extension of the thread channel 6 , which is formed by a plurality of lamellae 5 that are arranged in an annular manner. The lamellae 5 are held in a housing of the compression chamber 4 , in which the conveyor fluid discharged from the plug channel 7 is discharged via a fluid outlet. Each of the synthetic filaments of the thread 8 within the plug channel 7 is deposited on the surface of the thread plug 9 into loops and arcs by means of the conveyor fluid. For this purpose the thread plug 9 continuously moves from the plug channel 7 in the direction of a plug outlet.
A supply unit 15 is provided on the outlet side of the texturing apparatus 1 for the further guiding of the thread plug. In this example embodiment the supply unit 15 is formed by a guide mechanism 11 arranged directly at the compression chamber 4 , and a conveyor device 13 , which are arranged opposite of a conveyor gap 19 . In this manner a retaining force can be created at the thread plug 9 , which counteracts the pressure of the conveyor fluid for depositing the thread 8 and for forming the thread plug 9 . In this manner a uniform thread plug formation is obtained within the compression chamber 4 and a uniform conveying of the thread plug 9 . The conveyor device 13 is embodied as a conveyor roller 14 , by which the thread plug 9 is conveyed in a single engagement into the conveyor roller 14 . For this purpose the guide mechanism 11 has a slideway 12 , on which the thread plug 9 is guided in a sliding manner. The conveyor gap 19 formed between the guide mechanism 11 and the conveyor device 13 is embodied such that the shape of the thread plug 9 is changed so that the forces required for conveying and building up a retaining force can be created at the thread plug 9 . For this purpose the guide mechanism 11 is preferably embodied as a guide rail 20 , which extends between the texturing apparatus 1 and a processing drum 26 in an L shape. The free end of the guide rail 20 forms a plug outlet 10 , which is directly associated with the circumference of the processing drum 20 . The slideway 12 in the guide rail 20 is embodied in the shape of an arc, where the conveyor gap 19 is formed in the arc-shaped section of the slideway 12 by the conveyor roller 14 positioned on the opposite side. The conveyor roller 14 is coupled to a motor 18 via a drive shaft 17 .
The deflection of the thread plug 9 from the outlet side of the texturing apparatus 1 to the plug outlet 10 is coordinated to the circumference of the processing drum 26 such that the thread plug 9 can be supplied to the processing drum 26 in a substantially tangential manner.
For the thermal treatment the thread plug 9 is deposited in a straight line at the circumference of the processing drum 26 . For this purpose the circumference of the processing drum 26 is embodied as a gas permeable guide casing 27 . The processing drum 26 is rotationally driven via a drum drive 28 . The circumferential speed of the processing drum 26 and the conveyor speed of the thread plug 9 being conveyed via the conveyor device 13 are substantially equal such that the thread plug 9 gathers at the circumference of the processing drum 26 without any change in thickness, and is further conveyed. However, it is also possible to set a circumferential speed via the drum drive 28 , which is slightly increased as opposed to the conveyor speed of the conveyor device 13 . In this manner a slight loosening of the thread plug is achieved upon gathering on the processing drum 26 . An increase of circumferential speed of the processing drum of 5% to 40% as opposed to the conveyor speed of the conveyor device has been proven to be particularly advantageous.
The processing drum 26 is closed on the front sides and is connected to a suction device 30 via a suction connection 29 . Low pressure is created in the interior of the processing drum 26 via the suction device 30 such that gaseous fluid may be suction into the interior of the processing drum 26 from the exterior via the guide casing 27 . For the treatment of the thread plug 9 the same is deposited on the guide casing 27 of the processing drum 26 and guided at the circumference of the processing drum 26 .
For this purpose the processing drum 26 has a guideway 24 on the guide casing 27 . The thread plug 9 is guided in multiple wraparounds positioned directly side-by-side. The guide mechanism 11 has a control member 23 on the end facing the processing drum 26 , which is positioned on the side of the guide rail 20 opposite of the guideway 12 . The control member 23 , which is preferably embodied as a sliding edge, has a shape that is adjusted substantially congruent to the guide casing 27 of the processing drum 26 , and is held at a short distance above the processing drum 26 . The sliding edge extends at a slant to the circumference of the processing drum 26 such that a thread plug exiting at the plug outlet 10 via the slideway 12 and deposited at the circumference of the processing drum 26 is automatically guided against the sliding edge of the sliding device 23 after a straight course on the guideway 24 of the guide casing 27 , and is displaced on the guideway 24 .
As shown in FIG. 3 the thread plug 9 is axially displaced at the circumference of the processing drum 26 by the sliding device 23 . In this manner it is possible to guide the thread plug 9 with multiple wraparounds in the guideway 24 of the guide casing 27 , wherein the wraparounds of the thread plug are directly guided side-by-side. In this regard the guide mechanism 11 may be utilized both for guiding the thread plug 9 in front of the processing drum 26 and for guiding the thread plug 9 at the processing drum 26 .
In addition to the guideway 24 , the guide casing 27 of the processing drum 26 has a cast-off groove 22 . The cast-off groove 22 and the guideway 24 are separated from each other at the circumference of the processing drum 26 by a diameter step 34 . For this purpose the groove base of the cast-off groove 22 is positioned on a diameter that is slightly smaller than the diameter of the guideway 24 . The cast-off groove 22 and the guideway 24 are embodied in a gas permeable manner at the guide casing 27 such that air flows through the guideway 24 and the cast-off groove 22 from the exterior to the interior. Depending on the thread guide a guide zone may be embodied between the cast-off groove 22 and the guideway 24 . The guide zone could also be embodied in a gas permeable or gas impermeable manner in order to guide the thread.
A thread guide 31 is connected downstream of the processing drum 26 for guiding a thread at the circumference of the cast-off groove 22 . Together with the cast-off groove 22 the thread guide 31 , which is formed in this case by a deflection roller, tensions a guide plane of the crimped thread 35 at the circumference of the processing drum 26 .
A cast-off mechanism 16 having multiple godet units 32 . 1 and 32 . 2 is connected downstream of the thread guide 31 in the guide plane. A twirling unit 33 is provided between the godet units 32 . 1 and 32 . 2 , which is connected to a compressed air source that is not illustrated. The godet units 32 . 1 and 32 . 2 are formed by a driven godet and a non-driven accompanying roller.
In the example embodiment shown in FIGS. 1 , 2 , and 3 the multifilament thread 8 , which, for example, has been removed and stretched directly from the spinning zone, is supplied to the texturing apparatus 1 . The thread 8 formed from a plurality of extruded filament strands is conveyed through the conveyor nozzle 6 in the thread channel 6 by way of a hot fluid and guided into the adjoining compression chamber 4 . A thread plug 9 is formed within the compression chamber in the plug channel 7 , where the filaments of the thread 8 deposit themselves in loops and arcs onto the surface of the thread plug 9 . The thread plug 9 is then guided out from the texturing apparatus 1 via the supply unit 15 at a gentle deflection toward the circumference of the processing drum 26 . For this purpose a conveyor device 13 engages into the thread plug 9 on one side and conveys the thread plug 9 continuously along the slideway 12 embodied in the guide mechanism 11 . The thread plug 9 exits continuously from the plug outlet 10 at a uniform guide speed and is taken up by the rotating processing drum 26 . The circumferential speed of the processing drum 26 and the outlet speed of the thread plug are substantially identical such that no loosening of the thread plug 9 occurs. The thread plug 9 is guided at the guideway 24 of the guide casing 27 in multiple wraparounds. For this purpose the wraparounds of the thread plug 9 are positioned side-by-side such that the individual thread plug wraparounds contact each other at the circumference of the processing drum 26 .
As shown in FIG. 2 , the thread plug 9 is held at the guideway 24 of the guide casing 27 with two wraparounds. After two wraparounds of the thread plug 9 an unraveling area 25 is formed at the circumference of the processing drum 26 , in which the thread plug 9 is unraveled into a crimped thread 35 . For unraveling the thread plug 9 into the crimped thread 35 in the unraveling area 25 the thread 35 is guided from the unraveling area of the thread plug at a slant. For this purpose a gradient angle is formed between an imagined circumferential line corresponding to the course of the last wraparound of the thread plug 9 at the circumference of the processing drum 26 , and the thread 35 , which is denoted by the Greek character α. The gradient angle α is selected such that with a progressing wrapping around of the thread 35 at the circumference of the processing 26 a continuously increasing axial distance is formed between the thread plug 9 and the crimped thread 35 . For this purpose the gradient angle α for guiding the thread 35 may be embodied within a range of 10° to 80°. The gradient angle of the thread can be selected depending on the thickness and guiding of the thread plug 9 in the guide casing 27 .
In order to be guided the thread 35 is inserted out from the guideway 24 into the cast-off groove 22 . For this purpose the diameter step 34 formed between the guideway 24 and the cast-off groove 22 represents a deflection of the thread 35 at the circumference of the processing drum 26 such that a stable thread guide is ensured out from the unraveling area at a uniform gradient angle. The thread 35 is guided within the cast-off groove 22 at a substantially straight grain in the groove base until the thread separates from the circumference of the processing drum 26 in the cast-off area 36 shown in FIG. 3 . The cast-off area 36 and the unraveling area 25 are preferably held toward each other such that a wraparound area occurs for the thread 35 at the processing drum 26 , which includes at least one circumferential angle of greater than 45°. In this manner a sufficient thread tension required for the further treatment of the crimped thread 35 can be created.
The crimped thread 35 is twirled in the twirling unit 33 by a compressed air flow for further treatment. In this manner an intensive interweavement of the crimped filaments is achieved, thus particularly improving the coherence of the thread.
FIG. 4 shows a further example embodiment of the device according to the present invention for carrying out the method according to the present embodiment of the invention in a schematic side view. The example embodiment of FIG. 4 is substantially identical to the previous example embodiment with regard to construction and function so that only the differences are explained at this point and reference is made to the previous description as to the rest.
The example embodiment of FIG. 4 has a pipe connection 37 as the supply unit 15 , which is directly associated with an end of the texturing apparatus (not illustrated). The supply unit 15 is arranged above the processing drum 26 , in which a plug outlet 10 directly ends at the circumference of the processing drum 26 .
The processing drum 26 has a guideway 24 at the guide casing 27 , which is embodied in a gas permeable manner. The guide casing 27 is rotationally driven via the drum drive 28 . The guideway 24 at the circumference of the processing drum 26 has a first area for guiding the thread plug 9 in the guide casing 27 and a second area for guiding a crimped thread 35 at an axial offset. A thread guide element 21 is associated with the circumference of the processing drum 26 in the thread guide area of the guideway 24 . The thread guide element 21 is arranged at the circumference of the processing drum 26 in the area of the second section of the guideway 24 at an axial offset to an unraveling area 25 . A cast-off mechanism (not illustrated) is connected downstream of the thread guide element 21 , which is formed in this example embodiment, for example, as an eyelet-shaped thread guide.
In the example embodiment of the device according to the invention shown in FIG. 4 the thread plug 9 is guided with two wraparounds at the circumference of the processing drum after cast off. For unraveling of the thread plug 9 the crimped thread 35 is pulled off the circumference of the processing drum 26 via the thread guide element 21 . For this purpose a helical straight grain is created on the guideway 24 , which results in an axial distance at the circumference of the processing drum 26 that is formed between the thread plug 9 and the thread 35 , which continuously grows with increasing wraparounds of the thread 35 at the guide casing 27 . In this manner a removal of the thread 35 from the unraveling area 25 is achieved at a slant. The thread 35 is guided in this helical manner at the circumference of the processing drum 26 at the gradient angle α.
For the thermal treatment a tempered gaseous fluid is suctioned in from the exterior through the gas permeable guide casing 27 , and discharged into the interior of the processing drum 26 . For this purpose the gas permeable area of the guide casing 27 extends across the entire guideway area 24 such that the thread 35 is held at the circumference of the processing drum 26 under suction.
Ambient air is preferably used for cooling an already tempered thread plug 9 guided at the circumference of the processing drum 26 in multiple wraparounds. However, it is generally also possible to suction in and discharge a fluid released in the environment of the processing drum 26 via additional fluid sources, such as for heating the thread plug. In this manner multiple treatment zones may be also advantageously embodied on the processing drum 26 such that the thread plug with a plurality of wraparounds can be treated in multiple steps.
The example embodiments illustrated in FIGS. 1 to 4 each show one processing drum, on which a thread plug having multiple wraparounds is guided. However, it is also generally possible to guide multiple thread plugs side-by-side parallel to each other on a processing drum. Advantageously, the invention also extends to such devices. In this regard it is essential that the crimped thread is guided at the circumference of the processing drum at a gradient angle, which leads to an increase of the axial distance between the thread and the thread plug.
LIST OF REFERENCE SYMBOLS
1 texturing apparatus
2 conveyor nozzle
3 fluid connection
4 compression chamber
5 lamellae
6 thread channel
7 plug channel
8 thread
9 thread plug
10 plug outlet
11 guide mechanism
12 slideway
13 conveyor device
14 conveyor roller
15 supply unit
16 cast-off mechanism
17 drive shaft
18 motor
19 conveyor gap
20 guide rail
21 thread guide element
22 cast-off groove
23 control member
24 guideway
25 unraveling area
26 processing drum
27 guide casing
28 drum drive
29 suction connection
30 suction device
31 thread guide
32 . 1 , 32 . 2 godet device
33 twirling unit
34 diameter step
35 crimped thread
36 cast-off area
37 pipe connection
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A method and an apparatus involves crimping a multifilament thread, wherein the thread which is produced by melt spinning is compressed to a thread plug. The thread plug is cast on the circumference of rotating processing drum for thermal treatment and is wrapped around the circumference of the processing drum with many side-by-side wraparounds. Following that, the thread plug is unravelled in an unravelling area on the circumference of the processing drum into the crimped thread which is pulled of the processing drum. To obtain a continuous and regular unravelling of the thread plug with multiple wraparounds and mutual touching of the wraparounds of the thread plug, the thread is guided at a slant from the unravelling area of the thread plug such that a growing axial space appears between the thread and the thread plug, on the circumference of the processing drum, during increasing wraparounds of the thread on the circumference of the processing drum.
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention is related to gas detection devices and in particular to a small, inexpensive dosage badge for determining the exposure of firefighters to toxic gases.
Fire atmospheres to which firefighters are exposed commonly include toxic gas components. For example, many fireman are injured as a result of contact with hydrochloric acid gases formed when polyvinyl resins are burned. Accordingly, it is desirable to be able to detect the presence of toxic gases and monitor the exposure dosage to the gas.
Gas detection apparatus are, in general, well known. Examples of prior art systems are described in the following U.S. Pat. Nos. 2,741,912 (Schultze), 3,067,015 (Lawdermilt), 3,084,658 (Schell), 3,112,998 (Grosskopf), 3,113,842 (Udall), 3,876,378 (Montagnon), 3,884,641 (Kraffczyk, and 3,933,029 (Rabenecker).
In general, the presently available apparatus for sampling fire atmospheres are either too cumbersome, too fragile, or too expensive for generalized field use. For example, the patent to Udall (U.S. Pat. No. 3,113,842) describes a gas detection apparatus comprising an evacuated gas chamber having a constricted portion containing a color sensitive indicator chemical that changes color upon exposure to a particular gas. The detection process is initiated by breaking the tip of the glass chamber. While small, the Udall device requires relatively complex fabrication techniques and is thus relatively expensive. Further, an open glass container is not ideally suited for a field environment. Accordingly, a small and lightweight but rugged and inexpensive, individually worn badge for indicating the exposure dosage to toxic gases is needed.
It is believed that the present invention provides such a small, inexpensive dosage indicator badge. A plurality of discs impregnated with a chemical indicator material, which respond with color changes upon predetermined dosage exposures to various toxic gases, are disposed on plastic substrate. A removable cover sheet, suitably formed of a pressure sensitive tape and including a nonadhesive pull-tab to facilitate removal is disposed on the face of the substrate to enclose the chemical detectors. Dosage monitoring is initiated by pulling the cover sheet off of the substrate to expose the impregnated discs.
The badge is easily fabricated and it is presently estimated that the badges can be constructed for less than $0.25 each. Three concentration badges in accordance with the present invention have been tested, weighing less than 0.02 ounces and only on the order of 1-2 inches by 3-4 inches by 0.02-0.05 inches in dimension. The badge can be mounted by adhesive or by a suitable clip on, for example, a hat or the sleeve of a firefighter. Further, the badge is small enough so that it can be disposed within the face mask of breathing apparatus to provide an indication of any leakage of toxic gases into the system.
It is the primary object of the present invention to provide a simple, inexpensive, reliable hazardous environmental condition indicator. This and other objects of the invention will become clear from an inspection of the detailed description of the invention, and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective of an exemplary badge according to the present invention;
FIG. 2 is a pictorial illustration of the toxic gas dosage badge of FIG. 1; and
FIG. 3 is a pictorial graph of the response of a typical badge to various concentrations of a toxic chemical (HCl).
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a plastic substrate 10, suitably formed of a strip of polyethylene Lexan or other plastic sheet stock has punched therethrough a plurality of holes 12. Substrate 10 is suitably on the order of 0.2 inches thick, 37/8 inches long and 1 1/16 inches wide. Indicator element means, such as thin filter paper discs 14 impregnated with a chemical which changes color in reaction to exposure to a given toxic gas (or gases), are disposed on one side of substrate 10 adjacent the holes or apertures 12 and maintained in alignment with the apertures by an adhesive backing 16. Backing 16 is suitably a pressure sensitive tape and preferably an adhesive metallic foil. An identification tab 18 can also be interposed between substrate 10 and backing 16. An adhesive strip 20 can be included, if desired, for mounting the dosage badge, for example, on the hat or sleeve of a firefighter. It should be appreciated that, in the alternative, the badge can, of course, cooperate with a separate holder or clip.
A cover sheet means 22, suitably a further strip of pressure sensitive tape (adhesive metallic foil) is disposed on the front surface of substrate 10, effectively enclosing the indicator discs 14. Cover sheet 22 also includes a non-adhesive pull-tab 24, suitably formed of common masking tape, to facilitate removal. The discs 14 are preferably of greater dimensions than the substrate apertures 12.
The filter paper discs 14 are thin, suitably on the order of a few thousandths of an inch to facilitate measurement of the dosage, that is, the integrated time-concentration exposure to the toxic gas. Plural discs impregnated with respective predetermined concentrations of indicator chemicals, such that the respective discs change color in response to varying dosage levels, can be provided. The indicator discs change color as a function of the amount of indicator chemical on the badge, the rate of transfer of the toxic gas to the badge surface and the length of exposure time. The transfer of gas to each indicator element means 14 is effected by diffusion from the atmosphere, which is in turn controlled by the diffusion coefficient of the gas and the concentration gradient of the gas in the atmosphere to which the badge is exposed. A thin disc 14, on the order of a few thousandths of an inch thick, is utilized such that the amount of adsorption of the gas (e.g., HCl) on the badge, if any, required to effect a reaction with the indicator chemical is small. Accordingly, where the atmosphere is constantly renewed, dosage becomes proportional to exposure time. At relative air/badge velocities below one mile per hour local gas concentration tends to be depleted by the badge, which gives rise to an erroneous dosage indication. However, one mile per hour is comparable to normal movement. Thus in field usage, normal movement and wind generally maintain the circulation above the one mile per hour point. Accordingly, a badge mounted on a person provides indicia of the concentration dosage to which the person is exposed.
A dosage badge in accordance with the present invention can be utilized to measure the dosage of any gas for which a color sensitive indicator is available and can react with a reagent. For example, a conventional indicator for carbon monoxide would be PdCl 2 test paper. A partial list of gases for which conventional indicators exist capable of being fabricated into apparatus according to the present invention, is provided in Table I. It is to be understood that the apparatus according to the present invention also may include as the indicator elements thereof means that are responsive to other environmental conditions besides the presence of a gas--for instance the presence of soot or other particulate contaminant, or the presence of various concentrations of different types of radiation.
TABLE I______________________________________Badge Detectable Gases______________________________________Acetyline Hydrogen CyanideAmmonia Hydrogen SelenideArsine Hydrogen SulfideCarbon Dioxide Methyl BromideCarbon Monoxide Methyl MercaptanChlorine Nickel CarbonylChlorine Dioxide Nitrogen DioxideDimethyl Ether PhosgeneEthylene PhosphineEthylene Oxide Sulfur Dioxide Vinyl Chloride______________________________________
It should be appreciated that buffer solutions can be included on discs 14 to control dosage and glycol to inhibit evaporation and intensify the colors. For example, badges made utilizing K 2 CO 3 , sodium bicarbonite and glycerol solutions may be utilized.
Dosage measurement is initiated by removing cover sheet 22 from the front of substrate 10 to expose indicator discs 14 to the atmosphere through apertures 12. Such action is illustrated pictorially in FIG. 2. The dosage badge is affixed to, for example, the sleeve of a fireman's overcoat, either by adhesive strip 20 or by a suitable clip or holder. An exemplary clip is shown at 26 in FIG. 2, having elongated edges 30 which support edges of the substrate 10, and having supporting clip loops 32 extending from one end of each of the edges 30 for engaging an article of clothing of the user, the non-adhesive pull tab 24 of the pressure sensitive tape 22 extending from an end of the substrate adjacent the ends of the edges 30 from which the supporting clip loops 32 extend so that the tape 22 may be readily removed from the substrate 10 while the entire indicating assembly (substrate 10, disks 14, and backing 16) remain attached to the user. Cover sheet 22 is easily removed by pulling on tab 24. Each of the respective discs 14 changes color in response to respective predetermined dosages of a chosen toxic gas, for example, HCl. As illustrated in FIG. 3, at low dosages, all of the indicator discs are of a first color, suitably green or blue. As the dosage increases, the colors of the indicators change, in sequence, from green to orange, and then from orange to red. The color changes in the badge, analogous to the color changes of a conventional stop light, are thus easy to read and interpret.
It should be appreciated that a dosage badge in accordance with the present invention is particularly advantageous in that it can be inexpensively fabricated. In preparing the badge, the substrate is first formed. A plastic strip is cut, holes are punched therethrough, and the substrate cleaned with alcohol. The adhesive backing strips are cut to length, and paper filter discs, suitably preimpregnated with a predetermined concentration of indicator chemical and buffer, are disposed in spaced relation on the adhesive side of the backing by, for example, an automatic dispenser. Similarly, an ID tab can be disposed on the backing. The backing strip is then applied to the substrate with the discs in alignment with the apertures in the substrate. The cover strips are then disposed on the front surface of the substrate, and the pull-tab attached and cut to length. It should be appreciated that unimpregnated filter paper discs can be set into the badge and loaded with indicator solution just prior to sealing the badge with the cover strip.
A three concentration indicator badge has been tested in laboratory conditions utilizing a universal indicator with a sodium bicarbonate buffer and glycerol water solution (to inhibit evaporation and improve color change contrast). Tests results indicate the badge response to be linear with dosage within 20% with air speed exceeding 1 mile per hour. Tests in the presence of a crib fire containing 300 grams of polyvinyl chloride provided dosage indications agreeing with concentrations measured by Dragger tube sampling. The color changes were found to be easily seen and interpreted by the firefighters at distances of 15 feet in a smokey atmosphere.
It will be understood that the above description is of illustrative embodiments of the present invention, and that the invention is not limited to the specific forms shown. For example, backings more rigid than the pressure sensitive tape described above, can be utilized if desired. Modifications may be made in the design and arrangements of the elements without departing from the spirit of the invention as defined in the appended claims.
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An inexpensive badge for detection of dangerous gases wherein a plurality of paper discs impregnated with a color sensitive gas indicator chemical are mounted in alignment with apertures in a plastic substrate by a pressure sensitive tape backing. The front face of the substrate is covered with a further strip of pressure sensitive tape, which is removed to initiate indication of gas dosage by the detector.
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FIELD OF THE INVENTION
This invention relates generally to road working or repair equipment and more particularly to a novel road or pavement surfacing machine.
BACKGROUND
Unevenness of a road surface can reduce the useful life of the road. When a vehicle rides over an uneven road surface, it tends to bounce vertically on its suspension resulting in dynamic loading of the road. The forces created in this way are significantly greater than the static load due to the weight of the vehicle. These increased forces create damaging stresses on the pavement materials used in road construction and consequently decrease road life.
Road unevenness is attributable to a number of sources including the curling or warping of adjacent concrete slabs used in road construction. Other sources of unevenness include wheel wear and sub-base movement. Diamond grinding can be used to eliminate road surface unevenness by using diamond-impregnated saw blades to grind away material creating a new, smoother road surface. Diamond impregnated blades can also be used to introduce grooves running parallel to the direction of vehicle travel. Such grooves act as drainage channels for water between tires and pavement, and thus reduce skidding and hydroplaning accidents without increasing the dynamic forces experienced by the road surface. An example of a pavement surfacing machine that utilizes diamond grinding is described in U.S. Pat. No. 4,588,231 to Silay et al., which is incorporated herein by reference in its entirety.
Diamond-impregnated saw blades are typically circular and are ganged together on a common axle to form a grinding head several feet wide. The head is rotated and held against the road surface as it is moved in a direction perpendicular to its axis to grind away a portion of the road surface. The spacing between the diamond blades determines the type of cut. Narrow spacing typically results in the pavement surface being ground, whereas increasing the spacing results in grooving. A mechanism is also normally employed to maintain the head at a uniform height, thereby causing the cut surface to be smooth and level under normal operating conditions. One such mechanism that is commonly employed is a set of wheels that ride along the cut surface of the pavement behind the cutting head and another set of wheels that ride along the uncut surface of the pavement a substantial distance ahead of the cutting head.
Diamond impregnated saw blades wear during grinding, however, and are expensive and time-consuming to replace. A key consideration in diamond grinding is the lifetime of the blades, which is maximized if the blades are rotated at a rate within a specified range of optimal angular velocities and if the torque load on the blades is held within a specified range. Excessive angular velocities or torque loads can result in the blades wearing more rapidly than necessary to perform a desired grind, while insufficient angular velocities or torque loading can polish the cutting surfaces of the blades. Polishing dulls the blades and severely inhibits their ability to perform road surface grinding.
The amount of material ground from a road surface is often referred to as the depth of cut. Achieving a smooth surface typically requires cutting from the pavement surface an amount of material that varies over time, thereby creating a varying depth of cut. However, when a surface is ground by a diamond-impregnated cutting head moving at a constant angular velocity and a constant forward speed, the torque loading of the head varies with the depth of cut required. In this environment, an operator must manually alter the forward travel speed of the diamond-impregnated cutting head in response to varying loads to maintain the angular velocity of the blade and the torque loading on the blade within their optimal ranges. This requires a high level of operator skill and creates a risk that the operator will select a forward travel speed that will damage the blades.
SUMMARY OF INVENTION
The present invention provides closed loop control systems and methods for controlling the operation of a pavement surfacing machine. In one form, the invention monitors operating parameters of a pavement surfacing machine to control the forward travel speed of the pavement surfacing machine and to achieve an even cut while increasing productivity and grinding head blade life.
One embodiment that controls a pavement surfacing machine having a vehicle moveable in a preselected direction of travel along a pavement surface under the influence of a prime mover and configured to urge a rotatable grinding head against the pavement surface includes a controller and at least one sensor configured to measure a preselected operational parameter of the pavement surfacing machine and provide an output representative of the parameter. The controller is configured to control the rate at which the vehicle moves in response to the sensor output.
In another embodiment, the preselected operational parameter is indicative of the weight on the depth control assemblies and the controller is configured to decrease the speed of the vehicle when the weight on the depth control assemblies falls below a predetermined threshold. In a further embodiment, the sensor is a load cell connected to the controller and located within a depth control assembly for measuring the weight on the depth control assembly.
In yet another embodiment, the preselected operational parameter is indicative of the rotational speed of the grinding head and the controller is configured to increase the speed of the vehicle when the rotational speed of the grinding head is greater than a predetermined threshold and decrease the speed of the vehicle when the rotational speed of the grinding head is less than a predetermined threshold. In a still further embodiment, the sensor is an electronic load control module connected to the controller and located within a grinding engine to measure the power output of the grinding engine.
Yet another embodiment again also includes an engine connected to a hydraulic system for moving the vehicle and involves a sensor that is a rotary transducer mounted on the front wheel of the vehicle.
The method of the invention may include measuring a preselected operational parameter of the pavement surfacing machine and moving the pavement surfacing machine at a rate dependent upon the operational parameter. In an alternative embodiment, the operational parameter is indicative of the weight on the depth control assemblies, the speed of the pavement surfacing machine is decreased when the weight on the depth control assemblies falls below a predetermined threshold.
In another alternative embodiment, the operational parameter is indicative of the rotational speed of the grinding head, the speed of the pavement surfacing machine is increased when the rotational speed of the grinding head is greater than a predetermined threshold and the speed of the pavement surfacing machine is decreased when the rotational speed of the grinding head is less than a predetermined threshold.
In a further alternative embodiment, the operational parameter is the speed of the pavement surfacing machine.
In a still further alternative embodiment, the operational parameter is the output power of the grinding engine and the speed of the pavement surfacing machine is decreased when the output power of the grinding engine exceeds a predetermined threshold.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a side view of an embodiment of a pavement surfacing machine in accordance with one embodiment of the present invention;
FIG. 2 is a block diagram of a closed-loop control system usable in the pavement surfacing machine of the invention; and
FIG. 3 is a flow chart illustrating a method of the invention for generating control signals in response to inputs from an electronic control module, a rotary transducer and load cells.
DETAILED DESCRIPTION
Referring to the drawings, a pavement surfacing machine 10 constructed according to an embodiment of the invention includes a frame 12 that is supported by wheels 14 , 15 and on which a grinding head 16 is mounted for rotation. The pavement surfacing machine also includes two engines. A grinding engine 18 is used to provide mechanical power for rotation of the grinding head and an auxiliary engine 20 is used to provide hydraulic power to a drive axle assembly 22 for moving the pavement surfacing machine. The speed of the movement of the pavement surfacing machine during a grind is controlled by a closed loop control system 24 , which monitors operational parameters of the pavement surfacing machine and adjusts its forward travel speed accordingly.
Turning now to FIG. 1 , an embodiment of a pavement surfacing machine in accordance with the invention is shown that includes a frame 12 propelled by an auxiliary engine 20 , a grinding head 16 driven by a grinding engine 18 and a closed loop control system 24 . The frame of the pavement surfacing machine includes an overhead frame 30 and a hinged mainframe 32 . A front set of wheels 14 are connected to the overhead frame and a rear set of wheels 15 are mounted to the mainframe. The weight of the upper frame bears on the rear wheels via a traction cylinder 34 . The grinding head is mounted to the mainframe and the weight of the upper frame can also be used to urge the grinding head against a road surface via mainframe cylinders 36 . The position of the mainframe relative to the pavement surface is controlled by a pair of depth control assemblies 38 positioned on either side of the main frame. The details of these features of the pavement surfacing machine are set forth in U.S. Pat. No. 4,588,231 to Silay et al., the disclosure of which was incorporated by reference above.
When in operation, the grinding head rotates in a direction opposite to the rotation of the wheels of the pavement surfacing machine. This is referred to as “up cutting” and tends to cause the grinding head to be pulled down into the cut as it cuts. However, if the pavement surfacing machine moves at a speed that prevents the grinding head from removing all of the material encountered by the blades, then the blades will ride up out of the cut. This riding up is discernible as a decrease in the load on the depth control assemblies. In a heavy cut the grinding head may ride up a sufficient distance to lift the mainframe off the depth control assemblies, resulting in an uneven cut.
The pavement surfacing machine illustrated in FIG. 1 can use a closed loop control system in accordance with the invention to control its forward travel speed in response to varying conditions during a cut. The closed loop control system can be configured using known control techniques to achieve one or more objectives and typically seeks to achieve these objectives by measuring operational parameters of the pavement surfacing machine and modifying the operation of the pavement surfacing machine in response to these measurements. In one embodiment, the closed loop control system is configured to rapidly cut large pavement surface areas, while maintaining a high degree of evenness and avoiding unnecessary wear or damage to the grinding head blades. In other embodiments the closed loop control system can be configured to achieve other objectives such as minimizing blade wear, achieving a cut of the required evenness irrespective of time or other similar objectives.
A closed-loop control system 24 configured to rapidly cut large pavement surface areas, while maintaining a high degree of evenness and avoiding unnecessary wear or damage to the blades of the grinding head is shown in FIG. 2 . The illustrated system 24 operates by controlling the forward travel speed of the pavement surfacing machine in response to the amount of power from the grinding engine that is delivered to the grinding head and the weight on the depth control assemblies. The closed-loop control system includes a controller 40 and a memory 42 for storing both data and software used in conjunction with the controller. The controller 40 generates output signals to control the forward speed of the pavement surfacing machine in response to information provided by the sensors mounted on the pavement surfacing machine.
In the illustrated embodiment, an electronic control module 44 mounted on the grinding engine provides one or more signals to the controller indicative of the power delivered to the grinding head by the grinding engine. The controller also receives input from load cells 46 mounted within each of the depth control assemblies. The load cells measure the force or weight exerted upon the depth control assembly and communicate this information to the controller. Data can also be provided to the controller by a rotary transducer 48 mounted on the front wheel of the pavement surfacing machine. The output of this rotary transducer can be used to determine the forward travel speed of the pavement surfacing machine
One embodiment of the invention uses a programmable logic controller (PLC), such as Model Number SLC 500 PLC from the Allen Bradley Company, which is part of Rockwell Automation, Inc. of Milwaukee, Wis. In addition, load cells such as part number 1220AJ-50K manufactured by Interface, Inc. of Scottsdale, Ariz., can be used as the load cells within the depth control assemblies. In embodiments that use grinding head engines that have an electronic control module, such as a QSX 15 660 Horse Power Diesel Engine manufactured by Cummins, Inc. of Columbus, Ind., the electronic control module will typically generate an output indicative of the proportion of the engine power delivered to the load. When an engine lacking an electronic load control module is used as the grinding engine, then a tachometer can be used to measure the rate of rotation of the grinding head as an alternative input to the controller. The rotary transducer can be implemented using the part number 845H-SJDN22CKY2G manufactured by the Allen Bradley Company.
A number of mechanisms can be used to set or alter the forward travel speed of the pavement surfacing machine. In one such embodiment, the auxiliary engine 18 generates hydraulic flow by operating an electrically controlled hydraulic pump having a swash plate controllable via an electric signal. The magnitude of the flow generated by the swash plate determines the speed at which the pavement surfacing machine moves. Therefore, the control system can control vehicle speed by providing outputs 50 to the control card that ensure the swash plate provides the required hydraulic flow to the drive axle assembly.
A QSX 15 engine can also be used as the auxiliary engine and an example of a suitable electrically controlled hydraulic pump is the part number AA4VG56EP2D1/32RNSC52F023D manufactured by Bosch Rexroth Corporation of Hoffman Estates, Ill.
The closed-loop controller 18 can also include a user input/output (“I/O”) interface 52 combining an interface such as a display screen with user controls such as an alphanumeric keyboard or keypad that can be manipulated by the user. The I/O interface enables input of operational data for use by the controller.
As previously mentioned, the controller illustrated in FIG. 2 can be configured with the objective of rapidly cutting large pavement surface areas, while maintaining a high degree of evenness and avoiding unnecessary wear or damage to the blades of the grinding head. In doing so, the closed loop controller can use the I/O interface to prompt the operator for control parameters. When a control system similar to the system described above is used, then the system can prompt the user to enter a maximum allowable forward travel speed, a maximum allowable grinding engine power output and minimum allowable depth control assembly loads. The maximum allowable forward travel speed is typically chosen based upon operator knowledge of the speed at which the machine can travel through light cuts without “riding up”. In addition, the maximum allowable grinding engine power output is chosen to ensure that the blades do not wear too rapidly and the minimum allowable depth control assembly loads are chosen to provide a sufficient margin to ensure that evenness of the cut is maintained within an acceptable tolerance. User input in response to these prompts can then be provided to the controller through the I/O interface. Alternatively, the controller 40 can be pre-programmed with default values. The values entered by the user, or the default values, are then used by the controller to control the forward speed of the vehicle in response to signals received from sensors mounted on the pavement surfacing machine.
A flowchart illustrating a process for generating control signals in response to inputs from an electronic control module 44 , load cells 46 and a rotary transducer 48 in accordance with the present invention is illustrated in FIG. 3 . The process 68 involves determining ( 70 ) the vehicle speed using inputs from the rotary transducer. Once the speed is determined, it is compared ( 72 ) to a preselected maximum allowable vehicle speed. If the pavement surfacing machine exceeds the specified allowable maximum speed, then the control system 18 outputs ( 74 ) a signal to the hydraulic pump, which reduces the speed of the pavement surfacing machine.
If the vehicle speed is below the specified maximum allowable speed, then the power output of the grinding engine 30 is measured ( 76 ) by examining the input received from the electronic control module 44 . A decision ( 78 ) as to whether the power output of the grinding engine exceeds the specified maximum allowable power output is then performed. If the measured power output of the grinding engine exceeds the specified maximum allowable power output, then the controller 40 sends ( 80 ) a signal to the hydraulic pump, which results in a decrease in the hydraulic flow delivered to the drive axle assembly and a decrease in the vehicle speed.
If the measured output power of the grinding engine is determined ( 78 ) to be equal to or less than the specified maximum allowable output power, then a measurement ( 86 ) of the load on the load cells 46 is performed. Once a measurement has been performed, a decision is made ( 88 ) as to whether the load on either of the depth control assemblies 32 is less than the specified minimum allowable load. If the load on either of the depth control assemblies is less than the minimum allowable load, indicating that the grinding head is “riding up”, then a control signal is sent ( 90 ) to the hydraulic pump, which has the effect of reducing the speed of the pavement surfacing machine. This permits the grinding head to act on the high spot for a greater period of time, thereby removing sufficient material to increase the weight on the depth control assembly and causing that parameter to fall within the prescribed range. If the load on the depth control assembly is not less than the minimum threshold load, then a control signal is sent ( 92 ) to the hydraulic pump, which has the effect of increasing the forward travel speed of the pavement surfacing machine.
By specifying a maximum allowable forward travel speed, a maximum allowable power output from the grinding engine and minimum allowable depth control assembly loads, the controller can configure the control system to automatically operate the pavement surfacing machine during a grind. The above embodiment of a control system in accordance with the present invention causes a pavement surfacing machine to ramp up to the specified maximum allowable forward travel speed until a heavy cut is encountered. The increase in the power output of the grinding engine and the reduction in the weight on the depth control assemblies that result from a grinding head “riding up” during a heavy cut would typically cause the control system to respond by reducing the forward travel speed of the pavement surfacing machine until the power output of the grinding engine and the weight on the depth control assemblies had returned to acceptable levels. At which point, the control system can attempt to increase the forward travel speed. A continued heavy cut would prevent continued increase, however, the return of normal cutting conditions would see a ramping up of speed until the maximum allowable forward travel speed was obtained or another heavy cut encountered.
More specifically, to begin grinding in one embodiment an operator enters a pre-set maximum allowable forward travel speed via the control system I/O interface 52 . For illustrative purposes, this may be 20 feet per minute (F.P.M.). The operator would also enter a maximum allowable grinding engine power output as a percentage of full engine power, this may be 80% of full engine power. This percentage of power is directly proportional to the torque on the grinding head blades. Next, the operator would lower the mainframe cylinders 36 and traction frame cylinder 34 until the rear wheels 15 and depth control assemblies 38 are forced into contact with the pavement. The operator would then lower the blades into the pavement surface by use of the depth control assemblies, for example to a depth of ¼″. Next, the operator would use the controls of the pavement surfacing machine 10 to move the machine forward, which moves the grinding head 16 forward. This forward motion increases the load imposed on the grinding engine 18 and decreases the load on the depth control assemblies. The operator can then hand over control to the closed loop control system 24 , which causes the pavement surfacing machine to ramp up to the pre-set forward travel speed of the 20 F.P.M. unless the load on the engine reaches the pre-set allowable maximum of 80% or the load on the depth control assemblies falls below the pre-set allowable minimum. The event that the load on the engine exceeds the allowable maximum load or the loads on the depth control assemblies fall below the allowable minimum loads, then the speed of the machine will be reduced until these present parameters are satisfied. However, as soon as the load on the grinding engine decreases and the load on the depth control assemblies increases to acceptable levels, then the machine can attempt to ramp back up to the pre-set maximum allowable forward travel speed.
While the above description contains many specific embodiments of the invention, these should not be construed as limitations on the scope of the invention, but rather as an example of one embodiment thereof. Many other variations are possible. For example, the vehicle drive system need not be a fluid drive. Furthermore, additional inputs can be utilized by the controller 40 in other embodiment of the invention. For example, a pavement surfacing machine can include a single depth control assembly and/or load cells located within the structures used to suspend the grinding head 16 from the vehicle 12 . In addition, the controller need not be a PLC. A personal computer or another computing device with appropriate programming could be used in place of a PLC. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their equivalents.
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Apparatus and methods for controlling the operation of a pavement surfacing machine are described. One embodiment that controls a pavement surfacing machine having a vehicle moveable in a preselected direction of travel along a pavement surface under the influence of a prime mover and configured to urge a rotatable grinding head against the pavement surface includes at least one sensor configured to measure a preselected operational parameter of the pavement surfacing machine and provide an output representative of the parameter and a controller that is configured to control the rate at which the vehicle moves in response to the sensor output.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application Ser. No. 61/877,243, filed on Sep. 12, 2013, the entire contents of which are incorporated herein by reference.
SUMMARY
[0002] The invention relates to the problem of safely listening to music while riding a bicycle or engaging in other outdoor activities that take place near automobiles and other moving vehicles. Currently, to listen to music or other audio, cyclists typically ride with earphones in one or both ears. This creates a safety concern by isolating the user from the surrounding environment. So much so that many states have laws against riding a bicycle with earphones in both ears and some states disallow earphones completely. Furthermore, earphones require a wire to connect the actual speaker placed in the ear cannel to the music player. This wire is at best an annoyance and at worst a safety issue when is restricts the user's movement.
[0003] An embodiment of the system consists of two small side-firing high fidelity speakers and an electronics package contained in a small water resistant plastic housing. Microphones are located close to one or more of the speakers. Optionally offered is a small chinstrap mounted microphone so that the cyclist can use their cell phone in a hands free manner while riding. The speakers, microphone and electronics package are detachable from their respective helmet base mounts to enable the system to be moved from one helmet to the next. This is especially beneficial when the customer utilizes different helmets for different types of cycling or weather conditions. It also allows the removal of the system when washing the helmet.
[0004] The side-firing speakers are positioned vertically, so that the sound is directed generally downward from the speaker when the speakers are attached to a helmet or hat at a location that is above the ear. The use of side-firing speakers allows the speaker housing to be exceptionally thin, which among other things, reduces wind noise, reduces the likelihood of being dislodged from the helmet or hat or broken due to accidently hitting or being hit by something, and makes the system more unobtrusive.
[0005] Within the electronics package is a Bluetooth 3.0 receiver, a stereo amplifier, and a lithium-ion battery. The battery provides sufficient power to operate the system in play mode for up to 8 hours and standby for up to 400 hours.
[0006] Music is played by pairing the speaker unit with any Bluetooth 3.0 compatible device. This includes the popular Apple iPhone/iPod and most Android or Windows powered mobile devices. With the device synched to the speaker unit the user simply selects the speaker system from the device and adjusts the volume. When used with a smart phone this even allows the cyclist to enjoy music streamed from services like Pandora. Some embodiments include a handlebar mounted wireless volume control.
[0007] In an alternative embodiment, the unit is hat-mounted so that is usable in activities that do not require a helmet, such as running, jogging, and walking. This would offer the same safety benefits as the cycling helmet embodiments but also eliminate the annoyance of the dangling wire and self-ejecting earphones.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a diagram of an embodiment of a speaker system, with the right speaker housing shown in exploded view.
[0009] FIG. 2 is a photograph showing a side view of an embodiment of a speaker system as it may be connected to a hat.
[0010] FIG. 3 is a photograph showing a rear view of an embodiment of a speaker system as it may be connected to a hat.
[0011] FIG. 4 is a diagram of an embodiment of a speaker system shown in exploded view.
[0012] FIG. 5 is a diagram of an embodiment of a speaker system, with the right speaker housing shown in exploded view.
[0013] FIG. 6 is a diagram showing a side view of an embodiment of a speaker system as it may be connected to a helmet.
[0014] FIG. 7 is a diagram showing a side view of an embodiment of a speaker system as it may alternately be connected to a helmet.
[0015] FIG. 8 is an upward looking perspective view, exploded drawing of an embodiment of a speaker system.
[0016] FIG. 9 is a downward looking perspective view drawing of an embodiment of a speaker system.
DETAILED DESCRIPTION
[0017] An embodiment according to the invention is shown in FIG. 1 . A speaker system 100 includes an electronics body 110 connected to a right arm 120 and a left arm 125 . At the end of the left arm 125 is a left speaker housing 135 . A right speaker housing 130 , shown in exploded view in FIG. 1 , is at the end of the right arm 120 . Each speaker housing includes a speaker 140 and a microphone 150 . In some embodiments, however, no microphone is included or a microphone is only included in one of the speaker housings. The speakers 140 and microphones 150 are electrically connected to electronics (not shown) in the electronics body 110 by wire tape 160 . Speaker 140 is a side firing speaker in which the sound produced by the speaker 140 is directed out of the narrow bottom edge 145 of the speaker 140 . Speaker 140 and speaker baffle 170 fit inside a speaker chamber 175 within each speaker housing 130 / 135 . The speaker housing 130 / 135 , speaker 140 , and speaker baffle 170 form a back cavity that improves the sound and performance of the speaker. The speaker system 100 also includes one or more clips 180 for attaching the speaker system 100 to, for example, the lower edge of a hat. An embodiment according to the invention is shown in FIGS. 2 and 3 as it may be positioned relative to a hat using clips 180 .
[0018] In many embodiments the speakers are model RA11x15 speakers with side venting manufactured by Knowles Electronics. The use of side-firing speakers such as the Knowles model RA11x15 speakers allows for a very thin speaker housing which, among other things, reduces wind noise, reduces the likelihood of hitting or being hit by something, and makes the speaker system more unobtrusive.
[0019] In many embodiments the electronics in the electronics body 110 include (now shown), a battery, a Bluetooth receiver, a digital to audio converter and an amplifier. In many embodiments the speaker system 100 includes buttons (shown in other figures) for controlling operations of the speaker system such as volume and Bluetooth pairing. Alternatively or additionally, the same or additional buttons also control operations of a portable audio device, such as play/pause, forward/reverse, and skip track forward/reverse. The portable audio device may include an mp3 player, smart phone, or tablet. In some embodiments, some or all of the buttons are provided in a wireless module that may be mounted, for example, on the handlebars of a bicycle. In some embodiments the wireless connection is a dedicated wireless connection between the button module and the speaker system. In some embodiments the wireless connection is a Bluetooth connection separate from the Bluetooth connection between the speaker system and the portable audio device. In some embodiments the wireless connection is a Bluetooth connection directly between the button module and the portable audio device.
[0020] In some embodiments, the speaker system 100 does not have buttons for controlling operations of the speaker system. In many of these embodiments, the operations of the speaker system are controlled by voice commands. In such embodiments, the electronics in electronics body 510 include a processor that performs voice recognition functions. By using voice commands, the user of the speaker system is able to control the speaker system and the portable audio device with using their hands, allowing them, in the case of a cyclist, to keep both hands on the handlebars. In some embodiments the voice recognition function is performed by the portable audio device connected to the speaker system rather than by the electronics of the speaker system. In some embodiments, the portable audio device includes an application that will send commands back to the speaker system (such as volume up or down or mute) based on the results of the voice recognition performed by the portable audio device. In some embodiments the voice input received from the speaker system is sent by the portable audio system to a cloud-based application which performs the speech recognition function.
[0021] An embodiment according to the invention is shown in FIG. 4 . The speaker system 400 shown in FIG. 4 generally corresponds to the speaker system 100 shown in FIG. 1 . The speaker system 400 is shown in an exploded view that separately shown an inner housing 490 and an outer housing 495 . Fitting between the inner housing 490 and the outer housing 495 are speaker 440 , speaker baffle 470 , wire tape 460 , microphone 450 , and buttons 485 . In some embodiments inner housing 490 and outer housing 495 snap together. In some embodiments inner housing 490 and outer housing 495 are connected to each other by screws. In some embodiments inner housing 490 and outer housing 495 are connected by a combination of snapping and screws.
[0022] An embodiment according to the invention is also shown in FIG. 5 . The speaker system 500 shown in FIG. 5 also generally corresponds to the speaker system 100 and speaker system 400 shown in FIGS. 1 and 4 . Accordingly. Speaker system 500 includes an electronics body 510 connected to a right cable 520 and a left cable 525 . At the end of the left cable 525 is a left speaker housing 535 . A right speaker housing 530 , shown in exploded view in FIG. 5 , is at the end of the right cable 520 . Each speaker housing includes a speaker 540 and a microphone 550 . In some embodiments, however, no microphone is included or a microphone is only included in one of the speaker housings. The speakers 540 and microphones 550 are electrically connected to electronics (not shown) in the electronics body 510 by wires (not shown) in cables 520 / 525 . Speaker 540 is a side firing speaker in which the sound produced by the speaker 540 is directed out of the narrow bottom edge 545 of the speaker 540 . Speaker 540 and speaker baffle 570 fit inside a speaker chamber 575 within each speaker housing 530 / 535 . The speaker housing 530 / 535 , speaker 540 , and speaker baffle 570 form a back cavity that improves the sound and performance of the speaker.
[0023] The speaker system 500 also includes one or more clips 180 for attaching the electronics body 510 and the speaker housings 530 , 535 to, for example, a bicycle helmet. An embodiment according to the invention is shown in FIGS. 6 and 7 as the electronics body and a speaker housing may be positioned relative to a bicycle helmet using clips 580 . FIGS. 6 and 7 both show a speaker housing clipped to one of the straps that go under a riders chin to hold the helmet in place. FIGS. 6 and 7 show two different exemplary ways in which a speaker housing may be clipped to a strap of a bicycle helmet.
[0024] In many embodiments the speakers are model RA11x15 speakers with side venting manufactured by Knowles Electronics as described above in more detail.
[0025] In many embodiments the electronics in the electronics body 510 include (now shown), a battery, a Bluetooth receiver, a digital to audio converter and an amplifier. In many embodiments the speaker system 500 includes buttons (not shown) for controlling operations of the speaker system such as volume and Bluetooth pairing and alternatively or additionally, controlling operations of a portable audio device, such as play/pause, forward/reverse, and skip track forward/reverse, as described more completely above.
[0026] Another embodiment of the speaker system is shown in FIG. 8 . This embodiment is similar to the embodiments discussed above. In this embodiment, the outer housing 895 is made from polycarbonate material and the inner housing 890 is made of a silicone material. In other embodiments the outer housing is made of a material that is similarly impact resistant to polycarbonate material. In other embodiments the inner housing 890 is made of similarly flexible and/or soft material to silicone material. This embodiment also includes a USB port 885 in the electronics package. A portable audio device can be connected by wire through the USB port 885 rather than by using a Bluetooth or other wireless connection. In some embodiments the USB port 885 is substituted or supplemented with a 3.5 mm audio jack, another type of wired audio connection, or a combination of two or more of these (not shown).
[0027] Another embodiment of the speaker system is shown in FIG. 9 , in completely assembled form.
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A helmet speaker system includes two small side-firing high fidelity speakers and an electronics package contained in a small water resistant plastic housing. Microphones are located close to one or more of the speakers. The speakers, microphone and electronics package are detachable from their respective helmet base mounts to enable the system to be moved from one helmet to the next. The side-firing speakers are positioned vertically, so that the sound is directed generally downward from the speaker when the speakers are attached to a helmet or hat at a location that is above the ear. The side-firing speakers have a very thin profile when viewed from the rider's front.
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RELATED APPLICATIONS
The present invention claims the benefit of U.S. Provisional Application Ser. No. 60/067,511 entitled “Method and Apparatus For Dynamically Modifying Instructions in a Very Long Instruction Word Processor” and filed Dec. 4, 1997.
FIELD OF THE INVENTION
The present invention relates generally to improvements in parallel processing, and more particularly to advantageous techniques for providing dynamic very long instruction word (VLIW) sub-instruction selection for execution time parallelism in an indirect VLIW processor.
BACKGROUND OF THE INVENTION
In a VLIW processor, a typical problem is that it is difficult to make effective use of the full capabilities of the fixed length VLIWs available in the hardware. In previous designs, this design problem led to a very porous VLIW memory containing many No Operation (NOP) instructions within the VLIWs. Some machines have attempted to encode the NOPs to more fully utilize the VLIW memory space. One motivation of such attempts was to make better use of the costly VLIW memory included in these earlier processors. The encoded NOPs were typically assigned to each specific VLIW with no reuse of the VLIW possible in different areas of the program.
There are other needs to be met by a VLIW parallel data processor. For example, it is desirable to pipeline operations in order to achieve a steady state flow of data for maximum throughput. Consider the case of matrix multiplication using a VLIW architecture with four short instruction words (SIWs) per VLIW. In the example of FIG. 1, a 4-element vector 2 and a 4×4 matrix 4 are multiplied. Given a processor with operands stored in a register file and VLIW execution units that operate on register file source data operands and deliver result data to the register file, it can be reasonably assumed that the vector elements are stored in data registers R 20 =a 0 , R 21 =a 1 , R 22 =a 2 , and R 23 =a 3 , and the 4×4 matrix 4 is stored in a processor accessible memory. FIG. 2 illustrates how the entire operation is handled in a typical prior art approach. Each row in table 10 represents a unique short instruction word (SIW) or VLIW instruction with the program flow beginning at the top of the table and proceeding time-wise down the page. The Load operation is an indexed load that incrementally addresses memory to fetch the data element listed and load it into the specified register R 0 or R 1 . The Add and Mpy instructions provide the function Rtarget=Rx Operation Ry, where Rtarget is the operand register closest to the function name and the source operands Rx and Ry arc the second and third register specified. Each unique VLIW memory address is identified with a number in the first column. The table 10 of FIG. 2 shows that a minimum of seven VLIWs, each stored in a unique VLIW memory address, and three unique SIWs, are required to achieve the desired results in the prior art. It is important to note that of the seven VLIWs, three VLIWs, namely numbers 1 , 2 , and 7 , use only two SIWs per VLIW, the other four use three SIWs per VLIW. When a four instruction slot VLIW contains only two SIWs, the other two slots contain NOP instructions. When the four instruction slot VLIW contains three SIWs, the other slot contains a single NOP. With a five instruction slot VLIW as will be described in greater detail below, even poorer usage of the VLIW memory results using prior art techniques. In the vector matrix example, a five slot VLIW will use 7*5=35 VLIW memory locations with 17 NOPs assuming the fifth slot is not used for this matrix multiplication example. The prior art approach results in a very porous VLIW memory with numerous NOP instructions.
It is desirable to reduce the number of unique VLIW memory addresses to accomplish the same task since this makes more efficient use of the available hardware. It is also desirable to reduce duplicate instructions in the VLIW memory storage. This is an important consideration that allows a smaller VLIW memory to be designed into a processor thereby minimizing its cost. Further, if the same VLIW memory address could be shared by multiple sections of code and even multiple programs then the latency cost of loading the VLIW memories can be minimized, as compared to prior art approaches, and amortized over the multiple programs thereby improving overall performance. In addition, it is desirable to extend this concept into multiple Processing Elements (PEs) and to a controller Sequence Processor (SP) of a Single Instruction Multiple Data stream (SIMD) machine
SUMMARY OF THE PRESENT INVENTION
The present invention is preferably used in conjunction with the ManArray architecture various aspects of which are described in greater detail in U.S. patent application Ser. No. 08/885,310 filed Jun. 30, 1997, U.S. patent application Ser. No. 08/949,122 filed Oct. 10, 1997, U.S. patent application Ser. No. 09/169,255 filed Oct. 9, 1998, U.S. patent application Ser. No. 09/169,256 filed Oct. 9, 1998, U.S. patent application Ser. No. 09/169,072 filed Oct. 9, 1998, and U.S. patent application Ser. No. 09/187,539 filed Nov. 6, 1998, Provisional Application Ser. No. 60/068,021 entitled “Methods and Apparatus for Scalable Instruction Set Architecture” filed Dec. 18, 1997, Provisional Application Ser. No. 60/071,248 entitled “Methods and Apparatus to Dynamically Expand the Instruction Pipeline of a Very Long Instruction Word Processor” filed Jan. 12, 1998, Provisional Application Ser. No. 60/072,915 entitled “Methods and Apparatus to Support Conditional Execution in a VLIW-Based Array Processor with Subword Execution” filed Jan. 28, 1988, Provisional Application Ser. No. 60/077,766 entitled “Register File Indexing Methods and Apparatus for Providing Indirect Control of Register in a VLIW Processor” filed Mar. 12, 1998, Provisional Application Ser. No. 60/092,130 entitled “Methods and Apparatus for Instruction Addressing in Indirect VLIW Processors” filed Jul. 9, 1998, Provisional Application Ser. No. 60/103,712 entitled “Efficient Complex Multiplication and Fast Fourier Transform (FFT) Implementation on the ManArray” filed Oct. 9, 1998, and Provisional Application Ser. No. 60/106,867 entitled “Methods and Apparatus for Improved Motion Estimation for Video Encoding” filed Nov. 3, 1998, respectively, and incorporated herein in their entirety.
The present invention addresses the need to provide a compressed VLIW memory and the ability to reuse instruction components of VLIWs in a highly advantageous way. In one aspect, the present invention comprises a SIW fetch controller for reading instructions from the SIW memory (SIM), a VLIW memory (VIM) to store composed VLIWs at specified addresses, a VLIW controller for indirectly loading and reading instructions from the VIM, and instruction decode and execution units. VLIWs in the present invention are composed by loading and concatenating multiple SIWs in a VIM address prior to their execution.
In a SIMD machine, the SIW fetch controller resides in the SIMD array controller SP which dispatches the fetched 32-bit instructions to the array PEs. The SP and the PEs include a VIM, a VIM controller, and instruction and decode execution units. The concepts discussed in this disclosure apply to both the indirect VLIW (iVLIW) apparatus and mechanism located in the SP controller and each PE in a multiple PE array SIMD machine.
After at least one VLIW is loaded into VIM, it may be selected by an execute-VLIW (XV) instruction. There are two types of XV instructions described in this invention. The first one XV 1 provides sub-VLIW SIW selection across the slots at the same VIM address for execution time parallelism. The second XV 2 provides sub-VLIW SIW selection with independently selectable SIWs from the available SIWs within each of the slots VIM sections for execution time parallelism. The XV 1 instruction is described first with an example demonstrating the advantages of this approach. The XV 2 instruction description follows with an example demonstrating its inherent advantages.
The XV 1 instruction causes the stored VLIW to be read out indirectly based upon address information that is computed from a VIM base address register and an immediate Offset value that is present in the XV 1 instruction. The XV 1 instruction contains Mask-Enable-bits which select the instructions from the read-out VLIW that are to be scheduled for execution. In a preferred ManArray embodiment there are 8-bit Mask-Enable-bits, one bit per execution unit, supporting up to 8-SIWs in a single VLIW. For the first implementation, 5 SIWs are preferably used.
Due to the use of a VIM base register, Vb, unlimited VIM storage is possible. For each Vb base address, the XV 1 instruction preferably supports, in the first implementation, an 8-bit offset thereby allowing 256 VLIWs per Vb address. The preferred ManArray architecture specifies that up to 8 SIWs can be stored per VIM address and a minimum of eight Mask-Enable-bits, one per slot, are supported by the preferred embodiment. Also, because each VIM entry has a unique address, each VIM entry can be loaded, modified, executed, or disabled, independently.
With eight SIW slots available per VIM entry, up to 255 unique combinations of SIW types can be stored in each entry, where, for example, SIW instruction types can include Store, Load, Arithmetic Logic Unit (ALU), Multiply Accumulate Unit (MAU), and Data Select Unit (DSU) instruction types. Each combination represents a unique indirect VLIW (iVLIW) available for XV 1 execution. Furthermore, when invoking the execution of SIWs from a previously loaded VIM entry via the XV 1 containing the 8-bit mask, up to 255 unique iVLIW operations can be invoked from that VIM entry alone.
The XV 2 instruction provides the capability to remove duplicate instructions within groups of VLIWs within a slot specific section of the VIM. This capability provides optimum packing of instructions within the VIM thereby further optimizing its efficiency and minimizing its size for specific applications.
A more complete understanding of the present invention, as well as other features and advantages of the invention will be apparent from the following Detailed Description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the multiplication of a vector by a matrix;
FIG. 2 illustrates a prior art approach to the multiplication operation of FIG. 1;
FIG. 3 illustrates a ManArray 2×2 iVLIW processor showing the connections to a plurality of processing elements connected in an array topology for use in conjunction with the present invention;
FIG. 4A illustrates an iVLIW data path with a VIM in accordance with a presently preferred embodiment of the present invention;
FIG. 4B illustrates a presently preferred XV 1 , execute VLIW, instruction and syntax/operation details therefor;
FIG. 4C illustrates a presently preferred LV 2 , load/modify VLIW- 2 , instruction and syntax/operation details therefor;
FIG. 4D illustrates a presently preferred XV 2 , execute VLIW, instruction and syntax/operation details therefor;
FIG. 5 illustrates aspects of an iVLIW XV 1 pipeline with across slot compression utilized with an exemplary XV 1 instruction format in accordance with the present invention;
FIG. 6 illustrates the approach of the present invention applied to the multiplication operation of FIG. 1;
FIG. 7 illustrates dynamic cycle-by-cycle iVLIW instruction selection across instruction slots for execution time parallelism;
FIG. 7A illustrates program code using XV 1 instructions for the multiplication operation of FIG. 1;
FIG. 8 illustrates aspects of an iVLIW XV 2 pipeline with within slot compression utilizing an exemplary XV 2 instruction format in accordance with the present invention;
FIG. 9 illustrates dynamic cycle-by-cycle iVLIW instruction selection with within slot compression for execution time parallelism; and
FIG. 10 illustrates program code using XV 2 instructions for the multiplication operation of FIG. 1 .
DETAILED DESCRIPTION
In a preferred embodiment of the present invention shown in FIG. 3, a ManArray 2×2 iVLIW Single Instruction Multiple Data stream (SIMD) processor 100 containing a controller sequence processor (SP) combined with a processing element- 0 (PE 0 ) SP/PE 0 101 , as covered in more detail in co-pending application Ser. No. 09/169,072 entitled “Methods and Apparatus for Dynamic Merging an Array Controller with an Array Processing Element”, and three additional PEs 151 , 153 , and 155 are utilized to implement the dynamic iVLIW modification techniques of the present invention. The SP/PE 0 101 contains a fetch controller 103 to allow the fetching of SIWs from a 32-bit instruction memory 105 . The fetch controller 103 provides the typical functions needed in a programmable processor such as a program counter (PC), a branch capability, digital signal processing loop operations, support for interrupts, and also provides the instruction memory control which could include an instruction cache if needed by an application. In addition, the SIW I-Fetch controller 103 dispatches 32-bit SIWs to the other PEs in the system by way of a 32-bit instruction bus 102 .
In this exemplary system, common elements are used throughout to simplify the explanation. It will be recognized that further implementations are not limited to this restriction. For example, the execution units 131 in the combined SP/PE 0 101 can be separated into a set of execution units optimized for the control function, e.g. fixed point execution units, and the PE 0 as well as the other PEs can be optimized for a floating point application. For the purposes of this invention description, it is assumed that the execution units 131 are of the same type in the SP/PE 0 and the PEs. In a similar maimer SP/PE 0 and the other PEs use a five instruction slot iVLIW architecture which contains a VIM memory 109 and an instruction decode and VIM controller function unit 107 which receives instructions as dispatched from the SP/PE 0 's I-Fetch unit 103 and generates the VIM addresses-and-control signals 108 required to access the iVLIWs, identified by the letters SLAMD in block 109 , stored in the VIM. The loading of the iVLIWs is described in more detail in co-pending patent application Ser. No. 09/187,539 filed Nov. 6, 1998 and entitled “Methods and Apparatus for Efficient Synchronous MIMD Operations with iVLIW PE-to-PE Communications”. Also contained in the SP/PE 0 and the other PEs is a common PE configurable register file 127 which is described in more detail in co-pending patent application Ser. No. 09/169,255 filed Oct. 9, 1998 and entitled “Method and Apparatus for Dynamic Instruction Controlled Reconfiguration Register File with Extended Precision”. Due to the combined nature of the SP/PE 0 101 , the data memory interface controller 125 must handle the data processing needs of both the SP controller, with SP data in memory 121 , and PE 0 , with PE 0 data in memory 123 . The SP/PE 0 controller 125 also is the source of the data that is sent over the 32-bit broadcast data bus 126 . The other PEs, 151 , 153 , and 155 contain common physical data memory units 123 ′, 123 ″, and 123 ′″ though the data stored in them is generally different as required by the local processing done on each PE. The interface to these PE data memories is also a common design in PEs 1 , 2 , and 3 and indicated by PE local memory and data bus interface logic 157 , 157 ′ and 157 ″. Interconnecting the PEs for data transfer communications is the cluster switch 171 more completely described in co-pending patent application Ser. No. 08/885,310 filed Jun. 30, 1997 and entitled “Manifold Array Processor”, U.S. Pat Ser. No. 08/949,122 filed Oct. 10, 1997 and entitled “Methods and Apparatus for Manifold Array Processing”, and U.S. Pat Ser. No. 09/169,256 filed Oct. 9, 1998 and entitled “Methods and Apparatus for ManArray PE-to-PE Switch Control”. The above noted applications are assigned to the assignee of the present invention and incorporated herein by reference in their entirety. The interface to a host processor, other peripheral devices, and/or external memory can be implemented in many ways. The primary mechanism shown for completeness is contained in the DMA control unit 181 that provides a scalable ManArray data bus 183 that connects to devices and interface units external to the ManArray core. The DMA control unit 181 provides the data flow and bus arbitration mechanisms needed for these external devices to interface to the ManArray core memories via bus 185 .
FIG. 4A shows an overall basic iVLIW data path 400 in which a fetched instruction is stored in an instruction register 401 which is connected to a VIM load and store control function unit 403 . The VIM load and store control function provides interface signals to a VIM 405 . The output of the VIM 405 is pipelined to an iVLIW register 407 .
One presently preferred XV 1 instruction 425 is shown in FIG. 4 B. XV 1 instruction 425 is for 32-bit encoding as seen in encoding block 430 and has a presently preferred syntax/operation shown in syntax/operation block 435 as described further below. The XV 1 instruction 425 is one of the control group of instructions defined by the Group field bits 30 and 31 and is used to select VLIWs from VLIW memory (VIM) and execute individual instruction slots of the specified SP or PE, selectable by the SP/PE bit 29 . The VIM address is computed as the sum of a base VIM address register Vb (V 0 or V 1 ) plus an unsigned 8-bit offset VIMOFFS shown in bits 0 - 7 , the block of bits 431 , of encoding block 430 of FIG. 4 B. The VIM address must be in the valid range for the hardware configuration otherwise the operation of this instruction is undefined.
Similarly, FIG. 4C shows a presently preferred LV 2 instruction 455 for a load/modify VLIW- 2 function. An encoding block 450 for 32-bit encoding and syntax/operation block 460 are shown. FIG. 4D shows an XV 2 instruction 475 having a 32-bit encoding block 470 and syntax/operation block 480 .
Dynamic SP and PE iVLIW Across Slot Compression Operations
The XV 1 instruction is advantageously used to modify, enable/disable sub-iVLIW instructions, and indirectly execute iVLIW instructions in the SP and the PEs. The iVLIWs have been loaded into VIM by use of the LV instruction, also referred to as LV 1 elsewhere in this application, which is described in more detail in previously mentioned co-pending application Ser. No. 09/187,539. As illustrated in FIG. 5, each VIM 516 entry preferably consists of five SIW slots (one per execution unit) and associated with each SIW slot are additional state bits, of which only 5 are shown (one d-bit per slot). Included among the five execution units are a store unit 540 associated with VIM 51 6 store instruction slot 520 , load unit 542 associated with load instruction slot 522 , an arithmetic-logical unit (ALU) 544 associated with ALU instruction slot 524 , a multiply-accumulate unit (MAU) 546 associated with an MAU instruction slot 526 , and a data-select unit (DSU) 548 associated with a DSU instruction slot 528 .
The five state d-bits 521 , 523 , 525 , 527 , and 529 are LV-loaded disable bits for the instruction slots that indicate either: the SIW slot is available-for-execution or it is not-available for-execution. A binary value suffices to distinguish between the two states. An instruction slot with its d-bit set to the not-available-for-execution state is interpreted as an NOP (no-operation) instruction by the execution unit. In addition, the appropriate d-bit for that functional slot position is loaded into bit- 31 of that slot. Alternatively, the d-bits may be grouped and stored in a different location within a VIM address line while still maintaining the relationship between a d-bit and its associated execution unit and instruction slot within the iVLIW.
FIG. 5 illustrates an iVLIW XV 1 pipeline 500 , in which a received XV 1 instruction is loaded into an instruction register 1 (IR 1 ) 510 . The output of IR 1 is pre-decoded 512 early in the pipeline cycle prior to loading the VLIW Instruction Register 2 values (IR 2 ) 514 . Upon receipt of an XV 1 instruction in IR 1 510 , the VIM address 511 is calculated by use of the specified Vb registers, 501 or 502 , as selected by the Vb signal 509 sourced from IR 1 510 bit- 9 , and added by adder 504 to the offset value included in the XV 1 instruction via path 503 . It is noted that by using bit- 8 and bit- 9 together up to 4 Vb registers can be specified. The resulting VIM address 507 is passed through multiplexer 508 to address the VIM 516 . The iVLIW at the specified address is read out of the VIM 516 and passes through the multiplexers 530 , 532 , 534 , 536 , and 538 , to the IR 2 registers 514 . As an alternative to minimize the read VIM 516 access timing critical path, the output of VIM 516 can be latched into a register whose output is passed through a multiplexer prior to the decode state logic. The enable mask bits, bits 10 - 17 of the XV 1 instruction stored in IR 1 510 , are distributed via path 537 to bit storage latches, S bit- 14 to S latch 550 , L bit- 13 to L latch 552 , A bit- 12 to A latch 554 , M bit- 11 to M latch 556 , and D bit- 10 to D latch 558 .
These enable-mask-bits override the d-bit available-for-execution setting for each instruction slot for the XV execution cycle. In more detail, the Load VLIW- 1 (LV 1 ) instruction causes the d-bit setting to be loaded into each VIM slot. The d-bit per execution unit slot represents the enabled or disabled status of the slot position. An inactive state of this bit, for example a “0”, represents the disabled state and the active state of this bit, for example a “1”, represents the enabled state. If the d-bit in a slot is enabled, it may be over-ridden by the XV 1 mask enable bit appropriate for that slot. If the d-bit in a slot is disabled, it can not be overridden by the XV 1 mask enable bit appropriate for that slot. In other words, a slot disabled by a LV 1 instruction can not be reenabled by an XV 1 instruction. Conversly, a slot enabled by a LV 1 instruction can be disabled or kept enabled by an XV 1 instruction. The simple logic to accomplish this is located in each functional unit. This capability is required for the functionality described herein and to efficiently support synchronous MIMD operations as described in more detail in co-pending application Ser. No. 09/187,539 filed Nov. 6, 1998. Alternatively, the latches 550 - 558 can be avoided if the timing path allows the override logic to be placed at the output of the VIM prior to IR 2 clocking. In either case, the functional unit's decode and execute logic 540 - 548 either executes all instructions received from VIM or executes an NOP based upon the setting of the d-bits and the mask enable bits. For the XV 1 execution, the IR 2 MUX 1 control signal 519 in conjunction with the pre-decode XVcl control signal 517 cause all the IR 2 multiplexers, 530 , 532 , 534 , 536 , and 538 , to select the VIM output paths, 541 , 543 , 545 , 547 , and 549 . The mask enable bits are present at their latch inputs. At the end of the pre-decode cycle, the VLIW IR 2 514 and the mask enable bit latches are clocked and their outputs become present at the inputs of the functional units. At this point, the five individual decode and execution stages of the pipeline, 540 , 542 , 544 , 546 , and 548 , are completed, executing the instruction or an NOP, in synchrony providing the iVLIW parallel execution performance. To allow a non-XV single 32-bit functional instruction to execute by itself in the PE or SP, the bypass VIM path 535 is shown. For example, when a simplex ADD instruction is received into IR 1 510 for parallel array execution, the pre-decode function unit 512 generates the IR 2 MUX 1 519 control signal, which in conjunction with an ADD instruction pre-decode signal, causes the ALU multiplexer 534 to select the bypass path 535 . Since in this case there is no XV instruction in execution, the enable-mask-bits are ignored by the functional unit logic.
Any combination of individual instruction slots may be executed via the execute slot parameter ‘E={SLAMD}’, where S=Store Unit (SU), L=Load Unit (LU), A=Arithmetic Logic Unit (ALU), M=Multiply-Accumulate Unit (MAU), and D=Data Select Unit (DSU). A blank ‘E=’ parameter does not execute any slots. The Vx bit- 24 specifies if this XV 1 overrides the LV UAF setting. Vx=0 means do not override LV UAF setting and Vx=1 means override the LV UAF setting with the one specified in this XV 1 's UAF field bits 22 and 23 . The Unit Affecting Flags (UAF) parameter ‘F=[AMDN]’ overrides the UAF specified for the VLIW when it was loaded via the LV instruction. The override selects which arithmetic instruction slot (A=ALU, M=MAU, D=DSU) or none (N=NONE) is allowed to set condition flags for this execution of the VLIW. The override does not affect the UAF setting specified via the LV instruction. A blank ‘F=’ selects the UAF specified when the VLIW was loaded.
Condition Flags are set by the individual simplex instruction in the slot specified by the setting of ‘F=’ parameter from the original LV instruction or as overridden by a ‘F=[AMD]’ parameter in the XV 1 instruction. Condition flags are not affected when ‘F=N’.
The XV 1 operation takes one execute cycle to complete, though pipeline considerations must be taken into account based upon the individual simplex instructions in each of the slots that are executed.
Overall operation of the present invention may be better understood by examining its application to the exemplary problem presented in the discussion of the prior art. In the table 600 of FIG. 6, each row represents an iVLIW. Each unique VIM address 610 is identified with a number in the first column. The boxed table entries represent SIWs that are masked (i.e. disabled) by the XV 1 instruction during execution. In table 600 of FIG. 6, the shaded iVLIWs 612 , 614 , 616 and 618 at VIM address- 0 highlight four occasions in which the SIWs stored at VIM address- 0 are invoked by the XV 1 instruction, each time with a different mask. The first time the instructions are invoked, only the Load Unit is allowed to execute and the Multiply-Accumulate and the Store Units are masked out by the XV 1 instruction. The second time the VIM address- 0 iVLIW instructions are invoked, the Load and Multiply-Accumulate Units are allowed to execute and the Store Unit is masked out by the XV 1 instruction. The third time, all three units are allowed to execute. Finally, the fourth time the instructions stored in address- 0 iVLIW are invoked, only the Store Unit is allowed to execute and the Load and Multiply-Accumulate Units are masked out. In the 2×2 ManArray 100 of FIG. 3, four independent vector* matrix operations, on independent local PE data stored in each PEs local data memories, will be occurring in parallel and in synchronism while maintaining a single thread of control with the dispatching of the 32-bit XV 1 instructions to each PE. The iVLIWs identified in this example are the same in each PE with the operands accessed from each PE's local register file and local data memory.
FIG. 7 illustrates the FIG. 6 example's four iVLIWs as stored in VIM addresses 0 - 3 710 and the cycle-by-cycle dispatched instruction sequence 720 to the decode-and-execution units. The dispatched instruction sequence 720 illustrates the reuse and cycle-by-cycle redefinition of the iVLIWs that are executed in parallel at execution time. This redefinition is a selecting of the SIWs stored in an iVLIW at a specific VIM address. For example, iVLIW- 0 is shown used in instruction execution cycles 1 , 3 , and 7 with different groupings of the iVLIW- 0 's SIWs. In cycle- 1 , only the Load unit instruction is used. In cycle- 3 the Load and MAU units are used and in cycle- 7 , the Store, Load, and MAU units are used. FIG. 7 illustrates how the present invention accomplishes a significant saving in the number of unique VLIW memory entries required by a program, by effectively “packing” several VLIW operations into a single VLIW memory entry. Thus, with the present invention, multiple programs can share a single VLIW memory entry, by storing multiple iVLIWs at the same VIM address. The example also demonstrates the use of the invention to build up and tear down software pipelines. Furthermore, the size of the iVLIW memory in a parallel processor can be kept from becoming prohibitively expensive to build. FIG. 7A illustrates exemplary program code 730 using the XV 1 instruction to accomplish the vector* matrix multiplication of FIG. 1 on the 2×2 ManArray 100 of FIG. 3 .
Dynamic SP and PE iVLIW Within Slot Compression Operations
For the within slot compression mechanism, the VIM is divided up into separate VIM sections each associated with the functional decode-and-execute units. Each of the VIMs' address maps are divided into multiple 4-bit addressable sections as governed by the offset field included in a second version of the execute iVLIW instruction, XV 2 , with a separate offset that can be specified for each VIM slot section. This VIM configuration and XV 2 addressing option provide the ability to independently select instructions within each VIM slot 4-bit address range. By providing this ability, duplicate SIWs within the 16 addressable iVLIW range can be eliminated providing greater packing of SIWs within the composite VIM. Of course, many variations of addressing options can be envisioned utilizing the inventive techniques to allow the independent selection of SIWs within a partitioned VIM but one is described further below to illustrate various aspects of the within-slot-compression in accordance with the present invention.
The XV 2 instruction is similar to the XV 1 instruction in that it is used to modify, enable/disable sub-iVLIW instructions, and indirectly execute iVLIW instructions in the SP and PEs. It does so, however, in a different way than the XV 1 instruction. For the XV 2 instruction, it is still assumed that the iVLIWs have been loaded into this new partitioned VIM by use of a new version of the Load VLIW instruction, LV 2 455 shown in FIG. 4 C. The LV 2 encoding block 450 consists of a CtrlOp field, bits 25 - 28 , that represent the LV 2 instruction opcode, a load instruction bit- 23 that specifies if at least one instruction is to be loaded or if only the disable d-bit for the specified address is to be loaded. Bit- 22 is the disable d-bit that is loaded. Bits 18 - 21 specify that up to 16 instructions are to be loaded in the specified functional unit's VIM, bits 15 - 17 , beginning at the address specified by the Vb register address, bit- 9 , plus the VIMOFFS offset address, bits 0 - 7 . The syntax/operation details are shown in block 460 . The XV 2 instruction 475 is shown in FIG. 4 D. The encoding format is shown in encoding block 470 with new bit fields as follows. The UAF field bits 23 and 24 are not optional on XV 2 and must be specified with each XV 2 use. The VIM base register selection Vb is bit 20 and the five offset fields are Store VIM offset (SOFS) bits 16 - 19 , Load VIM offset (LOFS) bits 12 - 15 , ALU VIM offset (AOFS) bits 8 - 11 , MAU VIM offset (MOFS) bits 4 - 7 , and DSU VIM offset (DOFS) bits 0 - 3 . The syntax/operation is shown in block 480 .
Referring to FIG. 8 which illustrates aspects of an iVLIW XV 2 pipeline 800 , VIM 816 consists of multiple independent memory units each associated with their functional decode and execute units. Independent addressing logic is provided for each slot VIM. As illustrated in FIG. 8 each VIM entry preferably consists of five SIW slots (one per execution unit) and associated with each SIW slot are additional state bits, of which 5 are shown (one d-bit per slot). Included among the five execution units are a store unit 840 associated with store instruction VIM 820 , load unit 842 associated with load instruction VIM 822 , an arithmetic-logical unit (ALU) 844 associated with an ALU instruction VIM 824 , a multiply-accumulate unit (MAU) 846 associated with MAU instruction VIM 826 , and a data-select unit (DSU) 848 associated with DSU instruction VIM 828 .
The FIG. 8 VIM address adder functional blocks, as exemplified by ALU VIM address adder 804 , are different than the adder functional block 504 of FIG. 5 in order to support the VIM address increment capability required by the Load VLIW- 2 (LV 2 ) Instruction of FIG. 4C as described in Syntax/Operation block 460 . This capability allows the instructions following the LV 2 instruction to be loaded at:
(V[ 01 ]+VIMOFFS)[UnitVIM]←1 st Instruction following LV 2
(V[ 01 ]+VIMOFFS+1)[UnitVIM]←2 nd Instruction following LV 2
(V[ 01 ]+VIMOFFS)+InstrCnt)[UnitVIM]←1 st (InstrCnt) th Instruction following LV 2
The instruction count InstrCnt is a binary coded number, 0 thru F, that represents from 1 to 16 instructions that can be loaded into up to 16 consecutive UnitVIM locations.
The five state d-bits 821 , 823 , 825 , 827 , and 829 are LV-loaded disable bits for the instruction slots that indicate either: the SIW slot is available-for-execution or it is not-available-for-execution. A binary value suffices to distinguish between the two states. An instruction slot with its d-bit set to the not-available-for-execution state is interpreted as an NOP (no-operation) instruction by the execution unit. In addition, the appropriate d-bit for that functional slot position is loaded into bit- 31 of that slot.
The operation of the iVLIW XV 2 pipeline 800 is as follows. A received XV 2 instruction is loaded into instruction register 1 (IR 1 ) 810 . The output of IR 1 is pre-decoded by pre-decode function unit 812 early in the pipeline cycle prior to loading the VLIW instruction register 2 values in IR 2 814 . Upon receipt of an XV 2 instruction in IR 1 810 , multiple VIM addresses are calculated in parallel. The calculations differ for each VIM slot section due to each having its own offset value as set by the XV 2 instruction. Each Vim slot calculation is of the form Vb+ 0 extend{unitOFS[ 4 ]} where Vb represents one of two VIM address registers, and 0 extend aligns the 4-bit (unitOFS[ 4 ]) value with the extent of Vb. For example, the ALU VIM's address 811 is calculated by Vb+ 0 extend{AOFS[ 4 ]}, where the Vb value is sourced from either V 0 or V 1 as selected by the Vb field, bit- 20 , of IR 1 . Addition is accomplished by adder 804 . The AOFS[ 4 ]=IR 1 bits 8 - 11 are connected to adder 804 with the adder 804 output 807 being passed through multiplexer 808 to create the ALU VIM slot address 811 . The zero extend logic is not shown for clarity. The ability to mask an entry with XV 2 can be achieved without the use of the enable mask bits that were described in connection with the discussion of XV 1 operation. If a programmer desires the ability to mask an entry, he or she must plan for it in advance and ensure that within the group of 16 addresses, provided by the offset field, at least one of the SIWs is marked as disabled by use of the disable d-bit. For the particular IVLIW that is to be executed with a specific slot masked off, the unitOFS offset for that unit's VIM is used to select the disabled SIW previously stored. If no slots need to be disabled, full use of the 16 addresses are available for “enabled” SIWs. If only one slot is desired to be disabled, only that slot's VIM need contain the disabled instruction. Once the VIM addresses are selected, the appropriate SIWs are read out and sent to their decode and execution units. Since in XV 2 operation there is no need for the enable-mask-bits, there are no additional state bit latches required for input to the decode and execution units. Another difference between XV 1 and the XV 2 operation is that for XV 2 , the UAF field is always selected. The XV 2 operation takes one execute cycle to complete, though pipeline considerations must be taken into account based upon the individual simplex instructions in each of the slots that are executed.
The present invention may be better understood by examining the application of the XV 2 instruction to the exemplary problem in the discussion of the prior art. FIG. 9 illustrates the iVLIWs required using the XV 2 approach. Each decode and execution unit is associated with its own VIM each with different storage requirements for iVLIW usage. This is also depicted in FIG. 8 wherein a different address range per functional unit VIM is shown; ( 0 -(A- 1 )) store VIM 820 , ( 0 -(B- 1 ) load VIM 822 , ( 0 -(C- 1 )) ALU VIM 824 , ( 0 -(D- 1 )) MAU VIM 826 , and ( 0 -(E- 1 )) DSU VIM 828 . In FIG. 9, composite VIM 910 shows the five decode and execution units' VIMs. The storage requirements for this composite VIM 910 are as follows: the Store VIM requires only 2 locations, the Load VIM uses 3 locations, the ALU VIM uses 4 locations, the MAU VIM uses 5 locations, and the DSU VIM only needs one location. Only one set of disabled locations are used in each VIM which is shown by convention to be in VIM address 0 in each of the unit's VIMs. Dispatched instruction sequence 920 illustrates the reuse and cycle-by-cycle redefinition of the iVLIWs that are executed in parallel at execution time. This redefinition is a selecting of the SIWs stored in the units VIMs, but not all at the same VIM address as is done with XV 1 . For example, in instruction execution cycle- 4 of sequence 920 the store SIW is accessed from address 0 in the Store VIM, a disabled d-bit instruction, the Load SIW is accessed from address 2 in the Load VIM, a Load R 1 , Data instruction, the ALU SIW is accessed from address 3 in the ALU VIM, an Add R 9 ,R 5 ,R 6 instruction, the MAU SIW is accessed from address 3 in the MAU VIM, a Mpy R 5 ,R 0 ,R 22 instruction, and the DSU SIW is accessed from address 0 in the DSU VIM, a disabled d-bit instruction. FIG. 10 illustrates program code 1000 for using XV 2 instructions to accomplish the vector* matrix multiplication of FIG. 1 on the 2×2 ManArray 100 of FIG. 3 . Specifically, in the 2×2 ManArray of FIG. 3, four independent vector* matrix operations, on independent local PE data stored in each PE's local data memories, will be occurring in parallel and in synchronism while maintaining a single thread of control with the dispatching of the 32-bit XV 2 instructions to each PE. The iVLIWs identified in this exemplary description are the same in each PE with the operands accessed from each PE's local register file and local data memory.
In comparing the XV 2 approach with the XV 1 approach, it is observed that only 15 locations are used in the composite VIM 910 of the XV 2 approach illustrated in FIG. 9 and 20 locations are used in the VIM 710 of the XV 2 approach illustrated in FIG. 7 . Both approaches are significantly better than the prior art in their utilization of VLIW memory storage. Typically, 35 locations would have been required in a five slot VLIW prior art system. It is also noted that for cost sensitive applications, the XV 2 approach allows each functional unit's VIM to be cost optimized to the application.
While the present invention has been disclosed in the context of presently preferred methods and apparatus for carrying out the invention, various alternative implementations and variations will be readily apparent to those of ordinary skill in the art.
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A pipelined data processing unit includes an instruction sequencer and n functional units capable of executing n operations in parallel. The instruction sequencer includes a random access memory for storing very-long-instruction-words (VLIWs) used in operations involving the execution of two or more functional units in parallel. Each VLIW comprises a plurality of short-instruction-words (SIWs) where each SIW corresponds to a unique type of instruction associated with a unique functional unit. VLIWs are composed in the VLIW memory by loading and concatenating SIWs in each address, or entry. VLIWs are executed via the execute-VLIW (XV) instruction. The iVLIWs can be compressed at a VLIW memory address by use of a mask field contained within the XV 1 instruction which specifics which functional units are enabled, or disabled, during the execution of the VLIW. The mask can be changed each time the XV 1 instruction is executed, effectively modifying the VLIW every time it is executed. The VLIW memory (VIM) can be further partitioned into separate memories each associated with a function decode-and-execute unit. With a second execute VLIW instruction XV 2, each functional unit's VIM can be independently addressed thereby removing duplicate SIWs within the functional unit's VIM. This provides a further optimization of the VLIW storage thereby allowing the use of smaller VLIW memories in cost sensitive applications.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for manufacturing a semiconductor device; and, more particularly, to the method for manufacturing a ferroelectric random access memory (FeRAM) device to prevent the device from damage induced by a package process by applying an annealing process before the package process.
DESCRIPTION OF THE PRIOR ART
[0002] With the recent progress in film deposition techniques, applications of a nonvolatile memory cell using a ferroelectric thin film have increasingly been developed. This nonvolatile memory cell is a high-speed rewritable nonvolatile memory cell utilizing the high-speed polarization/inversion and the residual polarization of the ferroelectric capacitor thin film.
[0003] Therefore, a ferroelectric random access memory (FeRAM) where a capacitor thin film with ferroelectric properties such as strontium bismuth tantalate (SBT) and lead zirconate titanate (PZT) is increasingly used for a capacitor in place of a conventional silicon oxide film or a silicon nitride film, because it assures a low-voltage and high-speed performance, and does not require periodic refresh to prevent loss of information during standby intervals like a dynamic random access memory (DRAM).
[0004] Since a ferroelectric material has a dielectric constant ranging from hundreds to thousands value and stabilized residual polarization property at room temperature, it is being applied to the non-volatile memory device as the capacitor thin film. In case of employing the ferroelectric capacitor thin film in the nonvolatile memory device, information data are stored by polarization of dipoles when an electric field is applied thereto. Even if the electric field is removed, the residual polarization remains so that the information data, i.e., “0” or “1”, can be stored.
[0005] However, there are reliability problems for utilizing FeRAM as a memory device despite the fact that FeRAM has several advantages as aforementioned. Generally, there are two kinds of reliability problems in FeRAM, one of which is a fatigue problem and the other is a retention problem. The fatigue problem is related to how many times it preserves the data during repeated reading out and writing of the data, and the retention problem is related to how long it preserves the stored data.
[0006] To address the reliability problem of fatigue, attempts are made to use iridium oxide (IrO 2 ) or ruthenium oxide (RuO 2 ) as an electrode instead of platinum (Pt) when PZT is used as the capacitor thin film. Meanwhile, in case of using SBT as the capacitor thin film, a Pt electrode can be still available which shows improved property against the fatigue problem. Thus, the reliability problem related to fatigue of the memory device has been overcome to a considerable degree, i.e., 10 10 ˜10 13 cycles.
[0007] However, the second reliability problem of retention still remains as a serious matter. If the fabricated device is left alone for a long time after writing information data of “0” or “1”, a critical voltage is changed so that the stored data can hardly be read out with accuracy. In addition, if the device is exposed to high temperature for long time, the device characteristic is more deteriorated than in room temperature. For example, if a package process is carried out for the fabricated FeRAM device after a wafer level function test, the FeRAM experiences high thermal budget so that a pass rate of the device decreases eventually, because this package process is performed at high temperature for long time.
[0008] Especially, a post mold curing (PMC) process for curing the molding compound implicates the retention problem, where the process is carried out at 150˜175° C. for 5˜6 hours.
[0009] In more detail, after completing the fabrication of the FeRAM device, the wafer level function test is carried out to identify the defective device. However, after this test, the memory cells have one of the data, “0” or “1”. This means that domains in the ferroelectric capacitor thin film are arrayed in predetermined orientations to generate an electric field. Therefore, when the package process is carried out at high temperatures for a long time, providing that the domains are arrayed in the predetermined orientations, mobile defects easily move toward grain boundaries due to the electric field so that charge distributions at the grain boundaries get changed. This change of the charge distributions results in critical voltage shift, e.g., decrease or increase, and further this change brings a decrease of residual polarization, whereby the device eventually fails.
[0010] In other words, if the package process is performed after wafer level function test, the dipoles being oriented in the predetermined direction, the pass rate of the FeRAM device after the package process decreases more than that after the wafer level function test. Thus, the reliability problem of retention represents an obstacle for applying the FeRAM device as a memory device.
SUMMARY OF THE INVENTION
[0011] It is, therefore, an object of the present invention to provide a method for manufacturing a ferroelectric random access memory (FeRAM) device to prevent deterioration thereof by applying an annealing treatment.
[0012] In accordance with one aspect of the present invention, there is provided a method for manufacturing a ferroelectric random access memory (FeRAM) device, the method comprising the steps of: a) forming a unit die including a transistor and a capacitor on a semiconductor substrate; b) testing a wafer level function for the unit die; c) annealing the device above Curie temperature of ferroelectric material; and d) carrying out a package process for the device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] 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:
[0014] [0014]FIG. 1 is a flowchart setting forth a method for manufacturing a ferroelectric random access memory (FeRAM) in accordance with a preferred embodiment of the present invention; and
[0015] [0015]FIGS. 2A and 2B are hysterisis loop curves of polarization versus applied voltage before and after Curie temperature annealing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Referring to FIG. 1, there is provided a process chart for manufacturing a ferroelectric random access memory (FeRAM). To begin, after the memory devices have been completely fabricated on a wafer, step 201 , a wafer level function test is performed, step 203 , for identifying defective devices. That is, the wafer level function test detects defective memory cells by connecting detection probes to input/output terminals of the test circuit on the wafer. After this test, defective chips may be discarded or, in some cases, repaired on the wafer.
[0017] In a next process, an annealing process is carried out above a Curie temperature (Tc), step 205 , for getting rid of ferroelectricity of a ferroelectric capacitor thin film. The annealing process may be carried out in an inert gas ambient or in atmosphere by using a method such as a rapid thermal anneal (RTA) or in thermal anneal in a furnace. If the temperature rises above Tc, the ferroelectric thin film loses its ferroelectricity, i.e., has paraelectricity. On the contrary, if the temperature is lower than Tc, the ferroelectric material recovers its ferroelectricity again.
[0018] In more detail, the ferroelectric has a tetragonal crystal structure at room temperature so that this structure has polarization characteristic. But, above critical temperature, i.e., Curie temperature, the phase transformation occurs. That is, the tetragonal crystal structure is changed into a cubic crystal structure so that polarization characteristic disappears. Generally, the Curie temperature of ferroelectric materials for use in FeRAM devices ranges from 250° C. to 500° C. For example, Curie temperatures of PZT (PbZrTiO x ) and SBT (SrBiTaO x ) range from 350° C. to 500° C. and from 250° C. to 400° C. respectively.
[0019] In the case of lowering the temperature below Tc again, the cubic structure is changed into the tetragonal crystal structure so that paraelectricity is changed back into ferroelectricity. But, it is noted that in this state, the ferroelectric material has lost its experience, i.e., ferroelectricity before the annealing process. Thus, the domains are not arrayed in predetermined orientations, but are in random orientations.
[0020] Finally, a package process of post mold curing (PMC) is carried out for curing a molding compound, step 207 , and next, a package level function test is performed on the packaged devices, step 209 , to determine whether their electrical performance falls within specification. In this test, test signals are applied to the devices through the input pins of the packages, which are connected internally to the input/output pads of the test circuit. After this, the manufacturing process of the memory devices is completed, step 211 .
[0021] Referring to FIGS. 2A and 2B, there are shown two graphs of hysterisis loop curves setting forth a negative polling state and a positive polling state of the memory cell, respectively.
[0022] In FIG. 2A, after the wafer level function test, the ferroelectric may have a negative polling state at an initial state, which is denoted reference numeral 10 . But when this is experienced in the package process without Curie temperature annealing, the polling state of FeRAM device is changed, i.e., the graph is shifted to the right as denoted by reference numeral 20 . The change of the graph means that the switching charge and critical voltage are changed to degrade the reliability of the device and finally, the device fails. Meanwhile, reference numeral 30 denotes the P-V curve of the device which experiences the package process after Curie temperature annealing. In this graph, it is understood that there is no change of hysterisis loops before and after the package process.
[0023] In FIG. 2B, similar to FIG. 2A, when the device experiences the package process, the P-V curves are changed from the initial state 40 into a deteriorated state 50 . But, when the device has undergone Curie temperature annealing after the wafer level function test, the graph remains unchanged.
[0024] As described already, the present invention provides a solution for the retention problem of the FeRAM device by carrying out the Curie temperature annealing process after the wafer level test and before the package process.
[0025] In accordance with an embodiment of the present invention, the annealing process is a supplementary process in comparison with that of the prior art. But when making use of the conventional process of drying an ink mark which indicates “pass/fail” of the device after the wafer level function test, the supplementary annealing process is not required. That is, if the ink mark-drying temperature is heated up to the Curie temperature of the ferroelectric material, the annealing process can be carried out simultaneously with the ink mark-drying process.
[0026] Although the preferred embodiments of the invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claim.
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A method for manufacturing a ferroelectric random access memory (FeRAM) device, the method including the steps of forming a unit die including a transistor and a capacitor on a semiconductor substrate, testing a wafer level function for the unit die, annealing the device above Curie temperature of ferroelectric material, and carrying out a package process for the device.
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DESCRIPTION
1. Technical Field
This invention relates generally to measuring devices and, more particularly, to tape measuring devices containing means for marking or engraving articles.
2. Background Art
Tape measuring devices employing a coiled tape which may be slidably extended from a slotted housing for measuring an article are widely known in the art. Similarly, there have been several attempts to mount marking means on tape measuring devices in order to mark the desired measurement on the article.
One example of such a device is that disclosed in U.S. Pat. No. 3,802,083 to Freed. Freed discloses an attachment for a tape measuring device which employs a marking device mounted in an elongate housing with actuating means for manually imposing said marking means upon the article being measured. Freed also shows a pointer which is also mounted in the elongate housing and is slidably positioned to bear upon the top face of the extended tape as the marker is imposed upon the surface of the article in order to signal the exact tape position of the mark being made. It is also intended that the pointer secure the tape in position relative to the article as the mark is made.
However, as with the other devices which have attempted to incorporate a marking element into a tape measuring device, the Freed device has several deficiencies. As the marking element tip wears down, the marker element must be manually adjusted in order that it contact the item simultaneous to the pointer contacting the tape. In addition, the marking element must be at least long enough to extend from its mount to the surface of the article. When the marker element becomes shorter than this minimum length, it is practically unusable.
In the Freed device, the pointer arrests movement of the tape only so long as the device is held secure to the surface of the article. While several methods of locking the tape are known in the art, these locking mechanisms are manually engaged in an operation which is separate from the marking operation thus requiring two steps to lock the tape and mark the article at a desired length.
Accordingly, the present invention is directed to overcoming one or more of the problems as set forth above.
DISCLOSURE OF THE INVENTION
In accordance with one aspect of the present invention, a tape measuring device includes a casing with a coiled metal tape disposed within the casing which can be withdrawn through a slot in the casing for the purpose of measuring distance. Marking means is mounted within the casing to allow for marking an article being measured. In addition, means are provided for locking the extended tape in its current position simultaneous to actuating the marking means.
A manually operated actuator shaft is provided to engage the marking device and urge it into position to mark the article being measured. As the actuator shaft urges the marking device into position, it activates a tape braking mechanism which engages the tape and locks it in a fixed position relative to the casing.
According to another feature of this invention, a consumable marker is disposed within a feed mechanism within the casing which automatically maintains the consumable marker in the proper position for marking as the marker is consumed. This feed mechanism features a carrier unit in which the consumable marker is disposed. A series of horizontal feed segments are also contained in the carrier unit. These horizontal feed segments are stacked vertically within the carrier unit such that an end face of each of the feed segments contacts the marker along its length. The feed segments are spring loaded so that they are urged in a horizontal direction towards the consumable marker. As the length of the marker diminishes, the feed segments are urged into position above the top of the consumable marker thus enabling the downward force of the actuating shaft to be transmitted by the feed segments to the shortened marker.
In accordance with another feature of this invention, a scriber is mounted within the casing immediately along side the consumable marker. A second actuator shaft is provided for positioning the scriber to engrave the article being measured at a preselected length. This second actuator shaft will also simultaneously activate the tape braking mechanism as it is positioning the scriber. The first and second actuating shafts are positioned along side each other so that both the scriber and marker may be activated at the same time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of the present invention;
FIG. 2 is a cross-sectional view taken along the line 2--2 of FIG. 1;
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1, and showing the consumable marker in the marking position;
FIG. 4 is a cross-sectional view taken along line 3--3 of FIG. 1, and showing the consumable marker in the retracted position;
FIG. 5 is another perspective view of the preferred embodiment; and
FIG. 6 is a perspective view of the tape brake assembly of the preferred embodiment.
BEST MODE FOR CARRYING OUT THE INVENTION
Referring to FIG. 1, in one embodiment of the current invention there is provided a casing 10 with a coiled metal tape 12 disposed within the casing 10 such that the coiled tape 12 may be extended or retracted through a slotted opening 14 in the casing 10.
As most clearly shown in FIG. 2, two marking elements such as a consumable marker 34 and a scribe 24 are disposed within the casing and are positioned immediately forward of and along side the slotted opening 14 through which the coiled tape 12 is extended. However, a single marking or scribing means may be employed without departing from the spirit of applicant's invention. A pair of actuator shafts 16 and 18 extend through an opening 22 in the top of the casing 10. The downward force on either of the actuator shafts 16 or 18, or both actuator shafts 16 and 18 simultaneously, will be transmitted to consumable marker 34 or a scriber 24, thus positioning the consumable marker 34 or the scriber 24 for marking an item at the length indicated on the extended tape 12.
As will be appreciated by those skilled in the art, the employment of both a consumable marker 34 and a scriber 24 in a single device is of significant utility. The consumable marker 34 consists of any of a variety of materials such as crayon, chalk, lead, soap stone or tailor's crayons. Materials of this type provide a highly visable mark which may be readily removed from most items.
The scriber 24 may be made of any hard material such as stainless steel which would provide a pinpoint engraving on the item being marked. It should be noted that both the consumable marker 34 and the scriber 24 might be employed to mark a single position. Marking the desired position with the scriber provides an accurate, indellible mark. Marking that same position with the more visable consumable marker 34 allows for quick location of the mark made by the scriber 24.
An indicator of tab 20 is provided on the sidewall of the casing 10 in a position which is colinear with both of the marking means 34 and 24 and immediately adjacent to the extended tape 12. Thus, one may mark the article being measured at a preselected position by aligning the witness tab 20 with the corresponding position on the extended tape 12 and depressing the appropriate actuator shaft 16 or 18.
It will be appreciated by those skilled in the art that a second witness tab could be located on the opposite sidewall of the casing 10 in line with the consumable marker, scriber and the first witness tab. This second witness tab would be particularly useful in determining the location of a mark made by the consumable marker which is nearest the outer sidewall of the casing 10.
Reference to FIG. 2 will reveal that consumable marker 34 and scriber 24 is mounted along a line which is perpendicular to the edge of the extended tape 12. Each of the markers 34 and 24 is shown in a retracted position. Also shown are contact arms 28 and 30 which protrude from each of the actuator shafts 16 and 18 respectively. These contact arms will bear upon the end of the spring steel braking arm 26 whenever either of the actuating shafts 16 or 18 is depressed. As will be described, the braking mechanism is activated simultaneous with the activation of either of the actuator shafts for marking the item to be measured.
FIG. 3 shows the tape braking mechanism and the feed mechanism for the consumable marker employed in the preferred embodiment of the invention. The tape braking mechanism consists of a flexible braking arm 26 to which a tape brake 46 is mounted. The braking arm 26 may be made of any material which will provide a spring action when it is flexed, such as spring steel.
The tape brake 46 may be made from any rigid material, preferably molded plastic, and consists of a shaft 36 which extends in a direction perpendicular to the braking arm 26 and parallel to the surface of the tape 12, and an elongate tongue section 38 which extends from the lower surface of the shaft 36. The tape brake 46 is mounted upon the spring steel braking arm 26 by virtue of a slot in the shaft 36 of the tape brake 46 through which the braking arm 26 passes. The lower tongue portion 38 of the tape blade 46 is positioned along the length of the shaft 36 of the tape brake 46 such that, when the tape brake 46 engages the tape 12 the tongue portion 36 of the tape brake 46 contacts the tape 12 across substantially the entire width of the tape 12.
When in the engaged position the lower portion of the tape brake 46 bears down upon the top surface of the tape 12 and upon a brake pad 48 which contacts the bottom surface of the tape 12. The braking arm 26 is secured at one end by an anchoring element 50 which may be molded directly into the casing 10.
The braking arm 26 enters through an opening 56 in the wall of the casing 10 and extends through a slot 60 formed by recesses in the opposing faces of the actuator shafts 16 and 18 as best shown in FIG. 2. As either of the actuator shafts 16 or 18 is depressed, contact arm 28 or 30 bears down upon the braking arm 26 causing it to flex, with the sidewall of the casing at the opening 56 acting as a fulcrum for the braking arm 26. As the braking arm 26 bends, the tape brake 46 is rotated into position, contacting the tape 12 and securing it between the tongue of the tape brake 46 and the brake pad 48 on the opposite face of the tape 12. When the downward force is removed from the actuator shaft 16 or 18, the spring action of the braking arm 26 urges the actuator shaft 16 or 18 upward in the casing 10 to its retracted position. The braking arm 26 then assumes its relaxed position, and the tape brake 46 is lifted off of the face of the tape 12, thus disengaging the tape as shown in FIG. 3.
Either of the actuator shafts 16 or 18 may be downwardly positioned to engage the brake mechanism without forcing the corresponding markers 34 or 24 into marking position by providing detents at an intermediate position (not shown) on the actuator shafts 16 or 18 which may be slidably engaged with the casing 10 at the shoulder 52.
FIG. 3 also illustrates the positions of the various elements in the feed mechanism for the consumable marker 34 when the consumable marker 34 is in the retracted position. A carrier 40 is provided which houses the consumable marker 34 and a series of horizontal feed segments 64-74 which are mounted in a vertical fashion within the carrier 40 so that they contact the consumable marker 34 along substantially the entire length of the marker 34. For example, spring 44 contacts the sidewall of the carrier 40 and urges the horizontal feed segment 64 towards the consumable marker 34. The first actuator shaft 16 runs throughout the length of the carrier unit and through a narrow center section of each of the horizontal feed segments 64-74 into the upward position.
A spring mechanism 62 is mounted upon the inner wall of the casing 10 immediately adjacent to the outer surface of the carrier 40. The spring 62 projects through an opening 58 in the wall of the casing 10, and bears upon the surface of the carrier, insuring that the carrier unit remains aligned with the opening 70 in the casing 10 through which the marker 34 passes.
Referring to FIG. 4, as the first actuator shaft 16 is depressed, the actuator arm 82 moves through an opening 100 in the carrier 40 and bears down upon the top of the consumable marker 34 and the stack of horizontal feed segments 64-74. As the segment stack 64-74 is pushed into contact with the bottom face of the carrier 40, the carrier 40 moves downward until the carrier contacts the bottom face of the outer casing 10. At this point, the consumable marker 34 is projected through a hole 71 in the outer casing 10 and is in marking position.
It should be noted that, when the first actuator shaft 16 is released, the spring action of the braking arm moves the actuator shaft upward. Thus, the force of the lower contact arm on the feed segment stack forces the feed segment stack upward. When the stack of horizontal feed segments 64-74 contacts the upper surface of the carrier 40, the carrier 40 is then urged upward until it contacts the upper surface of the outer casing 10, leaving the consumable marker 34 in the retracted position. However, the marker itself, has been maintained in a fixed position relative to the carrier 40 by a relatively elastic retainer ring 32 which is mounted on the carrier 40 at the opening 70 through which the consumable marker 34 is issued.
As the consumable marker 34 is diminished in size to an extent greater than the height of the top horizontal feed segment 64, that horizontal feed segment 64 will be urged in a position over the consumable marker 34 when the feed mechanism is in its retracted position. Similarly, each of the subsequent horizontal feed segments will be urged into position above the marker as it continues to diminish in length. Thus, as the horizontal feed segments replace the void left due to the consumption of the consumable marker 34, the downward force of the upper contact arm 82 is transmitted by the displaced horizontal feed segments to the diminished consumable marker 34. FIG. 3 shows a consumable marker 34 which has been diminished in size to the extent that each of the horizontal feed segments 64 and 66 has been positioned above the consumable marker 34.
The feed mechanism for the scriber element 24 is best shown in FIG. 2 and includes a second actuator shaft 18 which is a mirror image design of the first actuator shaft 16, a scriber feed segment 94 contained within the casing 10, and the scriber 24. The scriber feed segment features a recess 98 which accomodates a scriber shaft end 96. Any downward motion of the actuator shaft 18 is transmitted by the scriber feed segment 94 to the top of the scriber 96, forcing the scriber 96 downward through an opening in the casing 10 into marking position.
The rear edge of the opening 22 in the casing 10 contains a shoulder portion 52 which serves as a detent for each of the actuator shafts 16 and 18. As best shown in FIG. 3, as the actuator shaft 16 is depressed, it may be slidably positioned such that the shoulder portion 52 of the casing 10 engages a slot 54 on the shaft, thus securing the consumable marker 34 in marking position. As previously mentioned, other slots may be provided at intermediate positions along the actuator shafts 16 and 18 which, when engaged with the shoulder 52, would maintain the shaft in a position which actuates the braking mechanism but does not place the consumable marker 34 or the scriber 24 in marking position.
As shown by FIG. 5, a viewing window 90 composed of plastic or any other suitable transparent material may be located at the front outer corner of the measuring device so as to provide easy monitoring of the consumable marker supply.
In its normal operation, the tab end 88 of the tape would be fixed on one edge of the article to be measured and the tape would be extended to some preselected distance. This distance would be marked on the article being measured by depressing either of the actuator shafts 16 or 18 depending on what type of mark is desired. The tape braking mechanism would allow the operator to lift the tape measuring device from the article and position it at a different point along the edge from the article while this tape remained in its preselected extended position. Both of the actuator shafts 16 and 18 may be depressed simultaneously at each position where both an accurate engraving and a highly visable mark necessary for locating the engraving is desired.
Other aspects, objects and advantages of this invention can be obtained from a study of the drawings, the disclosure and the appended claims.
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A tape measuring device including an outer casing and a coiled metal tape disposed within the casing which may be retracted or withdrawn through a slot in the front of the casing. In addition, a consumable marker and a scriber are disposed within the casing immediately forward of and along side of the slot through which the coiled tape is withdrawn. Either the consumable marker or the scriber may be positioned via manual actuating means to mark an object being measured at a preselected point along the length of the extended tape. Braking means are disposed within the casing which, when actuated, engage the tape and lock it into position relative to the casing. The braking mechanism is automatically activated when either the consumable marker or the scriber is positioned for marking the object being measured. In addition, the braking means may be activated without marking or engraving the object being measured. A plurality of feed segments disposed within the casing operate to insure that the marker continues to contact the workpiece even though its length is diminished over a period of usage.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/169,550, filed Apr. 15, 2009, and U.S. Provisional Application No. 61/169,602, filed Apr. 15, 2009, which are incorporated herein by reference.
BACKGROUND
This description relates to image and data segmentation.
The problem of segmentation or identification of objects or groups in data sets has applications in a wide number of fields. In the field of automated image processing and computer vision, problems including detecting boundaries between objects and detecting the presence of objects can be a difficult problem. For example, the problem of boundary detection has a long history in computer vision. In some approaches in a first era, boundaries were detected using gradient filters. In some approaches in a second era, contextual information was incorporated through optimization of objective functions based on Markov random fields, graph partitioning, and other formalisms. Today a new trend is to use machine learning to improve accuracy by training a computer to emulate human boundary judgments. In a typical approach, a boundary detector is trained by minimizing its pixel-level disagreement with humans.
One area of image processing in which boundary or object detection is important is in analysis of images of biological tissue. For instance, recent advances in electron microscopy (EM) have enabled the automated collection of nanoscale images of brain tissue. The resulting image datasets have renewed interest in automated computer algorithms for analyzing EM images. From the neuroscience perspective, development of such algorithms is important for the goal of finding connectomes, complete connectivity maps of a brain or piece of brain. To find connectomes, two image analysis problems must be solved. First, each synapse must be identified in the images. Second, the “wires” of the brain, its axons and dendrites, must be traced through the images. If both problems are solved, then it would be possible to trace the wires running from every synapse to the cell bodies of its parent neurons, thereby identifying all pairs of neurons connected by synapses. Other instances in which boundary or object detection in biological tissue is important is in analysis of medical images formed using computed tomography (CT) and magnetic resonance imaging (MRI) techniques, for example, locating and determining the extent of a tumor in the imaged tissue.
One approach to these problems in image processing makes use of boundary detection based on local image characteristics. For instance, pixels in an image are automatically labeled as boundaries versus object, and based on the labeled pixels, the image is segmented into objects. The automated labeling of boundary pixels can be based on a parametric technique, and the parameters are determined in a training procedure in which a set of training images and their corresponding boundary labeling are used to determine the parameters to be used in processing unknown images. For example, training images are analyzed manually to identify boundary pixels in the images, and the parameters are optimized to minimize the error between predicted and hand labeled boundary pixels (e.g., using a Hamming distance metric). A measure of accuracy of such approaches can use a metric based on the resulting segmentation of the image. For example, the Rand Index provides the average number of pairs of pixels in an image that are correctly identified as belonging to the same versus different segments or objects in the image.
SUMMARY
In a general aspect, certain approaches to segmentation or detection of objects and their boundaries in images (or other data sets) do not rely on machine learning approaches that aim to minimize pixel-level agreement between a computer and a human. Optimizing such pixel-level agreement does not, in general, provide the best possible result if boundary detection is a means to the ultimate goal of image segmentation, rather than an end in itself. In some examples, end-to-end learning of image segmentation specifically targets boundary errors with topological consequences, but otherwise does not require the computer to “slavishly” imitate human placement of boundaries. In some examples, this is accomplished by modifying a standard learning procedure such that human boundary tracings are allowed to change during learning, except at locations critical to preserving topology.
In another aspect, in general, the approach used for image segmentation is applied to a number of scenarios in which one desires high-throughput and automated analysis of structures within images. For example, such applications may include segmenting and profiling morphological properties of cells, segmenting neurons in light or electron microscopic images, and segmenting structures within MRI or other medical imaging.
In another aspect, in general, a system is applied to analysis of biological tissue. The system includes a segmentation apparatus configured to accept image data representing a three-dimensional image acquired from a biological sample, wherein the segmentation apparatus includes an input for accepting a data representation of segmentation parameters for controlling operation of the segmentation apparatus according to a segmentation procedure. The system also includes a parameter selection system configured to accept training image data and corresponding training segmentation data for a plurality of training images and produce the data representation of the segmentation parameters. The training segmentation data for a training image characterizes at least one of spatial extent of a plurality of objects in the training image and connectivity through a single object of pairs of locations in the training image. The parameter selection system is configured to select the segmentation parameters according to a parameter selection procedure that includes selecting the parameters according to a criterion based on at least one of (a) path connectivity between pairs of locations including path connectivity between non-adjacent locations and (b) a topology of the objects in the image.
Aspects may include one or more of the following.
The segmentation procedure includes determining a connectivity between pairs of locations according to the data representing the image and the segmentation parameters, and forming segments according to the determined connectivities.
The parameter selection procedure includes determining parameters associated with connectivity between pairs of location, and wherein the parameter selection procedure applies a non-uniform reliance on locations in the training images according to contribution of estimated connectivity at those locations to the estimated segmentation of the images.
The segmentation procedure determines a weighted connectivity between pairs of adjacent pixels of the training data, and forming the segments includes applying a threshold to the weighted connectivities to form binary connectivities and identifying pixels that are connected via sequences on adjacent pixels. For instance, the non-uniform reliance on pixel locations comprises a non-uniform reliance on pairs of adjacent pixels.
The parameter selection procedure includes, for each of a plurality of pixel locations in the training images, identifying a pair of adjacent pixels on a path between the pair of pixel locations, and determining the non-uniform reliance on pairs of adjacent pixels according to the identified pairs of adjacent pixels.
The parameter selection procedure includes iterating over a plurality of pairs of pixel locations in the training images, and for each pair of pixel locations, identifying a pair of adjacent pixels on a path between the pair of pixel locations according to a contribution of estimated connectivity between the pair of adjacent pixels to an estimated segmentation of the images and updating a subset of the segmentation parameters that affect an estimated weighted connectivity between the adjacent pixels.
The parameter selection procedure includes iterating over a plurality of pairs of pixel locations, including pairs of non-adjacent pixel locations, in the training images and for each pair of pixel locations identifying a link between two pixel locations on a path between the pair of pixel locations, the identified link representing degree of linkage between the pair of pixel locations. In some examples, the degree of linkage comprises a maximum linkage, which may be defined as maximum over paths linking the pair of pixel locations of minimal linkage between adjacent pixel locations the path.
The segmentation procedure includes determining a labeling as background versus object at locations according to the data representing the image and the segmentation parameters, and forming segments according to the determined labelings.
The parameter selection procedure includes selecting the parameters according to a criterion based topology of the objects in the images.
The parameter selection procedure includes jointly determining segmentation parameters and transformations of the training segmentation data associated with warpings of the segmentation data that maintain topology of the objects in the training images.
The parameter selection procedure comprises alternating between a phase for updating segmentation parameters and a phase for transformation of the training segmentation data.
Updating the segmentation parameters includes applying a gradient update according to a match between estimated pixel labelings and pixel labelings of the transformed segmentation data.
The parameter selection procedure comprises alternating between a phase for updating segmentation parameters and a phase for transformation of the training segmentation data.
The parameter selection procedure comprises jointly determining optimal segmentation parameters and transformation of the training segmentation data that maintains a set of topological properties of the training segmentations.
In another aspect, in general, a system is applied to forming segments of items represented in a data set. The system includes a segmentation apparatus configured to accept the data set representing a plurality of items, wherein the segmentation apparatus includes an input for accepting a data representation of segmentation parameters for controlling operation of the segmentation apparatus according to a segmentation procedure. The system also includes a parameter selection system configured to accept training data sets and corresponding training segmentation data for a plurality of training data sets and produce the data representation of the segmentation parameters. The training segmentation data for a training data set characterizes connectivity through a single segment of pairs of items in the training data set. The parameter selection system is configured to select the segmentation parameters according to a parameter selection procedure that includes selecting the parameters according to a criterion based on path connectivity through sequences of pairs of items.
Aspects can include one or more of the following features.
The parameter selection procedure includes, for each training data set, forming a data representation correspond to a spanning tree in which nodes of the tree are associated with items of the data set.
The parameter selection procedure includes, for pairs of items in the training data set, identifying a link on a path in the spanning tree between the pair of items, and updating parameters associated with that link according to the training segmentation data for the pair of items.
In another aspect, in general, software is stored on a computer readable medium. The software comprises instructions for causing a data processing system to implement a segmentation module configured to accept image data representing a three-dimensional image acquired from a biological sample, wherein the segmentation apparatus includes an input for accepting a data representation of segmentation parameters for controlling operation of the segmentation apparatus according to a segmentation procedure. The system also implements a parameter selection module configured to accept training image data and corresponding training segmentation data for a plurality of training images and produce the data representation of the segmentation parameters, the training segmentation data for a training image characterizing at least one of spatial extent of a plurality of objects in the training image and connectivity through a single object of pairs of locations in the training image. The parameter selection system is configured to select the segmentation parameters according to a parameter selection procedure that includes selecting the parameters according to a criterion based on at least one of connectivity between pairs of locations and a topology of the objects in the image.
Advantages of certain aspects can include or more of the following.
The approach may be applied to the challenging application of tracing the branches of neurons in three-dimensional images of brain tissue taken by electron microscopy. The empirical results show a dramatic reduction in the number of split and merge errors.
Other features and advantages of the invention are apparent from the following description, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a block diagram of an image processing system.
FIG. 2A is a representation of a two-dimensional pixel map showing edge pixels of objects, and FIG. 2B is a representation of a corresponding affinity graph;
FIGS. 3A and 3B are representations of transformations of the representations shown in FIGS. 2A and 2B , respectively;
FIG. 4 is a block diagram of a first example of a segmentation apparatus;
FIG. 5A is a representation of a pixel segmentation, and FIG. 5B is a representation of weighted affinity between pixels and a corresponding binary affinity graph;
FIG. 6 is a block diagram of a second example of a segmentation apparatus
DESCRIPTION
1 Introduction
Referring to FIG. 1 , a system 100 processes a biological sample 105 , and provides as output, for instance, a presentation image 155 or processed data 165 , or provides input to further processing 170 . The system 100 is described here in the context of an exemplary application related to analysis of biological tissue, but it should be understood that the techniques described below are applicable to a wider variety of image analysis, and more generally to a variety of data analysis tasks, as is outlined later in this description.
In the system shown in FIG. 1 , the biological sample 105 is processed in an imaging apparatus 110 to produce image data 115 . In some examples, the imaging apparatus comprises an electron microscope which processes a sample of brain tissue to produce three dimensional image data, for example, providing an intensity level at each voxel (i.e., three-dimensional pixel) location in a rectilinear (e.g., cubic) arrangement of pixel locations. In an example, one goal is to identify neurons in the image data.
A segmentation apparatus 120 processes the image data 115 and produces segmentation data 125 . In some examples, the segmentation apparatus is implemented using a computer processor controlled by software instructions as well as segmentation parameters 145 stored on a computer readable media. In some examples, the segmentation data comprises a labeling of pixels according to distinct labels for each separate object, for example, using consecutive positive integers (1, 2, . . . ), or as background, for example, using an index zero. Such a labeling is referred to as a segmentation, S, where the label of a pixel j has value s j . The segmentation apparatus is parametric (or otherwise configurable or trainable) and is configured according to segmentation parameters 145 , which are determined, for instance, during a prior training phase which is described below. The segmentation parameters are stored on computer readable media in a form that controls and/or imparts functionality to the segmentation apparatus.
In some examples, the segmentation data 125 may be used as an input to a display system 150 , for example, to produce a presentation image 155 that provides am operator (e.g., technician, researcher, physician or other clinician) with a view of the objects detected by the segmentation apparatus. The detected objects may be indicated in the presentation image in various ways, for example, using color, opacity, etc. In some examples, the clinician may be able to provide inputs that affect the segmentation, for example, providing an input (e.g., a threshold) that trades off detection of isolated objects versus merging of objects together.
Generally, the training process that determines the segmentation parameters 145 makes use training image data 135 , which in general comprises the outputs of the imaging apparatus 110 for a corresponding set of biological samples (not shown). The training image data is labeled, for example in a manual labeling procedure 130 , to produce training segmentation data 137 . Generally, the training segmentation data identifies locations of objects in the training image data, for example, providing segmentation values for some or all of the pixels in the corresponding image data. A parameter selection system 140 processes the training image data 135 and corresponding training segmentation data 137 to produce the segmentation parameters 145 that are used by the segmentation apparatus 120 for the unknown image 105 . In some examples, the parameter selection system 140 is implemented using a computer processor. The parameter selection system 140 is matched to the segmentation apparatus 120 such that the segmentation parameters 145 that are passed between these modules link their functionality.
Very generally, a number of approaches are described below in which the parameter selection system 140 selects the segmentation parameters 145 to match the overall structure of the objects in the training images, without necessarily attempting to reproduce a pixel-by-pixel match between automatically determined segmentations for the training image data 135 and the training segmentations 137 determined in the labeling process 130 .
Before discussing the various approaches for implementing the segmentation apparatus and associated parameter selection system, a number of representations and characterizing metrics of image data are outlined. Various approached described below use one or both of the representations shown in FIGS. 2A-B . First, referring to FIG. 2A , a two-dimensional image is represented as having object regions A, B, and C, with the remainder of the image forming a background. Three-dimensional data can be similarly represented, however, for the sake of presentation, the examples below focus primarily on two-dimensional situations. A grid of square pixels is illustrated, with the pixel based boundary of the object regions being shown with a bold line. The image data itself is not illustrated. In general, each pixel is associated with a numerical scalar or vector of image features, for example, representing image intensity in one or more spectral bands. The pixels in the object regions at the boundary of the object regions are shown in gray, and are referred to as “boundary pixels.”
Referring to FIG. 2B , another representation of the image uses an affinity graph in which each node corresponds to one of the pixels. Edges join certain pairs of nodes such that each connected set of nodes corresponds to one of the object regions. In general, the edges in the representation form a disjoint connected subgraphs of a complete graph. For instance, the complete graph may include all edges between nearest neighbor nodes, for example, with four edges per node in two dimensions and six edges per node in three dimensions, or alternatively, eight edges per node in two dimensions and 26 edges per node in three dimensions. Note that the same connected sets of nodes may be achieved with different subgraphs, for instance, by removing edges that do not divide a connected set of nodes, therefore the binary affinity graph is not necessarily unique for any particular segmentation.
Referring to FIGS. 3A-B , minor changes in identification of boundary pixels or corresponding edges in a graph representation do not necessarily change the overall structure of the objects in a segmented image. In particular, certain changes may move the boundaries of objects somewhat, but do not change the overall structure of the segmentation. For example, referring to FIG. 3A , an identification of the gray pixels as boundary pixels defines regions A′, B′, and C′, which do not exactly match regions A, B, and C, in FIG. 2A , yet the result generally preserves the overall structure.
To more precisely define the changes that are sufficiently minor to not affect the structure, a definition of “simple pixels” (also referred to below as “simple points”) is used. A binary image L is formed such that all the pixels in non-background regions (e.g., in regions A, B, and C, in FIG. 2A ) are given a value 1, and all remaining pixels are given a value 0 to form the binary image L. A simple pixel is then defined as a location in the binary image L at which a pixel can be flipped to its complementary value without changing any topological properties of the image. More specifically, the simple pixels are points in a binary image that can be modified (i.e., flipped from foreground to background or vice versa) without altering topological properties of the image including the numbers of components, cavities, and in the case of 3D images, tunnels. We write simple (L) to denote the set of simple points of L.
This definition of simple pixels is used to define a “warping” of a digital image. Specifically, given an initial binary image L*, then another binary image L is a warping of L* if a sequence of flips of simple points can yield L. In some examples, the allowable pixel flips are restricted to occur only in certain regions of the image, for example, within a prescribed distance of an edge in the original image L*. Note that given an original segmentation S*, a warping S can be defined to correspond to the warping of the related binary image. The notation L L* is used to denote that L is an allowable warping of L*.
Some approaches described below make used of segmentations based on affinity graphs. An affinity graph can be binary, for example, as shown in FIGS. 2B and 3B , with the connected sets of nodes corresponding to objects. An affinity graph can also be weighted such that a edge joining a node i and a node j has a weight A ij . A binary affinity graph can be formed from a weighted affinity graph by retaining edges whose weights exceed a threshold value.
It can be useful to introduce the concept of maximin affinity, which is defined for any pair of pixels in an affinity graph. Let be the set of all paths in the graph that connect pixels i and j. For every path P in there is an edge (or edges) with minimal affinity. This minimal affinity on a path P is written as
min <k,lεP A kl
where k,l εP means that the edge between pixels k and/are in the path P. A maximin path P ij * is a path between pixels i and j that maximizes the minimal affinity,
P ij *=argmax Pε min <k,l>εP A kl .
The maximin affinity of pixels i and j is the affinity of the maximin edge, or the minimal affinity of the maximin path, P ij *
A ij *=max Pε min <k,l>εP A kl .
Based on these definitions, a pair of pixels is connected in the thresholded binary affinity graph if and only if their maximin affinity exceeds the threshold value.
Pixel pairs can be classified as connected or disconnected by thresholding maximin affinities. Let Ŝ be the segmentation produced by thresholding the affinity graph A ij and then finding connected components. Then the connectivity indicator function between pixel locations i and j is
H ( A ij *−θ)
where H is the Heaviside step function and θ is the threshold applied to the affinities.
As introduced above, one measure of a similarity between two segmentations, S and T, is the Rand Index. The Rand Index is a statistical measure of the similarity between two data clusterings, which can be used as a measurement of segmentation quality that can operate directly on a segmentation by interpreting a segmentation as a grouping of pixels into separate clusters. More formally, consider an image space X with N pixels {x 1 , . . . , x N } and two segmentations S and T which assign to each pixel location i an integer label {s i } and {t i } respectively. Then the Rand Index is a [0,1]-valued measure of the number of pairs of points having the same label relationship in S and T:
R ( S , T ) = ( N 2 ) - 1 ∑ i , j ≠ i δ ( s i = s j , t i = t j ) + δ ( s i ≠ s j , t i ≠ t j )
Therefore, the Rand Index is 1 when the two segmentations perfectly match, and 0 when they completely disagree.
The Rand Index effectively focuses on whether the overall grouping of points into separate segments is correct; subtle geometric differences between two segmentations will decrease the Rand Index but will be much less numerically significant than, for example, the erroneous merging of two regions. Conceptually the Rand Index focuses on whether a segmentation has achieved the correct connectivity between pixels (i.e., whether two pixels are connected or disconnected correctly).
2 First Embodiment
A first embodiment of a segmentation apparatus 120 shown in FIG. 1 is the segmentation apparatus 120 A shown in FIG. 4 . This embodiment uses at its basis a classification approach for edges in an affinity graph. The image data 115 is passed to an edge classifier 212 . The classifier 212 outputs a weighted affinity graph, which provides a numerical degree to which each edge joining neighboring pixels in the image belongs to a same object versus forms a boundary between objects. The classifier 212 makes use of segmentation parameters 145 , which are trained using a procedure described below. The weighted affinity graph 216 is passed through a threshold function 218 , which transforms these numerical degrees into a binary affinity graph 220 (i.e., connectivity), and the component identifier 222 forms the connected components from the binary affinity to produce the segmentation data 125 at the output of the segmentation apparatus.
A simplified two-dimensional example is illustrated in FIG. 5A . In this figure, which represents a 6×6 pixel image (with pixels labeled A 1 through F 6 for discussion), a solid line 304 shows a human segmentation of the image into three connected components. A computer segmentation is illustrated by a dashed line 306 . As illustrated, the computer segmentation erroneously merges two of the true components (via pixel C 3 ), and erroneously splits a true component (via pixel F 4 ). Furthermore, the detailed boundaries of components do not match at pixels A 1 , A 6 , and D 6 .
In this embodiment, very generally, training of the segmentation parameters 145 involves updating of the parameters for the edge classifier 212 to focus on edges in the weighted affinity graph that significantly affect the segmentation result. The computer segmentation is determined according to the edge affinity data associated with each of the links joining adjacent pixels. A portion of the affinity data is illustrated in FIG. 5B for a limited number of pixels, with quantities less than 0.5 being associated with boundaries and quantities greater than 0.5 being associated with a link joining two pixels within one component of the segmentation. Based on the thresholding at a value of 0.5, a portion of a resulting binary affinity graph is shown in FIG. 5B . Note that the binary affinity graph incorrectly links nodes B 3 -C 3 and C 3 -D 3 , and erroneously breaks C 3 -C 4 , and is otherwise correct.
In order to focus training on links that affect the segmentation, pairs of pixels are considered in the training. For example, a pair of pixels, B 3 and D 4 are considered. According to the manual segmentation as shown in FIG. 5A , these pixels are truly in separated components. However, referring to FIG. 5B , weighted link affinity data for links in the vicinity of these pixels, and binary affinity data based on thresholding the values in FIG. 5B , shows that the computer segmentation links pixels B 3 and D 4 into a common component. The training to correct this error is focused on a particular edge by considering the paths joining the two pixels (e.g., B 3 -C 3 -C 4 -D 4 , or B 3 -C 3 -D 3 -D 4 ). Connectivity along a path is assessed according to the minimum affinity value, and the path with the largest such minimum value is attributed the error. For example, the path B 3 -C 3 -D 3 -D 4 has a minimum affinity value of 0.51 (at link C 3 -D 3 ), which is the maximum over the paths linking pixels B 3 and D 4 . Based on this identification of C 3 -D 3 being the critical link joining B 3 and D 4 , the weights for the classifier are adjusted so that the weighted affinity value for link C 3 -D 3 is driven down from 0.51 toward 0.
In a similar manner, certain links may be associated with erroneous splitting of a segment. For example, paths from pixel F 1 to F 5 may identify the link F 3 -F 4 as being the link that causes the erroneous separation of pixels F 1 and F 5 into different components.
Effectively, by considering a large number of pairs of pixels (e.g., all pairs of pixels, pairs of pixels within a fixed distance of one another, pairs of pixels chosen from a subset that are hand labeled), and for each pair of pixels identifying the portion of the image (i.e., the edge) that most contributes to the training data segmentation (merging or segmentation error), the links that contribute to erroneous merging or splitting of components are more highly weighted in the retraining of the classifier weights, thereby focusing the training on the end-to-end accuracy of the overall segmentation that is determined by the weighted affinity data.
A description of an implementation of the first embodiment is provide below. For reference, notation used in this description is provided for reference.
2.1 Notation
I The underlying image, or more generally a dataset
I n Individual pixel, or other data element, at coordinate nε
= Graph, where the image/data is defined at nodes of the graph
The nodes of the graph. In the case of a three (two) dimensional image, the nodes form a regular rectangular lattice.
Edges of the graph. In the case of the three (two) dimensional image, the links join adjacent node in the lattice.
The set of paths from node i to node j in the graph .
* In general, the superscript * represents the “truth,” for example as set by human annotation of images, and no superscript indicates computer generated.
s n * The true classification of the image/data at coordinate n.
S* The true classification of the entire image.
s n The computer classification of the image at coordinate n.
S The computer classification of the entire image.
δ(s i ,s j ) Similarity between class s i and class s j : 0 if s i ≠s j ; 1 if s i =s j .
e l The computer generated classification of edge l in the graph.
mm i,j Maximin distance between nodes i and j, computed as
mm i,j =max pε min lεp e l
Θ(mm i,j ) Thresholding of mm i,j : 0 (disconnected) if less than the threshold and 1 (connected) if greater;
m l Dissimilarity for edge l in the graph.
m i,j Minimax ultrametic between nodes i and jε computed as
m i,j =min pε max lεp m l
l i,j (max) The minimax edge on paths from i to j.
l i,j (max) =argmax lεp i,j (min) m l ; p i,j (min) =argmin pε max lεp m l ; m ij =m l i,j (max) ;
m l *, m i,j * Define m i,j *=00 if nodes i and j are in a connected component, and 1 otherwise, and define m l *=m i,j * for l=(i,j).
Φ(m i,j ) Thresholding of m i,j : 0 (connected) if less than the threshold and 1 (disconnected) if greater.
M(l; I, W) The computer generated ultrametric for link l given an image (or data set) I and estimated parameters W.
T Clustered subgraph of , such as a spanning tree, such that for example, formed by agglomerative clustering of the nodes according to an ultrametric between nodes.
2.2 Initial Estimation of W
Initial training uses a set of images I and corresponding true pixel classification S*. An error function
E = 1 2 ∑ l ∈ ( m l * - M ( l ; I , W ) ) 2
is minimized by varying W, for example, using gradient-based incremental training
2.3 Training on Split and Merge Points
Consider a choice of pairs of pixels (node of graph) i and j. The minimax edge joining the nodes based on the computer calculation is l i,j (max) , defined in the Notations section above, and therefore m i,j =m l i,j (max) . The training data specifies that the true metric should be m i,j * (e.g., 0 if the two nodes are in a connected class, and 1 otherwise).
The contribution of the minimax link corresponding to a pair of nodes i and j to the error function is
1 2 ( m i , j * - M ( l i , j ( max ) ; I , W ) ) 2 .
The derivative with respect to the weights W is
-
(
m
i
,
j
*
-
M
(
l
i
,
j
(
max
)
;
I
,
W
)
)
∂
∂
W
M
(
l
i
,
j
(
max
)
;
I
,
W
)
The procedure for training on the splits and merges is to iterate over random pairs of nodes (i, j) and for each pair to update the weights W according to the derivative above.
In some implementations, the random pairs of points are restricted to be within a predetermined distance of one another.
2.4 Spanning Tree Implementation
In some implementations, given the link dissimilarities m l determined according to the parameters W, a minimal spanning tree is formed for the nodes of the graph. The) spanning tree forms a subgraph = such that and that for any pair of nodes i and j, the minimax link l i,j (max) is on the path from i to j in the spanning tree.
In an iteration with a random node pair (i j), the minimax link is located in the spanning tree, and the parameters of W are updated as above.
After updating the parameters, a portion of the spanning tree is recomputed according to the updated parameters and the iteration continues.
3 Second Embodiment
Referring to FIG. 6 , in second embodiment the segmentation apparatus 120 B makes use of a pixel classifier 312 , which accepts the input image data 115 and produces a weighted map 314 , which provides a value in the range [0,1] for each pixel location. Larger values indicate greater certainty of the pixel being in an object and a lower value indicating a greater certainty of the pixel being in the background. The weighted map 314 is processed in a component identifier 322 , which outputs the segmentation data 125 as output of the segmentation apparatus 120 B.
The goal of the training procedure for the segmentation parameters 145 that are used by the pixel classifier 312 is to find a function that maps an image patch to an estimate of the probability that the central pixel is labeled “1.” We will call such a function an image patch classifier. If the classifier is applied to patches centered at all locations in an image, it produces an output image that is called in-out map. In some alternative examples, rather than an in-out map, the pixel classifier is formulated to produce a boundary map identifying pixels that are likely to be edge pixels. The analog values in this probability map can be thresholded to produce a binary image labeling. In this example, both the classifier output and ground truth are represented as in-out maps.
Consider a binary machine labeling T and a human labeling L* of the same image. When optimizing pixel error, we would ideally like to minimize the number of binary disagreements between T and L*: Σ i δ(t i ,l i *) where the machine and human labeling at location i are denoted by t i and l i *, respectively.
One way of applying supervised learning to boundary detection is to find an image patch classifier, a function that maps an image patch to an estimate of the probability that the central pixel is a boundary. The output of the pixel classifier 312 is referred to as the boundary map 314 and written as F I ({right arrow over (w)}), where I is the image, and {right arrow over (w)} specifies the adjustable parameters in segmentation parameters 145 . The analog values in the boundary map can be thresholded at scalar value θ to produce a binary boundary labeling H(F I ({right arrow over (w)})−θ), where image-valued quantity H(M) represents the Heaviside step function applied to each pixel location in a map M.
3.1 Learning Pixel Error
Supervised learning can be formulated as the minimization of the pixel error ∥H(F I ({right arrow over (w)})−θ)−L*∥ 2 with respect to the classifier parameters {right arrow over (w)}, where r is a human boundary labeling of the same image. However, it is often easier to optimize a smooth cost function that depends on the real-valued output of the classifier. One choice is the squared error: d(F I ({right arrow over (w)}), L)=Σ i ∥f i ({right arrow over (w)})−l i , where the boundary map and human boundary labeling at location i is written as f i ({right arrow over (w)}) and, respectively. The dependence of f i ({right arrow over (w)}) on the image I is left implicit for notational convenience. Optimizing the squared error thus serves as an approximation to optimizing the binary classification error. Since the squared error cost function depends smoothly on the analog output of the classifier, gradient descent can be applied to find a local minimum. A “batch” implementation computes the gradient of the cost function for the whole image or set of images. An “online” implementation computes the gradient of the cost function for a single pixel. Since the pixel is chosen at random, the average of the online gradient is equal to the batch gradient, which means that online learning is a form of stochastic gradient descent. Online learning is described in the following algorithm:
gradient ( I,L,{right arrow over (w)},k ) for iter = 1 to k i = random location in random image {right arrow over (w)}:= {right arrow over (w)}−η∇ {right arrow over (w)}d(fi ({right arrow over (w)}),l i ) end return {right arrow over (w)}
where η is a rate parameter, which is a positive and generally small number.
3.2 Warping Error
A preferred approach to supervised learning of the parameters does not necessarily attempt to exactly match the training segmentation data 137 . Rather, for any choice of segmentation parameters, a best warping to the training segmentation is found to match the boundary map output from the pixel classifier. Specifically, we define the warping error as
D
(
T
||
L
*
)
=
min
L
⊲
L
*
T
-
L
2
One approach to finding the best warping in the above minimization is to use a descent algorithm for finding local minima During warping, we are allowed to flip simple points of L that lie inside the mask M, i.e., points in the set simple (L)∩M. Flipping any such pixel j of L satisfying |t j −l j |0.5 produces a new warping with smaller error. A descent algorithm greedily picks the pixel for which this error reduction is the largest, breaking ties randomly as follows:
warp( L*,T,M )
L := L*
do
S := simple(L)∩M
i := argmax jεS |t j −l j | , breaking ties randomly
if |t i −l i | > 0.5
l i := 1−l i
else
return L
end
Since ∥T−L∥ 2 is decreasing, the algorithm is guaranteed to converge to a local minimum of the warping error. How problematic is the lack of an efficient algorithm for finding a global minimum? This does not appear to be a problem in practice.
3.3 Learning Warping Error
In this preferred approach, warping error is used to optimize the classifier weights rather than pixel error, formulating the weight selection as an optimization of D(F 1 ({right arrow over (w)})∥L*) with respect to {right arrow over (w)},
min {right arrow over (w)} D ( H ( F I ( {right arrow over (w)} )−θ∥ L*,
which can be represented using the definition of D(T∥L*) above as the nested optimization:
min
w
→
min
L
⊲
L
*
H
(
F
I
(
x
→
)
-
θ
)
-
L
2
.
We call this method Boundary Learning by Optimization with Topological Constraints, or BLOTC. Note that standard training is the case where no warping of L* is allowed, i.e., the geometric constraint becomes completely tight. In order to make this cost function easier to optimize, we again use a smooth approximation of the binary error.
The preferred approach makes use of an algorithm that alternates between gradient descent for {right arrow over (w)} and descent for the warped image L as follows:
blotc ( I,L*,M,k 1 ,k 2 )
L := L*
{right arrow over (w)} := random initialization
{right arrow over (w)} := gradient (L, {right arrow over (w)}, k 1 )
repeat
L := warp ( L,F I ({right arrow over (w)}),M )
{right arrow over (w)} := gradient ( I,L,{right arrow over (w)},k 2 )
until convergence
return {right arrow over (w)}
4 Classifiers
The approaches can be applied with a variety of parametric pixel or edge classifiers. One choice is a convolutional network. One examples of such a network that has been evaluated containing 6 hidden layers, 24 feature maps in each hidden layer, and full connectivity between feature maps in adjacent layers. Each individual filter has 5×5 pixels, but the multiple-layers yield an effective field of view of the classifier of 28×28 pixels. In an example with the BLOTC approach examples, such a network was trained for 1,000,000 updates using the traditional optimization with the labels fixed. The BLOTC network was initialized with the weights from a standard network after 500,000 gradient updates and then further trained for 500,000 additional updates using BLOTC optimization. Each network was trained in roughly 18 hours, using a layer-wise procedure that iteratively adds hidden layers to the network architecture. The training used a fast shared-memory GPU implementation that provides between a 50-100× increase in training speed as compared to CPU implementations.
5 Other Embodiments
In other embodiments, one or both of two general approaches, of which the description above provides specific examples, generally focus the training of the classifier on significant edges or pixels. Other approaches also permit certain discrepancies between the manual segmentation and the computer segmentation if the discrepancies are not significant in that they do not affect the segmentation.
For example, the specific example in which a nested optimization considers both warping of the training segmentation as well as parameter optimization of the classifier is an example of modification of the training data to better match the automated prediction to the extent that the modification is not significant. In the example above, maintaining the digital topology in permissible warpings is the example of an insignificant modification. In other examples, modifications of the training data can include other types of changes. For example, rather than warping by flipping pixels, other forms of warping may be used (e.g., continuous warping or deformations of the image space).
A specific example presented above focuses parameter updating on maximin edges in an affinity graph addresses edges that may affect the segmentation more than others. Other focusing on significant edge or pixel classification parameters may be used in other embodiments. For example, in a pixel classification rather than an edge classification approach, the importance of correct classification of certain pixels may vary by pixel, and therefore a weighting to the important pixels may be used. Furthermore, the approach to updating parameters of maximin edges may alternatively focus on all edges weighting their contribution according to the degree to which they are close to a maximin value.
Examples presented above use training image data 135 that is separate from the image data 115 of an unknown sample. In some examples, an operator can provide some partial labeling of the data for the unknown image, for example, by indicating a small number of pairs of pixels that are in same versus different object. Such labeling can occur prior to applying the segmentation procedure to the unknown data, or as a correction phase after an initial segmentation. When such partial labeling of the unknown data is available, the parameter selection system 140 can adapts the segmentation parameters 145 to better match the unknown sample.
6 Applications
As introduced above, examples of the approaches described above address segmentation of two- (e.g., image slices) and three-dimensional (e.g., volume) images of biological or other physical objects. In some examples, the segmentation 130 determined by the system is used to form data representing an output image, for example, for presentation to a user on an image output device (e.g., a graphical computer display). Examples of such output images include enhancements showing the segmentation of the image in conjunction with the original image. In some examples, segmented components are further classified (e.g., according to image properties within the segments) and the segments are enhanced with color, intensity, or other visual attributes. In some examples, automatic segmentation of an image is used for further computation, and the result of the computation is stored, further processed, or presented to a user. For example, the segmentation may be used for counting components (e.g., cells, neurons), or determining physical characteristics (e.g., average size, area, cross-section).
In another example, techniques described above are applied to a task of tumor detection and/or localization. As a specific example, tumors are detected and/or localized in two-dimension mammography images (e.g., X-ray images of projections through breast tissue) or in three dimensional images of breast tissue (e.g., using Computed Tomography (CT), Magnetic Resonance (MR), or ultrasound techniques). In some examples, the techniques are based on training a classifier to classify each image location (e.g., pixel) as tumor versus non-tumor, or for classifying adjacent locations as same versus different object (e.g., both tumor or both normal versus transition/edge between normal and tumor). In training, each abnormality has some geometry which will be subjected to warping, but the number of independent abnormalities in each image (which may be zero) is a topological feature that is preserved. The approach may be applied to a variety of abnormalities or objects in the image, which typically include (micro)califications, masses, and architectural distortions, not all of which are necessarily malignant.
7 Non-Image Data Sets
For a data set I of size N, a fully linked graph with N nodes is formed. An initial estimate of W that parameterizes the link metric is formed as above. Note that in the image segmentation approach above, the graph with nodes corresponding to pixels is not fully connected, but rather has links forming a rectangular lattice.
As above, a minimum spanning tree of the graph is formed using the computer predicted metrics m l =M(l;I,W). For example, the nodes are agglomeratively clustered to form the spanning tree.
For a fixed tree, a series of iterations are performed. At each iteration a pair of data points is selected, and W is incremented according to the derivative above.
After a number of iterations, the agglomerative clustering tree is recomputed, and a further set of iterations is performed.
To classify a new data point, the trained ultrametric is used to identify the nearest training data point to the new data point to classify the new data point according to one of the classes found in the training data.
As introduced above, the parameter estimation approach can include adaptation of the parameters based on partial labeling or correction of the unknown data set.
Applications to such non-image data can include forming groups or clusters of items according to trainable similarity metrics between pairs of items (e.g., for computer implemented advertising or product recommendation systems), and forming groups or clusters of individuals based on trainable similarity metrics between pairs of individuals.
8 Implementations
The approach can be implemented in the form of a computer program (e.g., software instructions stored on a computer readable medium for controlling a data processing system) which would be tailored to accept three-dimensional data, for example, from current available cross-sectional imaging datasets that are output by imaging units. In some implementations, the approach is incorporated into a system that acquires a three-dimensional image of a patient and provides a representation of the image to an operator of the system, typically a clinician. In some implementations, the approach is hosted separately from the system that acquires the image, for example in a separate image processing module or server that provides image analysis services. In some implementations, the approach is combined with a system that performs volume segmentation, which may combined with or separate from the image acquisition and/or image display systems.
It is to be understood that the foregoing description is intended to illustrate and not to limit the scope of the invention, which is defined by the scope of the appended claims. Other embodiments are within the scope of the following claims.
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Approaches to segmentation or detection of objects and their boundaries in images (or other data sets) do not rely on machine learning approaches that aim to minimize pixel-level agreement between a computer and a human. Optimizing such pixel-level agreement does not, in general, provide the best possible result if boundary detection is a means to the ultimate goal of image segmentation, rather than an end in itself. In some examples, end-to-end learning of image segmentation specifically targets boundary errors with topological consequences, but otherwise does not require the computer to “slavishly” imitate human placement of boundaries. In some examples, this is accomplished by modifying a standard learning procedure such that human boundary tracings are allowed to change during learning, except at locations critical to preserving topology.
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FIELD OF THE INVENTION
This invention relates to substituted triazine compounds and to their use. In particular, it relates to sym-triazine (1,3,5-triazine) compounds containing at least one phosphonate, phosphonamidate or phosphonamide group which are generally useful as flame retardants in various organic materials, for example plastics materials such as plastics sheet or film, foamed polymers, moulded plastics articles or fibrous materials such as textiles. Many of the phosphorus-containing triazine compounds have spumescent properties, that is to say they foam at high temperatures and can be used in intumescent coatings or claddings which form an expanded char acting as protective insulation in a fire. Many of the phosphorus-containing triazine compounds are also useful as corrosion inhibitors, for example in surface coatings which inhibit corrosion of metals to which they are applied or which inhibit rust staining.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,210,350 describes sym-triazine compounds having one or two of the three ring carbon atoms attached to a phosphonic radical of the formula: ##STR4## where R represents hydrogen or a saturated hydrocarbon group of up to 12 carbon atoms and X represents -OR or -NR 2 ; the other ring carbon atom(s) are attached to a hydroxy, mercapto, nitro, acyl, acyloxy, amino, alkoxy, aryloxy, cycloalkyloxy, alkylsulpho, arylsulpho, cycloalkylsulpho, ureido, hydrazino, alkyl, aryl or cycloalkyl group. The compounds are stated to be useful as fire retardants, rust inhibitors, chemical intermediates, rust removers, electroplating additives, herbicides, insecticides, ion exchange resins, tanning agents, water-soluble interfacial agents, water-insoluble dispersion agents, detergents, wetting agents, gasoline inhibitors and monomers for vinyl polymerisation and copolymers. U.S. Pat. No. 3,158,450 describes the use of such a compound or a metal derivative thereof as an additive to leaded gasoline to inhibit engine misfiring. U.S. Pat. No. 3,011,998 describes condensation products of such triazine compounds with an aldehyde.
An article by J. P. Moreau and L. H. Chance in "American Dyestuff Reporter", May 1970 at pages 37-38 and 64-65 describes the evaluation of 2-amino-4,6-bis(diethoxyphosphinyl)-1,3,5-triazine and 2,4-diamino-6-diethoxyphosphinyl-1,3,5-triazine as possible flame retardant finishes for cotton. An article by the same authors in the same Journal in February 1971 at pages 34-38 describes the evaluation of the formaldehyde derivative of 2,4-diamino-6-diethoxyphosphinyl-1,3,5-triazine as a flame retardant for cotton. U.S. Pat. No. 3,654,274 describes new processes for preparing this compound.
An article by J A Mikroyannidis in J Polymer Science: Part A; Polymer Chemistry, Vol. 26, pages 583-593 (1988) describes linear poly(dialkoxyphosphinyl-sym-triazine)s prepared by interfacial or solution polycondensation reactions of various diamines such as ethylene diamine, hexamethylene diamine or bis(4-aminocyclohexyl) methane with 2-dialkoxyphosphinyl-4,6-dichloro-sym-triazines.
SUMMARY OF THE INVENTION
According to one aspect of the invention a plastics material contains a phosphorus-containing heterocyclic flame retardant and is characterised in that the flame retardant is a sym-triazine compound of the formula: ##STR5## or a polymer comprising repeating units of the formula: ##STR6## where R 1 represents hydrogen, an alkyl or cycloalkyl group having 1 to 12 carbon atoms, an aryl or aralkyl group having 6 to 20 carbon atoms, a heterocyclic group having 2 to 14 carbon atoms and 1 to 4 hetero-atoms selected from N, S and O, or an -NH 2 , -CONH 2 or-NHCONH 2 group, and R 2 represents hydrogen or an alkyl or cycloalkyl group having 1 to 12 carbon atoms, or R 1 and R 2 are joined together so that the group R 1 R 2 N- is a heterocyclic group having 2 to 14 carbon atoms and 0 to 3 hetero-atoms selected from N, S and O in addition to the N atom bonded to the triazine ring;
G 1 and G 2 are each independently selected from an -OR 3 group, an amine group of the formula -NR 4 R 5 , an -OH group or an anionic group -O - in the form of a metal salt or an amine or ammonium salt, where R 3 represents an alkyl or cycloalkyl group having 1 to 12 carbon atoms, and R 4 and R 5 each independently represent hydrogen or an alkyl or cycloalkyl group having 1 to 12 carbon atoms;
Z represents an amine group of the formula -NR 6 R 7 or a phosphonic group of the formula: ##STR7## where G 1 and G 2 are defined as above;
R 6 represents hydrogen, an alkyl or cycloalkyl group having 1 to 12 carbon atoms, an aryl or aralkyl group having 6 to 20 carbon atoms or a heterocyclic group having 2 to 14 carbon atoms and 1 to 4 hetero-atoms selected from N, S and O, and R 7 represents hydrogen or an alkyl or cycloalkyl group having 1 to 12 carbon atoms, or R 6 and R 7 are joined together so that the group R 6 R 7 N- is a heterocyclic group having 2 to 14 carbon atoms and 0 to 3 hetero-atoms selected from N, S and O in addition to the N atom bonded to the triazine ring;
R 8 and R 9 each independently represent hydrogen or an alkyl or cycloalkyl group having 1 to 12 carbon atoms, and E represents a divalent organic group having 1 to 20 carbon atoms linked to each -NR 8 - and -NR 9 - group through a carbon atom and containing 0 to 3 carbocyclic aromatic rings, 0 or 1 heterocyclic ring having 1 to 4 hetero-atoms selected from N, S and O, and 0 to 2 ether, ester, amide, amine or urethane linkages, or R 8 and R 9 are joined together so that the group ##STR8## is a heterocyclic group having 3 to 14 carbon atoms and 0 to 2 hetero-atoms selected from N, S and O in addition to the N atoms bonded to triazine rings.
The compounds and polymers of formulae (I) and (II), which are essentially halogen-free, are at least as effective as present commercial flame retardants containing halogen; halogenated compounds are becoming regarded as environmentally undesirable for some uses.
The plastics material can be in the form of a foam, sheet, film, filament or moulded article. It can be thermoplastic or thermoset. The flame retardants used in the invention are particularly suitable for incorporation in polyurethane foam used in furniture and in seats for cars, trains or aircraft; the flame retardant can be mixed with the polyol which is reacted with polyisocyanate to form the polyurethane foam.
The invention thus includes a polyol composition comprising a polyol selected from polyether and polyester polyols suitable for preparing polyurethane foam, said polyol composition containing as flame retardant a phosphorus-containing sym-triazine compound of the formula: ##STR9## in which the groups R 1 , R 2 , R 3 and Z are defined as above but R 3 preferably represents an alkyl group having 1 to 6 carbon atoms, the groups R 3 being the same or different, and Z is preferably an amine group of the formula -NR 6 R 7 or a phosphonate group of the formula -P(OR 3 ) 2 0. The invention also includes a process for the production of polyurethane foam of reduced flammability in which such a polyol composition is reacted with a polyisocyanate in the presence of a foaming agent.
The invention also includes an artificial fibre having a flame retardant dispersed throughout the fibre-forming material, characterised in that the flame retardant is a substantially water-insoluble phosphorus-containing sym-triazine compound of formula (I) or polymer of formula (II). The invention also includes a process for the production of artificial fibre of reduced flammability by incorporating such a flame retardant of formula (I) or (II) in a spinning dope and extruding the dope through a spinneret to form filaments.
The invention also includes an intumescent fire protection composition comprising a carbon source capable of providing a char, a spumific agent and sources of nitrogen and phosphorus, characterised in that a compound of formula (I), in which at least one of the groups G 1 and G 2 is an anionic group -O - in the form of an ammonium, amine or metal salt, acts as a spumific agent as well as providing a source of nitrogen and phosphorus.
Certain of the compounds of formula (I) are new compounds. Thus according to another aspect of the invention a phosphorus-containing flame retardant is a sym-triazine compound which is liquid at ambient temperature, is soluble in a polyether polyol (for example a polyoxypropylene triol of molecular weight 3500) and has the formula (III) above, in which the group R 1 contains at least two carbon atoms.
Certain of the polymers of formula (II) are new, particularly those in which at least one of the groups R 8 and R 9 is other than hydrogen and those in which E contains at least one aromatic or heterocyclic ring, and such compounds form a further aspect of the invention.
DETAILED DESCRIPTION
The compounds of formula (I) can be prepared with a wide range of physical properties by varying the groups R 1 , R 2 , G 1 , G 2 and Z, in particular by changes in the number and type of alkyl substituents in -NR 1 R 2 and -PO(OR 3 ) 2 groups. The compounds of formula (I) can for example be high-boiling liquids or solids of low or high melting point, and can have varying solubility in organic solvents. The ratio of nitrogen to phosphorus atoms can be varied in the compounds of formula (I), particularly by varying the nature of the group Z. The optimum ratio of nitrogen to phosphorus atoms required for greatest flame retardancy may be different for different flame-retardant uses. Polymers of formula (II) can be produced with a high or low melting point and glass transition temperature.
The compounds of formula (I) in which R 1 represents an alkyl or cycloalkyl group having 1 to 12, preferably 1 to 6, carbon atoms, an aryl (e.g. phenyl or alkyl-substituted phenyl) or aralkyl group having 6 to 20 carbon atoms, or a heterocyclic group having 2 to 14 carbon atoms and 1 to 4 hetero-atoms selected from N, S and O, particularly the phosphonate esters of formula (III), are more easily processed than the compounds in which R 1 and R 2 (and R 6 and R 7 if present) are both hydrogen. These compounds having an N-organo substituent, particularly those in which R 1 is an alkyl group, generally have lower melting points and increased solubility in organic solvents. For example, the compounds in which R 1 represents an alkyl group are soluble in the polyols (polyether or polyester polyols) used in polyurethane foam manufacture. They are generally soluble in most common organic solvents except alkanes, for example alcohols, cyclic ethers, aromatic ethers, diethers, ether-alcohols, ketones, nitriles and aromatic hydrocarbons. The compounds of formula (I) which contain no amine hydrogen atoms, in particular those in which R 1 and R 2 (and R 6 and R 7 if present) are all alkyl or cycloalkyl groups, are soluble in alkanes as well as the above solvents. The compounds in which Z represents -NR 6 R 7 and R 1 , R 2 , R 6 and R 7 all represent hydrogen are soluble only in highly polar organic solvents such as dimethyl sulphoxide or N-methylmorpholine oxide. Some of the compounds of formula (I) are liquids, particularly those in which both R 1 and R 2 (and R 6 and R 7 if present) are alkyl groups. Liquid flame retardants are often preferred in polyurethane foam manufacture. Other compounds of formula (I) which are liquid are the diphosphonates in which Z represents a -PO(OR 3 ) 2 group and compounds in which at least one of the groups R 1 and R 2 is a long chain alkyl group having at least 6, particularly 8 to 12, carbon atoms. Compounds of formula (I) in which Z is an -NR 6 R 7 amino group which is different from the -NR 1 R 2 amino group, for example where -NR 1 R 2 is an alkylamino group and -NR 6 R 7 is a dialkylamino group, or where the alkyl group(s) of -NR 6 R 7 are different from the alkyl group(s) in -NR 1 R 2 , have a lower melting point than compounds with similar amino groups and may be liquid at ambient temperature. Examples of preferred alkyl and aryl groups for R 1 are ethyl, isopropyl, methyl, hexyl and phenyl. R 2 can for example be hydrogen or a methyl or ethyl group so that preferred groups -NR 1 R 2 are diethylamino, isopropylamino, dimethylamino, ethylamino or n-butylamino.
The compounds of formula (I) in which Z represents an -NR 6 R 7 group generally have a lower water solubility than the compounds in which Z represents a -PO(OR 3 ) 2 group. The compounds in which Z represents an -NR 6 R 7 group and at least one of the groups R 1 , R 2 , R 6 and R 7 is an alkyl or other hydrocarbyl group have very low water solubility and resist washing out of a substrate such as a foam or textile material. Within the class of compounds of formula (I) in which Z represents a -PO(OR 3 ) 2 group, those compounds in which R 1 and R 2 are both alkyl or other hydrocarbyl groups have lower water solubility (generally less than 5% by weight when both groups R 3 are ethyl). Compounds in which Z represents a -PO(OR 3 ) 2 group and R 1 represents a phenyl or other aryl group also have lower water solubility and may be preferred flame retardants if an increased ratio of phosphorus to nitrogen atoms is required.
The compounds of formula (I) in which Z represents a -PO(OR 3 ) 2 group and in which R 3 is an alkyl group having more than two carbon atoms, for example where R 3 is an isopropyl group or an n-butyl group, have markedly reduced water solubility and are generally liquid when at least one of R 1 and R 2 is an alkyl group. Such compounds, particularly those in which R 1 and R 2 are both alkyl groups, are another class of preferred flame retardants having an increased ratio of phosphorus to nitrogen atoms.
Polyurethane foams are generally produced by reacting a polyol composition with a polyisocyanate in the presence of a foaming agent. The polyol is generally a polyether polyol or polyester polyol. The polyol is usually a polyether polyol of functionality 2.5-3.5 for production of a flexible foam, for example a polyether triol of molecular weight 3000-6000 prepared by the addition of propylene oxide and optionally ethylene oxide to a polyalcohol such as glycerol or to an aminoalcohol or polyamine. The polyether triol can optionally contain a dispersion of another polymer, for example a polyurea or a styrene/acrylonitrile copolymer, to produce a high- resilience flexible foam. For production of a rigid foam, a more highly functional polyol, for example of average functionality 4 to 5, of lower equivalent weight, for example 100-150, is used. The polyisocyanate is usually toluene diisocyanate (TDI) for production of flexible foam, and it may be a TDI prepolymer or diphenylmethane-4,4'-diisocyanate or an oligomer thereof for rigid foam production. The foaming agent can be a volatile compound such as a halocarbon, but for flexible foams it is usually water, which reacts with isocyanate groups to release CO 2 . The foam-forming composition also generally contains a surfactant and catalysts and may contain other additives; all these are generally premixed with the polyol.
The flame retardant is preferably dissolved in the polyol. Particularly preferred flame retardants for use in polyurethane foam, for example for mixing with a polyether or polyester polyol in the above process, are those of the formula: ##STR10## in which at least one of the groups R 1 and R 2 is an alkyl group, at least one of the groups R 6 and R 7 is an alkyl group, and the total number of carbon atoms in the groups R 1 , R 2 , R 6 and R 7 is 3 to 8 carbon atoms; compounds within this definition in which the groups -NR 1 R 2 and -NR 6 R 7 are different may be especially preferred. Alternative preferred flame retardants are those of the formula: ##STR11## in which R 1 and R 2 are each alkyl groups having 6 to 12 carbon atoms.
Examples of preferred flame retardants are: Diethyl 2,4-bis(isopropylamino) -1,3,5-triazine-6-phosphonate, diethyl 2,4-bis(n-butylamino)-1,3,5-triazine-6-phosphonate, di- ethyl 2,4-bis(diethylamino)-1,3,5-triazine-6-phosphonate, di-ethyl 2-n-butylamino-4-diethylamino-1,3,5-triazine-6-phosphonate, tetraisopropyl 2-diethylamino-1,3,5-triazine- 4,6-diphosphonate, tetraisopropyl-2-dimethylamino-1,3,5-triazine-4,6-diphosphonate and diethyl 2,4-bis(N-methyl-N-phenyl-amino)-1,3,5-triazine-6- phosphonate.
The compounds of the formula (I) in which R 1 and R 2 are joined, so that -NR 1 R 2 is a heterocyclic group such as pyrrolidino, piperidino or morpholino and in which Z represents a -PO(OR 3 ) 2 group are readily soluble in water and are useful if a water-soluble flame retardant is required, for example for application from an aqueous medium to a plastics substrate which does not encounter water in use. The compounds of formula (I) in which Z represents an -NR 6 R 7 group and in which R 1 and R 2 are joined and R 6 and R 7 are joined, so that -NR 1 R 2 and -NR 6 R 7 represent heterocyclic groups, are however of very low solubility in water and are among the preferred flame retardants for use in a substrate which may encounter water in use.
Although many of the flame retardants of the invention are especially suitable for use in polyurethane foam, they are highly effective flame retardants in substantially all polymers which contain oxygen or nitrogen, for example polyesters, polyamides, acrylic ester polymers, vinyl ester polymers, nitrile polymers such as polyacrylonitrile and unfoamed polyurethanes, and they can also be used as flame retardants in other polymers such as polyolefins or polystyrene. The flame retardants of the invention can be used at 0.1-50% by weight based on the plastics material. In general, at least 0.5% by weight and preferably at least 1% is used to obtain a significant effect. The amount of flame retardant is preferably less than 20% by weight, and most preferably less than 10%, based on the plastics material. When the flame retardant is incorporated in a polyol composition for producing polyurethane foam, it preferably forms 1.5 to 15% by weight of the polyol composition.
The flame-retardant compounds of formula (I) can in general be prepared from cyanuric chloride (2,4,6-trichlorotriazine) by reaction with an appropriate derivative of phosphorous acid, followed by reaction with an amine. For example, cyanuric chloride can be reacted with a trialkyl phosphite of the formula (R 3 O) 3 P in a molar ratio of 1:1, 1:2 or 1:3 to produce a triazine having 1, 2 or 3 ##STR12## phosphonate ester substituents with 2, 1 or 0 remaining chlorine substituents, i.e. a dialkyl 2,4-dichloro-1,3,5-triazine-6-phosphonate, a tetraalkyl 2-chloro-1,3,5-triazine-4,6-diphosphonate or a hexaalkyl 1,3,5-triazine-2,4,6-triphosphonate. The reaction is carried out in an organic solvent, for example an aromatic hydrocarbon such as benzene, toluene or xylene, in the absence of moisture, preferably at an elevated temperature in the range 50°-150° C. The reaction can be catalysed by a catalyst such as sodium iodide. A catalyst is preferably used if the trialkyl phosphite is a secondary alkyl phosphite such as triisopropyl phosphite, allowing complete reaction at 120° C. without decomposition of the product. Alkyl chloride R 3 Cl is evolved as by-product; it is most convenient if the alkyl chloride R 3 Cl can be removed from the reaction mixture, for example if the alkyl chloride R 3 Cl has a lower boiling point than the solvent. The reaction with trimethyl or triethyl phosphite proceeds readily at 120° C. in toluene. Reaction with tri-n-butyl phosphite is preferably at 140° C. in xylene. However, it is preferred in most cases that R 3 contains at least 2 carbon atoms, since the methyl phosphonate groups react differently with amines compared to other alkyl phosphonate groups.
If the trialkyl phosphite P(OR 3 ) 3 is unavailable or too expensive, it is possible to prepare the phosphonate by transesterification of a triazine phosphonate which can be made readily. For example, hexaisopropyl triazine triphosphonate can be prepared by reacting hexamethyl triazine triphosphonate with excess isopropanol.
The dialkyl 2,4-dichlorotriazine-6-phosphonate, tetraalkyl 2-chlorotriazine-4,6-diphosphonate and hexaalkyl triazinetriphosphonate can each react with ammonia, or a primary or secondary amine R 1 R 2 NH to introduce primary, secondary or tertiary amino groups -NR 1 R 2 respectively. The reaction may be carried out in an organic solvent, for example an aromatic hydrocarbon as described above, at a temperature in the range from -20° to 150° C., preferably at at least -10° C. and below 100° C. In many cases the reaction is preferably carried out by addition of the amine or ammonia to the triazine phosphonate, or vice versa, at a temperature in the range -10° C. to 0° C. The reaction can then be completed by allowing the reaction mixture to warm to 0° C. and above, with heating to 50° C. or above if necessary. The amino groups replace the chloro groups on the triazine ring more readily than they replace the phosphonate ester groups, so that reaction of a dialkyl dichlorotriazine phosphonate with at least 2 moles of amine or ammonia per mole of phosphonate will produce a product substantially free from chlorine, as will reaction of a tetraalkyl chlorotriazine-diphosphonate with at least an equimolar amount of amine or ammonia. The amine or ammonia can also replace phosphonate ester groups in a triazine ring having no chloro-substituents. Thus, cyanuric chloride can be reacted with 3 moles of trialkyl phosphite to produce a hexaalkyl triazinetriphosphonate followed by reaction with an amine or ammonia. Excess trialkyl phosphite can be used but is not recommended as it makes isolation of the hexaalkyl triazinetriphosphonate more difficult.
Removal of successive phosphonate ester groups by an amine or ammonia generally requires increasingly forcing conditions, with the single phosphonate ester group in a 2,4-diaminotriazine-6-phosphonate being very hard to replace. A hexaalkyl triazinetriphosphonate, for example, will react with a primary alkyl amine at room temperature or at elevated temperatures below 100° C. to replace two phosphonate ester groups by secondary amine groups. A hexaalkyl triazinetriphosphonate will react with a secondary dialkyl amine at room temperature to replace only one phosphonate ester group by a tertiary amino group. The 2,4-bis(alkylamino)-triazine-6-phosphonate, in the former case, and the 2-dialkylamino-triazine-4,6-diphosphonate, in the latter case, are each produced in high yield. At temperatures of 50° C. and above, for example 50°-100° C., the secondary amine will replace two phosphonate ester groups to form primarily a 2,4-bis(dialkylamino)-triazine-6-phosphonate. This reaction may require the use of excess amine and an extended reaction period, for example at least 24 hours at 60° C.
When a primary aromatic amine such as aniline is reacted with a hexaalkyl triazine triphosphonate, only one phosphonate ester group is replaced at room temperature, forming a 2-arylamino-triazine-4,6-diphosphonate in high yield. When a secondary alkyl aryl amine such as N-methylaniline is reacted with a hexaalkyl triazine triphosphonate, the reaction generally proceeds at room temperature to replace two phosphonate ester groups, and high yields of 2,4-bis(alkyl aryl amino)-triazine-6-phosphonate can be produced at temperatures of 30°-60° C.
A heterocyclic amine such as pyrrolidine, morpholine or piperidine reacts readily with a hexaalkyl triazine triphosphonate, replacing two phosphonate groups to produce for example a 2,4-dipyrrolidino-triazine-6-phosphonate in high yield at room temperature.
The amount of amine required for the above reaction is generally more than the stoichiometric amount required to substitute -NR 1 R 2 groups on the triazine ring, since base is required to neutralise chloride or phosphite groups displaced from the triazine ring. The same amine can act as both nucleophile and base. For example, the reaction with a chlorotriazine Tz-Cl can be represented by the equation:
2R.sup.1 R.sup.2 NH+Tz-Cl→R.sup.1 R.sup.2 N-Tz+R.sup.1 R.sup.2 N.sup.+ H.sub.2 Cl.sup.-
The reaction to displace a phosphonate ester group from a triazine-phosphonate Tz-PO(OR 3 ) 2 is generally according to the equation:
R.sup.1 R.sup.2 NH+Tz-PO(OR.sup.3).sub.2 →R.sup.1 R.sup.2 N-Tz+HPO(OR.sup.3).sub.2
but some amine is consumed by reaction with the dialkyl phosphite co-product according to the equation:
HPO(OR.sup.3).sub.2 +R.sup.1 R.sup.2 NH→HPO(OR.sup.3)O.sup.- R.sup.1 R.sup.2 N.sup.+ H.sub.2 +R.sup.3 OH
Excess amine is preferably used, although less is required than for reaction with a chlorotriazine. The amine phosphite by-product HPO(OR 3 )O - R 1 R 2 N + H 2 can readily be removed from the desired aminotriazine phosphonate, since the by-product is readily soluble in both water and organic solvents.
As an alternative to the use of excess of the amine R 1 R 2 NH, this amine can be used in conjunction with a tertiary amine such as triethylamine. Use of a tertiary amine is preferred when it is desirable to avoid excess of the substituting amine, for example when the amine R 1 R 2 NH is expensive, or is involatile or of low volatility, or when different amines R 1 R 2 NH and R 6 R 7 NH are successively employed to introduce dissimilar substituents. Use of a tertiary amine is also preferred when the amine R 1 R 2 NH is only a weak nucleophile and/or a weak base, for example an aromatic amine such as aniline. The tertiary amine is generally used in an equimolar amount to the amine R 1 R 2 NH when reacting with a chlorotriazine, but it can be used in catalytic amounts, for example 10-50 mole % based on R 1 R 2 NH, when reacting with a triazinetriphosphonate. The reaction of R 1 R 2 NH with a chlorotriazine phosphonate can alternatively be carried out in a 2-phase aqueous/organic solvent system using an inorganic base in the aqueous phase and a phase transfer catalyst.
The dialkyl dichlorotriazinephosphonate, tetraalkyl chlorotriazinediphosphonate or hexaalkyl triazinetriphosphonate can be reacted with two amines, of the general formula R 1 R 2 NH and R 6 R 7 NH, respectively, either simultaneously or successively to produce compounds of formula (I) in which Z is a group -NR 6 R 7 which is different from -NR 1 R 2 . If successive reaction is used, it may be more convenient to use the more reactive amine in the second part of the reaction, since substitution of one phosphonate group by amino reduces the reactivity of the triazine. For example a hexaalkyl, e.g. hexaethyl, triazine triphosphonate can be reacted with an aromatic primary amine such as aniline to introduce one anilino group followed by reaction with a heterocyclic amine such as pyrrolidine to produce diethyl 2-anilino-4-pyrrolidino- 1,3,5-triazine-6-phosphonate. Hexaethyl triazine triphosphonate can be reacted with an equimolar amount of n-butylamine to introduce one n-butylamino group followed by reaction with diethylamine at elevated temperature to produce diethyl 2-n-butylamino-4-diethylamino-1,3,5-triazine-6-phosphonate.
Some of the above reactions are set out in the following reaction scheme; the reactions with amine shown are the predominant reactions at room temperature: ##STR13## Use of the symbol R means a hydrocarbon group, particularly an alkyl group, (the groups R may be the same or different). This scheme may be summarised more succinctly as follows: ##STR14##
In the above reaction schemes, the group R 3 preferably has at least two carbon atoms and the reaction scheme applies most accurately to the case where R 3 is ethyl (use of triethyl phosphite). When the group R 3 is methyl, the tetramethyl aminotriazine diphosphonate of the formula ##STR15## can be formed by the above reaction scheme using a primary or secondary amine R 1 R 2 NH with strict avoidance of excess amine. In the presence of excess amine or ammonia the phosphonate ester group reacts at least partly with the amine or ammonia (R 1 R 2 NH) to form phosphonate salt groups of the formula: ##STR16##
The following phosphonate salt compounds have been prepared by the method described above: ##STR17## where Me=methyl, Et=ethyl and iPr=isopropyl.
These aminotriazine compounds containing ammonium or substituted ammonium phosphonate salt groups are effective flame retardants, but they cannot be mixed with a polyol in the preparation of polyurethane foam because the salts cause foam to collapse. The salts generally have lower solubility in organic solvents and higher water solubility than the corresponding phosphonate esters. The aminotriazine compounds containing ammonium or substituted ammonium phosphonate salt groups do however show intumescent behaviour, foaming at temperatures in the range 100°-400° C., and they can be used in intumescent fire protection products such as coatings, claddings or fire barriers.
Aminotriazine compounds containing ammonium phosphonate salt groups can also be formed by the reaction of a hexa (primary alkyl) triazine triphosphonate (that is, where R 3 is a primary alkyl group having at least 2 carbon atoms) with aqueous ammonia. Whereas hexamethyl triazine triphosphonate reacts with ammonia under aqueous or anhydrous conditions to form an ammonium phosphonate salt, a higher hexa (primary alkyl) triazine triphosphonate such as the ethyl or n-butyl ester will react with anhydrous ammonia to form a dialkyl diaminotriazine phosphonate, but with aqueous ammonia to form a phosphonate salt. A hexa (secondary alkyl) triazine triphosphonate will react with either anhydrous or aqueous ammonia to form mainly a tetra (secondary alkyl) aminotriazine diphosphonate at ambient temperature and a di(secondary alkyl) diaminotriazine phosphonate if heated.
The various reactions of different hexaalkyl triazinetriphosphonates with ammonia are summarised as follows: ##STR18## where anh. means anhydrous and aq. means aqueous.
A hexa(secondary alkyl) triazine triphosphonate is preferred for reaction with amino compounds R 1 R 2 NH which are readily available only as a gas or aqueous solution. Examples of such amino compounds are ammonia, methylamine, dimethylamine, ethylamine, hydrazine, urea and semicarbazide. For example, aqueous hydrazine reacts with hexaisopropyl triazine triphosphonate in isopropanol to produce tetraisopropyl 2-hydrazinotriazine diphosphonate. Urea and semicarbazide will react similarly to introduce respectively -NHCONH 2 and -NHNHCONH 2 groups bonded to the triazine ring.
The polymers of formula (II) can be prepared by the reaction of a phosphonate-substituted triazine with a diamine HR 8 N-E-NR 9 H containing two amino groups selected from primary and secondary amino groups. The phosphonate-substituted triazine can be the reaction product of cyanuric chloride with an equimolar amount of a phosphite, the reaction product having the formula: ##STR19## for example a dialkyl dichlorotriazine phosphonate, or alternatively it can be a fully phosphonated compound such as a hexaalkyl triazinetriphosphonate where the groups G 1 and G 2 are -OR 3 groups in which R 3 is alkyl, preferably ethyl. The diamine can be a diprimary amine, forming polymers where the groups R 8 and R 9 are both hydrogen. Polymers where the linking group E contains at least one arylene or heterocyclic moiety have the highest flame resistance. The linking group E can for example be an arylene, diarylene, triarylene, arylenedialkylene, or alkylenediarylene group. The diamine can alternatively be a disecondary amine, forming polymers where the groups R 8 and R 9 are the same or different alkyl or cycloalkyl groups, or a primary secondary diamine, forming polymers in which the group R 8 is alkyl and the group R 9 is hydrogen. An alternative type of secondary amine group is one in which the amine nitrogen atom forms part of a heterocyclic ring. If a heterocycle containing two secondary amine nitrogen atoms such as piperazine is used, a polymer is formed in which R 8 and R 9 are joined together so that ##STR20## is a divalent heterocyclic group such as piperazin-1,4-diyl. If only one of the amine nitrogen atoms (say R 8 ) is in the heterocyclic ring, a polymer is formed in which ##STR21## is a heterocyclic group, for example piperidin-1,4-diyl from 4-amino-piperidine. Examples of diamines of the formula HR 8 N-E-NR 9 H are ethylene diamine, meta-phenylene diamine, para-phenylene diamine, propane-1,2-diamine, N-methyl-ethylene diamine, N-methyl-propane-1,3-diamine, N,N'-dimethyl-ethylene diamine, N,N'-dimethyl-propane- 1,3-diamine, butane-1,4-diamine, meta- or para-xylylene diamine, methylenebisaniline, 2,4-tolylene diamine, piperazine, (1,2-diaminoethyl)-benzene, 4-amino-piperidine, bis(2-aminoethyl)ether, a diaminopyrimidine such as 4,6-diaminopyrimidine or 2,4-diamino-6-hydroxy-pyrimidine, or melamine. When the groups R 8 and R 9 are different or the bridging group E is unsymmetrical, the repeating units of formula (II) can be arranged in head-to-tail or head-to-head configuration or a random mixture thereof; we believe that random polymerisation generally occurs.
Polymers in which R 8 and R 9 are other than hydrogen have increased solubility in organic solvents compared to polymers containing >NH groups, and polymers in which the linking group ##STR22## is a heterocyclic ring are soluble in most polar organic solvents. For example, poly (ethylene diamino triazine phosphonate) is soluble in highly polar organic solvents such as dimethyl sulphoxide or N-methylmorpholine oxide. Poly (piperazino triazine phosphonate ester) is soluble in the above solvents and additionally is readily soluble in chloroform, dichloromethane, methanol, acetone and acetonitrile. Moreover, the polymer consisting of triazine rings linked by heterocyclic rings such as piperazine has increased compatibility with other organic polymers such as polyesters or polyamides, facilitating blending of the flame retardant of formula II into a fibre-forming polymer composition.
Another type of polymer having increased solubility in organic solvents and increased compatibility with fibre-forming and other polymers is a triazine phosphonate polymer with alternate aromatic diamine and heterocyclic diamine bridging groups. This can be produced by the successive reaction of hexaalkyl, e.g. hexaethyl, triazine triphosphonate with an aromatic diamine such as m- or p-phenylene diamine and then with a heterocyclic diamine such as piperazine or a substituted piperazine. The phenylene diamine will react with the triazine triphosphonate to produce a compound of the formula: ##STR23## but will not readily react further to replace a second phosphonate group on the triazine ring by an amino group. The intermediate (IV) will however react with piperazine to produce a polymer of the formula: ##STR24##
The diamine HR 8 N-E-NR 9 H is preferably used in conjunction with a tertiary monoamine such as triethylamine. This avoids the premature termination of polymer chains with salts of the diamine such as -Tz-NH-E-N + H 3 Cl - or -Tz-NH-E-N + H 3 HPO(OR 3 )O - , since the tertiary amine will form salts more readily and displace the diamine in any salt groups formed.
The polymer (II) according to the invention can be a segmented copolymer in which poly(aminotriazine phosphonate) segments are incorporated in another polymer. For example, an amino-tipped polymer can be reacted with excess of a dichlorotriazine-phosphonate or triazine-triphosphonate, and the product reacted with a diamine HR 8 N-E-NR 9 H.
The polymers of formula (II) can be used as flame retardants in the same way as the compounds of formula (I); in particular they can be added to a polyol during the manufacture of polyurethane foam. The polymer of formula (II) can be incorporated in artificial fibres to impart flame resistance. It can for example be melt-blended with a polyamide, polyester or polyolefin in the formation of melt-spun synthetic fibres. Alternatively, the polymer of formula (II) can be mixed into a spinning dope which is a solution of cellulose in a tertiary amine N-oxide such as N-methylmorpholine N-oxide and extruded into an aqueous bath to form flame-resistant solvent-spun cellulose filaments. When thus incorporated into artificial fibres, the polymers of formula (II) are highly resistant to washing out and impart durable flame resistance. The proportion of (II) in the fibres is preferably at least 2% by weight, for example 5-25%.
The polymers of formula (II) can alternatively be used alone as flame-resistant plastics material. They can be extruded to form fibres or films or moulded, for example by injection, extrusion, blow or compression moulding, to produce flame-resistant moulded articles.
Compounds or polymers containing more than one phosphonate group are generally useful in inhibiting corrosion of metals or for any other use requiring complexing of metals as a chelate. The polymers of formula (II) are particularly useful in this respect. They can be incorporated into paints for surface coating either as a polymer miscible with the binder polymer of the paint or as an insoluble material forming part of the pigment component of the paint. The polymer can for example form 2-60% by weight, preferably 5-40% by weight, of the binder component of the paint, or it can form 2-100% by weight, preferably from 5 up to 50 or 80% by weight, of the pigment component of the paint.
The invention is illustrated by the following Examples.
EXAMPLE 1
Diethyl 2,4-bis(isopropylamino)-1,3,5-triazine-6-phosphonate
To a stirred solution of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol) in toluene (90 ml), cooled at -2° C. and protected from atmospheric moisture, was added dropwise over 40 minutes a solution of isopropylamine (21.24 g, 0.36 mol) in toluene (45 ml). The resulting solution was stirred for 1 hour at 0° C., and then allowed to react for a further 3 days at 20° C. with stirring. Removal of solvent, and drying at 95° C./1 mm, gave a pale yellow solid (21.98 g). A solution of the solid in dichloromethane was extracted with water and dried (Na 2 SO 4 ). Removal of solvent, and drying at 95° C./1.5 mm, gave diethyl 2,4-bis(isopropylamino)-1,3,5-triazine-6-phosphonate (19.49 g, 98%), identified by 1 H-NMR, 13 C-NMR and FT-IR. Recrystallisation from diisopropyl ether gave the analytical sample (14.00 g, 70%) as a white solid, mp 97.0°-98.5° C.
1 H-NMR: δ(CDCl 3 ) 1.22 (12H, d, J=6 Hz, Me 2 CH-N), 1.38 (6H, t, J=7 Hz, MeCH 2 O-P), 4.04-4.31 (6H, overlapping multipiers, Me 2 CH-N and Me-CH 2 -O-P), 5.08-5.19 ( 1 H, broad doublet, NH), 5.29-5.31 (1H, broad doublet, NH);
13 C-NMR: δ(CDCl 3 ) 16.0 (s, MeCH 2 O-P), 22.0 and 22.4 (0.75:0.25, Me 2 CH-N), 41.8 and 42.1 (0.2:0.8, Me 2 CH-N), 63.0 and 63.3 (0.8:0.2, Me-CH 2 -O-P), 163.7 (d, J PCNC =20 Hz, triazine ring carbons with nitrogen substituents), 169.2 (d, J PC =266 Hz, triazine ring carbon with phosphorus substituent);
FT-IR: ν max (neat) 3265, 3100, 2975, 2935, 2875, 1600, 1530, 1265, 1060, 1030 cm -1 .
(Analysis: Found C, 47.18; H, 7.91; N, 20.90; P, 9.00. C 13 H 26 N 5 O 3 P requires C, 47.12; H, 7.91; N, 21.14; P, 9.35%).
EXAMPLE 2
Tetraethyl 2-diethylamino-1,3,5-triazine-4,6-diphosphonate
To a stirred solution of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol) in toluene (90 ml), cooled at -5° C. and protected from atmospheric moisture, was added dropwise over 25 minutes a solution of diethylamine (26.28 g, 0.36 mol) in toluene (45 ml). The resulting solution was stirred for 1 hour at 0° C., and then allowed to react for a further 3 days at 20° C. with stirring. Removal of solvent, and drying at 95° C./1 mm, gave a mobile oil (26.57 g). A solution of the oil in dichloromethane was extracted with water and dried (Na 2 SO 4 ). Removal of solvent, and drying at 95° C./1.5 mm, gave the analytical sample of tetraethyl 2-diethylamino-1,3,5-triazine-4,6-diphosphonate (24.50 g, 96%) as a yellow oil, identified by 1 H-NMR, 13 C-NMR and FT-IR. 1 H-NMR: δ (CDCl 3 ) 1.22 (6H, t, J=7 Hz, MeCH 2 N), 1.41 (12H, t, J HH =7 Hz, MeCH 2 O-P), 3.68 (4H, quartet, J=7 Hz, Me-CH 2 -N), 4.38 (8H, doublet of quartets, J HH =7 Hz, J PH =7 Hz, Me-CH 2 -O-P);
13 C-NMR: δ (CDCl 3 ) 12.2 (s, MeCH 2 N), 16.1 (s, MeCH 2 O-P), 41.9 (s, Me-CH 2 -N), 64.0 (s, Me-CH 2 -O-P) , 161.4 (t, J PCNC =19 Hz, triazine ring carbon with nitrogen substituent), 170.6 (dd, J PC =265 Hz, J PCNC =15 Hz, triazine ring carbons with phosphorus substituents);
FT-IR: ν max (neat) 3495, 2985, 2935, 2910, 1575, 1535, 1480, 1255, 1045, 1025 cm -1 .
(Analysis: Found C, 42.21; H, 7.30; N, 13.27; P, 14.89. C 15 H 30 N 4 O 6 P 2 requires C, 42.45; H, 7.13; N, 13.20; P, 14.60%).
EXAMPLE 3
Diethyl 2-anilino-4-pyrrolidino-1,3,5-triazine-6-phosphonate
To a stirred solution of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol) in toluene (90 ml), cooled at -5° C. and protected from atmospheric moisture, was added dropwise over 25 minutes a solution of aniline (5.58 g, 0.06 mol) and triethylamine (6.06 g, 0.06 mol) in toluene (30 ml). The solution was stirred for 1 hour at 0° C., and then allowed to react at 20° C. for a further 3 days. To the resulting solution, cooled with stirring at +1° C., was added dropwise over 20 minutes a solution of pyrrolidine (4.32 g, 0.06 mol) and triethylamine (6.06 g, 0.06 mol) in toluene (30 ml). The solution was stirred for 1 hour at 0° C., and then allowed to react at 20° C. for another 3 days. Removal of solvent, and drying at 95° C./1 mm, gave a damp yellow solid (25.58 g). A solution of the solid in dichloromethane was extracted with water and dried (Na 2 SO 4 ). Removal of solvent, and drying at 95° C./1.5 mm, gave the crude product as a light yellow solid (22.69 g, 100%). Recrystallisation from carbon tetrachloride gave the analytical sample of diethyl 2-anilino-4-pyrrolidino-1,3,5-triazine-6-phosphonate (16.97 g, 75%) as a white solid, mp 150°-151° C., identified by 1 H-NMR, 13 C-NMR and FT-IR.
1 H-NMR: δ (CDCl 3 ) 1.40 (6H, t, J HH =7 Hz, MeCH 2 O-P), 1.94-2.01 (4H, symmetrical narrow multiplet, C-CH 2 -C of pyrrolidine ring), 3.59-3.65 (4H, symmetrical narrow multiplet, CH 2 -N of pyrrolidine ring), 4.36 (4H, doublet of quartets, J HH =7 Hz, J PH =7 Hz, Me-CH 2 O-P), 7.04 ( 1 H, t, J mp =8 Hz, p-hydrogens of Ph), 7.31 (2H, dd, J om =J mp =8 Hz, m-hydrogens of Ph), 7.40 (1H, sharp singlet, NH), 7.64 (2H, d, J om =8 Hz, o-hydrogens of Ph);
13 C-NMR: δ (CDCl 3 ) 16.6 and 16.7 (1:1, MeCH 2 O-P), 25.3 and 25.4 (1:1, C-CH 2 -C of pyrrolidine ring), 46.6 and 46.7 (1:1, CH 2 -N of pyrrolidine ring), 64.0 and 64.1 (1:1, Me-CH 2 -O-P), 120.0, 123.3, 129.0 and 138.8 (four singlets, ca. 2:1:2:1, aromatic carbons of Ph group), 162.3 (d, J PCNC =21 Hz) and 163.0 (d, J PCNC =21 Hz) [triazine ring carbons with different nitrogen substituents], 170.2 (d, J PC =266 Hz, triazine ring carbon with phosphorus substituent);
FT-IR: ν max (neat) 3300, 2965, 2930, 2870, 1610, 1580, 1525, 1490, 1235, 1020 cm -1 .
(Analysis: Found C, 54.00; H, 6.28; N, 18.59; P, 8.21. C 17 H 24 N 5 O 3 P requires C, 54.11; H, 6.41; N, 18.56; P, 8.21%).
EXAMPLE 4
Poly(diethyl N,N'-ethylene-2,4-diamino-1,3,5-triazine-6-phosphonate)
To a stirred solution of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (146.7 g, 0.30 mol) in toluene (450 ml), cooled at +3° C. and protected from atmospheric moisture, was added dropwise over 75 minutes a solution of ethylenediamine (18.0 g, 0.30 mol) and triethylamine (60.6 g, 0.60 mol) in toluene (150 ml). The resulting solution was stirred for 70 minutes at +2° C., and then allowed to react for a further 6 days at 20° C. with stirring. Crystallised solid was removed by filtration, washed with further toluene (300 ml), then dried in vacuo. Poly(diethyl N,N'-ethylene-2,4-diamino-1,3,5-triazine-6-phosphonate) (81.4 g, 99%) was obtained as a white solid, identified by 1 H-NMR, 13 C-NMR and FT-IR. 1 H-NMR: δ (CDCl 3 ) 1.2-1.4 (6H, m, MeCH 2 O-P), 3.3-3.9 (broad multiplet, CH 2 -N) and 4.23 (m, Me-CH 2 -O-P) [total 8H], 8.12 (ca.2H, broad singlet, NH); δ (DMSO-d 6 ) 1.25 (6H, broad singlet, MeCH 2 O-P), 3.36 (broad singlet, CH 2 -N and absorbed H 2 O), 4.15 (4H, m, Me-CH 2 -O-P), 7.4-7.9 (2H, broad multiplet, NH);
13 C-NMR: δ (CDCl 3 ) 16.3 (s, MeCH 2 O-P), 38.9 (broad singlet, CH 2 -N), 63.6 and 64.2 (two singlets, Me-CH 2 -O-P), 164.1 (d, J PCNC =20 Hz, triazine ring carbons with nitrogen substituents), 168.5 (d, J PC =265 Hz, triazine ring carbon with phosphorus substituent);
FT-IR: ν max (neat) 3255, 3140, 3100, 2985, 1620, 1600, 1545, 1245, 1050, 1020 cm -1 .
(Analysis: Found C, 38.34; H, 5.94; N, 23.37; P, 12.54%).
EXAMPLE 5
Poly[diethyl 2,4-(N,N'-piperazino)-1,3,5-triazine-6-phosphonate]
To a stirred solution of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol) in toluene (90 ml), cooled at -2° C. and protected from atmospheric moisture, was added dropwise over 40 minutes a solution of piperazine (5.16 g, 0.06 mol) and triethylamine (12.12 g, 0.12 mol) in ethanol (30 ml). The resulting solution was stirred for 1 hour at 0° C., and then allowed to react for a further 6 days at 20° C. with stirring. Removal of solvent, and drying at 95° C./1 mm, gave a light yellow powderable glass (24.00 g). A solution of the material in dichloromethane was extracted with water and dried (Na 2 SO 4 ). Removal of solvent, and drying at 95° C./1.5 mm, gave poly[diethyl 2,4-(N,N'-piperazino)-1,3,5-triazine-6- phosphonate] as a pale yellow glass (17.57 g, 98%), which was crushed to a pale yellowish-white powder, and identified by 1 H-NMR, 13 C-NMR and FT-IR.
1 H-NMR: δ (CDCl 3 ) 1.34-1.46 (narrow multiplet, MeCH 2 O-P), 3.85-4.12 (m, CH 2 -N of piperazine ring), 4.26-4.43 (m, MeCH 2 -O-P);
13 C-NMR: δ (CDCl 3 ) 16.4 (s, MeCH 2 O-P), 42.9 (broad singlet, CH 2 -N of piperazine ring), 63.9 (s, Me-CH 2 -O-P), 163.7 (d, J PCNC =22 Hz, triazine ring carbons with nitrogen substituents), 170.3 (d, J PC =267 Hz, triazine ring carbon with phosphorus substituent) [piperazinotriazinephosphonate polymer backbone]; 64.3 (s, Me-CH 2 -O-P), 162.4 (t,J PCNC =18 Hz, triazine ring carbon with nitrogen substituent), 171.3 (dd, J PC =264 Hz, J PCNC =15 Hz, triazine ring carbons with phosphorus substituents) [triazinediphosphonate end-groups];
FT-IR: ν max (neat) 3485, 2985, 2925, 2865, 1545, 1495, 1445, 1250, 1220, 1025 cm -1 .
(Analysis: Found C, 40.74; H, 6.35; N, 17.54; P, 13.20%).
Reaction of a stirred mixture of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (48.90 g, 0.10 mol) and piperazine (8.61 g, 0.10 mol) at 120° C. for 6 hours in the absence of solvent, followed by aqueous washing of a chloroform solution of the resulting gum, removal of solvent and drying, afforded a shorter-chain variant of the same polymer as a pale yellow glassy gum (21.51 g, 72%), identified by 1 H-NMR, 13 C-NMR and FT-IR.
EXAMPLE 6
Diethyl 2,4-diamino-1,3,5-triazine-6-phosphonate
Reaction of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate and ammonia in ethanol gave diethyl 2,4-diamino-1,3,5-triazine-6-phosphonate as a white solid (yield 77%), mp 273°-274° C. (decomp.), identified by 1 H-NMR, 13 C-NMR and FT-IR.
(Analysis: Found C, 34.45; H, 5.45; N, 28.47; P, 12.98. C 7 H 14 N 5 O 3 P requires C, 34.01; H, 5.71; N, 28.33; P, 12.53%).
Flexible polyurethane foam, of density 32.8 kg m -3 and containing 3.0% w/w of diethyl diaminotriazinephosphonate (DDTP), was made from Shell Caradol 48-2 polyol, containing DDTP (4.5 parts per hundred), plus 2,4-/2,6-tolylene diisocyanate (isomer ratio 80:20). Assessment of the horizontal burning characteristics of foam strips of dimensions 150 mm×50 mm×13 mm was carried out in accordance with the BS 4735 combustion test. For 10 strips, the mean time to burn a distance of 125 mm was 81.6 seconds, and hence the mean burn rate was 1.5 mm sec -1 . For foam of the same mean density, containing the chlorinated flame retardant tris-(2-chloroethyl) phosphate at the same level (3.0% w/w) instead of DDTP, the time to burn 125 mm was 80.6 seconds and the burn rate was 1.5 mm sec -1 . The corresponding figures for 20 foam strips of the same mean density, containing no flame retardant but otherwise identical, were 48.3 seconds and 2.6 mm sec -1 .
EXAMPLE 7
Diethyl 2,4-bis(isopropylamino)-1,3,5-triazine-6-phosphonate
To a stirred solution of cyanuric chloride (9.22 g, 0.05 mol) in toluene (45 ml) at 53° C., protected from atmospheric moisture, was added dropwise with gentle warming a solution of triethyl phosphite (16.60 g, 0.10 mol, 2 equivalents) in toluene (30 ml) over a period of 30 minutes, during which the temperature increased to 97° C. Heat input was increased, and the temperature was raised to reflux (115° C.) over 50 minutes. The reaction mixture was then heated under reflux, with collection of ethyl chloride (5.3 ml, 75%), for a further 2 hours. After cooling the resulting solution for 30 minutes, a solution of isopropylamine (17.75 g, 0.30 mol) in toluene (25 ml) was added dropwise over 55 minutes at -3° C. The reaction mixture was warmed to 45° C. over 15 minutes, and maintained at 47° C. for a further 70 minutes. After cooling to 20° C., dichloromethane and water were added to the reaction mixture, and the separated organic phase was extracted with water and dried (Na 2 SO 4 ). Removal of solvent, and drying at 95° C./1.5 mm, gave diethyl 2,4-bis(isopropylamino)-1,3,5-triazine-6-phosphonate (15.10 g, 91%) as a yellowish-white solid, mp 91°-94° C. identified by 1 H-NMR, 13 C-NMR, FT-IR, and TLC comparison with the authentic sample produced in Example 1. The residual chlorine content was only 0.16% w/w, and no 2-chloro-4,6-bis(isopropylamino)-1,3,5-triazine or other significant impurities were detected by TLC.
EXAMPLE 8
Diethyl 2,4-bis(isopropylamino)-1,3,5-triazine-6-phosphonate
To a stirred solution of cyanuric chloride (18.45 g, 0.10 mol) in toluene (90 ml) at 56° C., protected from atmospheric moisture, was added dropwise with gentle warming a solution of triethyl phosphite (16.60 g, 0.10 mol, 1 equivalent) in toluene (60 ml) over a period of 30 minutes, during which the temperature increased to 98° C. Heat input was increased, and the temperature was raised to reflux (116° C.) over 35 minutes. The reaction mixture was then heated under reflux, with collection of ethyl chloride (5.3 ml, 75%), for a further 2 hours. After cooling the resulting solution for 30 minutes, a solution of isopropylamine (35.50 g, 0.60 mol) in toluene (50 ml) was added dropwise over 80 minutes at +1° C. The reaction mixture was warmed to 40° C. over 25 minutes, and maintained at 46° C. for a further 70 minutes. After cooling to 20° C., dichloromethane and water were added to the reaction mixture, and the separated organic phase was extracted with water and dried (Na 2 SO 4 ). Removal of solvent, and drying at 95° C./1 mm, gave a stiff gum (28.47 g), which was separated into a white powder and a pale yellow gum by treatment with diisopropyl ether. The products, identified by a combination of 1 H-NMR, 13 C-NMR, FT-IR, TLC and elemental analysis, were diethyl 2,4-bis(isopropylamino)-1,3,5-triazine-6-phosphonate (yield 76%), 2-chloro-4,6-bis(isopropylamino)-1,3,5-triazine (yield 15%), and a trace of N,N',N"-triisopropylmelamine.
Similar reactions, in which 1,1,1-trichloroethane (reflux 75° C.) and 1,4-dioxan (reflux 105° C.) were used as solvents instead of toluene, both gave diethyl 2,4-bis(isopropylamino)-1,3,5-triazine-6-phosphonate in 81% yield, together with 2-chloro-4,6-bis(isopropylamino)-1,3,5-triazine (yield 12-17%).
The reaction between cyanuric chloride and triethyl phosphite can be carried out in the absence of solvent if desired. The subsequent reaction with an amine is, however, preferably carried out in a solvent to moderate the exothermic reaction.
EXAMPLE 9
Diethyl 2,4-bis(diethylamino)-1,3,5-triazine-6-phosphonate
A solution in diethylamine (125 ml, 88.4 g, 1.2 mol) of tetraethyl 2-diethylamino-1,3,5-triazine-4,6-diphosphonate (25.44 g, 0.06 mol), produced according to Example 2, was heated under reflux at 59° C. for 36 hours with stirring, until TLC indicated complete consumption of starting material. The reaction mixture, consisting of a pale yellow liquid with much crystalline solid, was allowed to cool to 20° C., and then dissolved in dichloromethane (60 ml). Removal of solvent and excess diethylamine, and drying at 95° C./1 mm, gave a damp yellow solid (30.38 g). A solution of the solid in toluene was extracted with water and dried (Na 2 SO 4 ). Removal of solvent, and drying at 95° C./1.5 mm, gave diethyl 2,4-bis(diethylamino)-1,3,5-triazine-6-phosphonate (11.40 g, 53%) as a waxy solid, identified by 1 H-NMR, 13 C-NMR and FT-IR. Recrystallisation from n-hexane at -78° C. gave the analytical sample (10.49 g, 49%) as light yellow crystals, mp 45°-46° C.
(Analysis: Found C, 50.10; H, 8.54; N, 19.43; P, 8.63. C 15 H 30 N 5 O 3 P requires C,50.13; H, 8.41; N, 19.49; P, 8.62%).
EXAMPLE 10
Diethyl 2,4-bis-(n-butylamino)-1,3,5-triazine-6-phosphonate
Reaction of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol) and n-butylamine (26.28 g, 0.36 mol) in toluene (total 135 ml), according to the procedure described in Example 1, on removal of solvent gave a soft grey gum (23.75 g). Aqueous washing of a dichloromethane solution, removal of solvent and drying afforded the analytical sample of diethyl 2,4-bis-(n-butylamino)-1,3,5-triazine-6-phosphonate (21.49 g, 100%) as a colourless syrup, identified by 1 H-NMR 13 C-NMR and FT-IR.
(Analysis: Found C, 50.01; H, 8.19; N, 18.65; P, 8.79. C 15 H 30 N 5 O 3 P requires C, 50.13; H, 8.41; N, 19.49; P, 8.62%).
EXAMPLE 11
Diethyl 2,4-dipiperidino-1,3,5-triazine-6-phosphonate
Reaction of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol) and piperidine (30.60 g, 0.36 mol) in toluene (total 135 ml), according to the procedure described in Example 1, on removal of solvent gave a pale pink solid (26.52 g). Aqueous washing of a dichloromethane solution, removal of solvent and drying afforded diethyl 2,4-dipiperidino-1,3,5-triazine-6-phosphonate (23.43 g, 100%), identified by 1 H-NMR, 13 C-NMR and FT-IR. Recrystallisation from cyclohexane gave the analytical sample (22.50 g, 98%) as white crystals, mp 103°-105° C.
(Analysis: Found C, 52.78; H, 8.10; N, 17.88; P, 8.13. C 17 H 30 N 5 O 3 P requires C, 53.25; H, 7.89; N, 18.26; P, 8.08%).
Reaction occurs readily according to the procedure described herein, which is contrary to the claim by Hewertson, Shaw and Smith, in J. Chem. Soc., 1963, 1670-1675, that these authors found no reaction of the same starting materials under similar conditions.
EXAMPLE 12
Diethyl 2,4-dimorpholino-1,3,5-triazine-6-phosphonate
Reaction of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol) and morpholine (31.32 g, 0.36 mol) in toluene (total 135 ml), according to the procedure described in Example 1, on removal of solvent gave a pale yellow solid (26.39 g). Aqueous washing of a dichloromethane solution, removal of solvent and drying afforded diethyl 2,4-dimorpholino-1,3,5-triazine-6-phosphonate (22.76 g 98%), identified by 1 H-NMR, 13 C-NMR and FT-IR. Recrystallisation from cyclohexane/toluene (5:1 v/v) gave the analytical sample (22.02 g, 95%) as white crystals, mp 114°-116° C.
(Analysis: Found C, 46.36; H, 6.87; N, 17.98; P, 7.98. C 15 H 26 N 5 O 5 P requires C, 46.51; H, 6.77; N, 18.08; P, 8.00%).
EXAMPLE 13
Diethyl 2,4-dipyrrolidino-1,3,5-triazine-6-phosphonate
Reaction of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol) and pyrrolidine (25.56 g, 0.36 mol) in toluene (total 135 ml), according to the procedure described in Example 1, on removal of solvent gave a pale grey solid (25.44 g). Aqueous washing of a dichloromethane solution, removal of solvent and drying afforded diethyl 2,4-dipyrrolidino-1,3,5-triazine-6-phosphonate (21.71 g, 100%), identified by 1 H-NMR, 13 C-NMR and FT-IR. Recrystallisation from cyclohexane gave the analytical sample (20.17 g, 95%) as a pale brown solid, mp 65°-69° C.
(Analysis: Found C, 49.89; H, 7.44; N, 19.16; P, 9.05. C 15 H 26 N 5 O 3 P requires C, 50.70; H, 7.37; N, 19.71; P, 8.72%).
EXAMPLE 14
Tetraethyl 2-bis-(2'-ethylhexyl)amino-1,3,5-triazine-4,6-diphosphonate
Reaction of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol), di-2-ethylhexylamine (14.46 g, 0.06 mol) and triethylamine (6.06 g, 0.06 mol) in toluene (total 135 ml), according to the procedure described in Example 2, on removal of solvent gave a solid/liquid mixture (39.60 g). Aqueous washing of a toluene solution, removal of solvent and drying afforded the analytical sample of tetraethyl 2-bis-(2'-ethylhexyl)amino-1,3,5-triazine-4,6-diphosphonate (29.37 g, 83%) as a red viscous oil, identified by 1 H-NMR, 13 C-NMR and FT-IR.
(Analysis: Found C, 54.80; H, 9.43; N, 8.59; P, 10.24. C 27 H 54 N 4 O 6 P 2 requires C, 54.72; H, 9.18; N, 9.45; P, 10.45%).
EXAMPLE 15
Tetraethyl 2-anilino-1,3,5-triazine-4,6-diphosphonate
Reaction of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol), aniline (5.58 g, 0.06 mol) and triethylamine (6.06 g, 0.06 mol) in toluene (total 135 ml), according to the procedure described in Example 2, on removal of solvent gave a soft yellow gum (28.49 g). Aqueous washing of a dichloromethane solution, removal of solvent and drying afforded tetraethyl 2-anilino-1,3,5-triazine-4,6-diphosphonate (26.02 g, 98%) as a yellow viscous syrup, identified by 1 H-NMR, 13 C-NMR and FT-IR.
An otherwise identical reaction in which double quantities of aniline (11.16 g, 0.12 mol) and triethylamine (12.12 g, 0.12 mol) were used and aqueous washing of the crude product was carried out in toluene solvent instead of dichloromethane, also gave tetraethyl 2-anilino-1,3,5-triazine-4,6-diphosphonate (21.90 g, 82%), which was identified by 1 H-NMR, 13 C-NMR and FT-IR. (Analysis: Found C, 45.61; H, 5.83; N, 12.34; P, 13.76. C 17 H 26 N 4 O 6 P 2 requires C, 45.95; H, 5.90; N, 12.61; P, 13.94%).
EXAMPLE 16
Tetraethyl 2-pyrrolidino-1,3,5-triazine-4,6-diphosphonate
Reaction of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol), pyrrolidine (4.26 g, 0.06 mol) and triethylamine (12.12 g, 0.12 mol) in toluene (total 150 ml), according to the procedure described in Example 2, on removal of solvent gave a mobile oil (26.27 g). Aqueous washing of a dichloromethane solution, removal of solvent and drying afforded tetraethyl 2-pyrrolidino-1,3,5-triazine-4,6-diphosphonate (24.49 g, 97%) as a pale yellow oil, identified by 1 H-NMR, 13 C-NMR and FT-IR.
(Analysis: Found C, 42.49; H, 6.59; N, 13.21; P, 14.25. C 15 H 28 N 4 O 6 P 2 requires C, 42.66; H, 6.68; N, 13.27; P, 14.67%).
An otherwise identical reaction in which diethylamine (4.38 g, 0.06 mol) was added 1 hour after the pyrrolidine (at +1° C.) also gave tetraethyl 2-pyrrolidino-1,3,5-triazine-4,6-diphosphonate in the same yield.
EXAMPLE 17
Tetraethyl 2-n-butylamino-1,3,5-triazine-4,6-diphosphonate
Reaction of hexaethyl 1,3,5-triazine-2,4,6-triphosphonate (29.34 g, 0.06 mol), n-butylamine (4.38 g, 0.06 mol) and triethylamine (12.12 g, 0.12 mol) in toluene (total 150 ml), according to the procedure described in Example 2 except for a reaction time of 6 days, on removal of solvent gave a mobile oil (26.21 g). Aqueous washing of a dichloromethane solution, removal of solvent and drying afforded tetraethyl 2-n-butylamino-1,3,5-triazine-4,6-diphosphonate (24.07 g, 95%) as a pale yellow oil, identified by 1 H-NMR 13 C-NMR and FT-IR
(Analysis: Found C, 42.40; H, 7.10; N, 13.30; P, 14.56. C 15 H 30 N 4 O 6 P 2 requires C, 42.45; H, 7.13; N, 13.20; P, 14.60%).
An otherwise identical reaction in which diethylamine (4.38 g, 0.06 mol) was added 1 hour after the n-butylamine (at 0° C.) also gave tetraethyl 2-n-butylamino-1,3,5-triazine-4,6-diphosphonate in 87% yield.
EXAMPLE 18
Diethyl 2-n-butylamino-4-diethylamino-1,3,5-triazine-6-phosphonate
Tetraethyl 2-n-butylamino-1,3,5-triazine-4,6-diphosphonate prepared as described in Example 17 was dissolved in excess diethylamine and heated at reflux (59°-60° C.) for 6 hours to produce diethyl 2-n-butylamino-4-diethylamino-1,3,5-triazine-6-phosphonate.
EXAMPLE 19
Diisopropyl 2,4-diamino-1,3,5-triazine-6-phosphonate
To a stirred solution of anhydrous ammonia (12.5 ml liquid, 8.5 g, 0.5 mol) in isopropanol (70 ml), cooled at -5° C. and protected from atmospheric moisture, was added dropwise over 20 minutes a solution of hexaisopropyl 1,3,5-triazine-2,4,6-triphosphonate (25.70 g, 0.045 mol) in isopropanol (40 ml). The reaction mixture was warmed to 18° C., and then allowed to react for a further 3 days at 18° C. with stirring. Crystallised solid was removed by filtration, washed with water and acetone and then dried in vacuo. Diisopropyl 2,4-diamino-1,3,5-triazine-6-phosphonate (1.87 g, 15%) was obtained as a yellowish-white solid, mp >400° C., identified by 1 H-NMR, 13 C-NMR and FT-IR.
(Analysis: Found C, 39.64; H, 6.53; N, 24.83; P, 10.95. C 9 H 18 N 5 O 3 P requires C, 39.27; H, 6.59; N, 25.44; P, 11.25%).
Evaporation of the mother liquor, and drying at 95° C./1 mm, gave a waxy solid (14.96 g). A solution of the solid in dichloromethane was extracted with water and dried (Na 2 SO 4 ). Removal of solvent, and drying at 95° C./0.3 mm, gave tetraisopropyl 2-amino-1,3,5-triazine-4,6-diphosphonate (11.91 g, 63%) as a yellowish-white solid, identified by 1 H-NMR, 13 C-NMR and FT-IR. Recrystallisation from diisopropyl ether/toluene (4:1 v/v) gave the product as white crystals, mp 123°-124° C.
(Analysis: Found C, 42.54; H, 6.98; N, 12.67; P, 13.81. C 15 H 30 N 4 O 6 P 2 requires C, 42.45; H, 7.13; N, 13.20; P, 14.60%).
EXAMPLE 20
Tetraisopropyl 2-amino-1,3,5-triazine-4,6-diphosphonate
To a stirred solution of hexaisopropyl 1,3,5-triazine-2,4,6-triphosphonate (42.98 g, 0.075 mol) in isopropanol (105 ml), cooled at -6° C. and protected from atmospheric moisture, was added dropwise over 10 minutes a mixture of aqueous ammonia (35% w/w, 21.86 g, 7.65 g NH 3 , 0.450 mol) and isopropanol (33 ml). The resulting solution was stirred for 1 hour at -2° C., and then allowed to react for a further 3 days at 18° C. with stirring. Removal of solvent, and drying at 95° C./1 mm, gave a stiff gum (38.41 g). A solution of the gum in dichloromethane was extracted with water and dried (Na 2 SO 4 ). Removal of solvent, and drying at 95° C./0.4 mm, gave tetraisopropyl 2-amino-1,3,5-triazine-4,6-diphosphonate as a yellowish-white solid (25.06 g, 79%), which was shown by 1 H-NMR, 13 C-NMR, FT-IR, TLC and mixed melting point to be identical with the sample of tetraisopropyl 2-amino-1,3,5-triazine-4,6- diphosphonate produced in Example 19.
EXAMPLE 21
Tetraisopropyl 2-dimethylamino-1,3,5-triazine-4,16-diphosphonate
Following the procedure of Example 20, aqueous dimethylamine (40% w/w, 50.63 g, 20.25 g (CH 3 ) 2 NH, 0.450 mol) was reacted with hexaisopropyl 1,3,5-triazine-2,4,6-triphosphonate (42.98 g) to produce tetraisopropyl 2-dimethylamino-1,3,5-triazine-4,6-diphosphonate.
EXAMPLE 22
Di-n-butyl 2,4-diamino-1,3,5-triazine-6-phosphonate
To a stirred solution of anhydrous ammonia (12.5 ml liquid, 8.5 g, 0.5 mol) in n-butanol (70 ml), cooled at -6° C. and protected from atmospheric moisture, was added dropwise over 15 minutes a solution of hexa-n-butyl 1,3,5-triazine-2,4,6-triphosphonate (32.85 g, 0.05 mol) in n-butanol (40 ml). The reaction mixture was warmed to 18° C., and then allowed to react for a further 3 days at 18° C. with stirring. Crystallised solid was removed by filtration, washed with water and acetone, and then dried in vacuo. Di-n-butyl 2,4-diamino-1,3,5-triazine-6-phosphonate (11.54 g, 76%) was obtained as a white solid, mp 303°-307° C. (decomp.), identified by 1 H-NMR, 13 C-NMR and FT-IR.
(Analysis: Found C, 43.66; H, 7.15; N, 23.56; P, 10.04. C 11 H 22 N 5 O 3 P requires C, 43.56; H, 7.31; N, 23.09; P, 10.21%).
EXAMPLE 23
Combustion Tests of Polyurethane Foams containing Amino Triazine Phosphonates
Rigid polyurethane foam, of density 40 kg m -3 and containing 6.2% w/w of amino triazine phosphonate, was made from ICI "PBA 6919" polyol, containing amino triazine phosphonate (15 parts per hundred), plus ICI "Suprasec 5005" p,p'-methylenediphenyl diisocyanate (MDI). Assessment of the horizontal burning characteristics of foam strips was carried out as described in Example 6, in accordance with the BS 4735 combustion test. Where flame became extinguished without total burn-out of specimens, the extent of combustion quoted refers to the average of percentage distance burnt and percentage weight lost. For 10 foam strips of density 40 kg m -3 containing 6.2% w/w of diethyl diaminotriazinephosphonate [DDTP], the extent of combustion was 19% and the mean burn rate was 0.6 mm sec -1 . For 10 foam strips of density 41 kg m -3 containing 6.2% w/w of tetraethyl diethylaminotriazinediphosphonate [TDTDP], the extent of combustion was 29% and the mean burn rate was 0.9 mm sec -1 . For foam of density 39 kg m -3 containing no flame retardant but otherwise identical, the extent of combustion was 100% (total burn-out) and the burn rate was 2.3 mm sec -1 .
The flame retardant performances of several amino triazine phosphonates were compared with those of the commercial chloroalkyl phosphate flame retardants tris-(2-chloroethyl) phosphate [TCEP] and tris-(1-chloro-2-propyl) phosphate [TCPP] in rigid polyurethane foam. The foam, of mean density 38 kg m -3 and containing 4.1% w/w of amino triazine phosphonate or chloroalkyl phosphate, was made from PBA 6919 polyol, containing the appropriate phosphorus ester (10 parts per hundred), plus Suprasec 5005 MDI, and combustion tests were carried out in an identical manner to those previously described. The amino triazine phosphonates tested were diethyl diaminotriazinephosphonate [DDTP] (Example 6), poly(diethyl ethylenediaminotriazinephosphonate) [pDEDTP] (Example 4), diethyl bis(isopropylamino)triazinephosphonate [DBITP] (Example 1), diethyl bis-(n-butylamino)triazinephosphonate [DBNTP] (Example 10) and tetraethyl diethylaminotriazinediphosphonate [TDTDP] (Example 2). The extent of combustion and rate of burn for the amino triazine phosphonates and for TCPP are expressed relative to the corresponding figures for TCEP in the following Table.
__________________________________________________________________________BS4735 Combustion Tests of Polyurethane Foam containingPhosphorus Esters TCEP TCPP DDTP pDEDTP DBITP DBNTP TDTDP__________________________________________________________________________Relative Extent of Combustion 1.00 1.11 0.94 0.94 1.01 1.11 1.00Relative Rate of Burn 1.00 1.23 0.95 1.02 0.97 1.06 0.85__________________________________________________________________________
The flame retardant performances of DDTP, pDEDTP, DBITP, DBNTP and TDTDP are at least as good as those of TCEP and TCPP under these conditions.
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Triazine compounds useful as flame retardants have the formula: ##STR1## where Am represents an amino group, Pp represents a phosphonate group and Z represents an amino group or a phosphonate group, or are polymers comprising repeating units of the formula: ##STR2## where ##STR3## is a diamine residue. The triazine compounds are used as flame retardants in plastics materials, particularly polyurethane foam or artificial fibres, or in intumescent fire protection compositions.
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BACKGROUND OF THE INVENTION
Previous Filing Information
On Sep. 20, 2003 the United States Patent Office received a copy of—and assigned Ser. No. 60/503,976 to—a Provisional Patent Application (PPA) filed by the same inventors hereof. That PPA is incorporated herein by this reference as though set out here in full. Additionally, the PPA is being supplemented by this Regular Patent Application (RPA). Applicant expressly reserves all rights and privileges flowing from the PPA and its earlier official filing date and contents thereof. This RPA follows, and it is supported by the PPA.
FIELD OF THE INVENTION
This invention relates to masonry wall bracing and bracing systems for such wall. More specifically, the field of this invention relates to adjustable bracing anchored at a self-supporting base for safely assuring the construction of masonry walls. Additionally the field of this invention relates to a bracing system that sandwiches both sides of a wall under construction by a “connected-through-at-the-base” device which interconnects a pair of bookend right angle braces.
EXPLANATION OF TERMS
Our invention involves a pair of right angle adjustable braces abutting both sides of a wall under construction, and offers telescoping adjustments in plumb and height to selected brace members while the brace sets remain positioned against both sides of the wall. The novel system does so without the use of deadmen and all of the attendant disadvantages associated with such deadmen.
Set out below are brief descriptions of certain relevant terms which further the understanding of the invention. These terms provide a basis for a detailed teaching of the improvements of this invention in the relevant arts. Such terms are not intended to replace the claims but rather serve as helpful guides in understanding our novel improvements in these arts.
Concrete Pillars—or Deadman
Standard bracing approaches involve spaced right angle braces—often of wooden timbers—having a vertical member against the wall, an angled member and a horizontal base member running horizontally away from the wall to a gusseted footing plate that is bolted into a concrete pillar set in the ground. These pillars, or so-called “deadmen” each require about a cubic yard or more of concrete per anchoring point.
For example, the minimum dimension for a deadman as mandated for a 32 foot wall, must be about 3 feet across in both width and depth, and must be set into the ground a depth of about 3 and ½ feet. (The deadmen for shorter walls may be slightly smaller.) Earth moving equipment, or pick and shovel laborers, are mandatory to install and remove such deadmen. Each one is thus costly to set into place and even more costly to subsequently remove after wall construction is finished. In fact, when short spacing distances are required between bracing, the deadmen often take the form of a solid running concrete trench or bunker. These deadmen requirements pose significant disadvantages of the prior art.
Although such pillars/deadmen may be used, the invention does not require such deadmen.
Outrigger Screwjacks
Rather than use deadmen, the invention employs vertical oriented outrigger screwjacks that are adjustably connected at the outermost end of the base, or horizontal, leg of each of the angle braces. Such screwjacks may preferably take the form of a threaded riser formed above a foot plate in contact with the ground. The ground need only have a modicum of levelness and need not be trenched, framed and/or poured as is true for the deadmen requirements of the prior art.
Extending upward from the screwjack foot plate is a threaded shaft that mates with or passes through a receiving opening at about the outer end of the horizontal leg of the brace. A threaded locking wing is used to secure height adjustments made via this screwjack. Pipe clamps may also be used to hold the adjusted locking wing in place simply as an effort to deter vandalism which is sometimes encountered on construction sites. The outrigger screwjack takes the place of the cumbersome deadmen; and, by comparison, is far more economical, safe and convenient.
Base-Located Interconnector
A single connection hole is located through the base of the wall being built to hold a pair of braces together on opposite sides of the wall. This opening—being located at a block course just above the wall's foundation—does not significantly detract visually nor does it weaken the structures as do a series of vertical through openings typical of the prior art. Each brace of the invention, at the right angle location, is fitted with openings that receive a base connector. That connector may be in the form of a long threaded shaft, which shaft is passed through aligned openings in the brace pair and is fitted with nuts for tightening. As the threaded nuts are tightened, the vertical legs of a brace pair are drawn snugly against opposite sides of the wall. They, in turn, hold and support the masonry wall being.
Temporary Tie Wire
As a practical matter several courses of blocks will normally have been laid before the inventive brace(s) need be erected on the work site. At a height that may safely and easily be reached by a workman (e.g. standing on a ladder, for example) a short section of tie wire is inserted in one of the higher block courses being laid. This tie wire is vertically in line with the lower connector opening and need only be a short length of wire. Its primary function is simply to receive a few twists by a masonry craftsman around the vertical brace member, in order to temporarily hold the brace upright against the wall. This temporarily hold by our tie-wire assures that the vertical brace member will remain upright—thus physically freeing a workman so that our connector and leveler means may be appropriately adjusted.
Telescoping Members
Each vertical and angle (diagonal) brace member of the inventive opposing brace pair may preferably be formed from rugged telescoping steel square tubes that fit within each other. Telescoping of these members achieves length adjustments required for workmen protection as wall height progressively increases. Since the height of each newly laid wall section to be braced may be foreknown, the telescoped tubes are appropriately formed with drilled adjustment holes that are aligned so that they may receive connecting bolts or pins. The length of a brace member can easily be achieved from a scaffold or a ladder, and the two or more telescoped members (vertical and diagonal) may again be secured together after the required extension to the bracing system has been made. A telescoping bind bolt makes such adjustments easier and more economical.
BACKGROUND—DESCRIPTION OF PRIOR ART
Block walls include internal voids that are filled or “grouted” with wet cement at specified intervals along the wall being constructed. Such walls may soar to various heights in today's building environment. Once the first eight foot height is reached, OSHA mandates—and practical safety requires—that the block wall should be additionally braced. Four feet more of non-grouted masonry wall can be added above that first eight foot limit before more and higher bracing again becomes mandatory.
In effect, a block wall goes upward in eight foot increments and common sense safety requires that no more than four feet of non-grouted wall should be added without some additional safety bracing being applied to the construction zone. Construction of such walls also requires scaffolding for the masons. Such scaffolding is stationed at least on one, and often on both sides, of the wall. This invention provides ready scaffolding access for laying up blocks while assuring safety as wet grouting is being poured into the block voids. Indeed, the compact and ease of elevation of the vertical and diagonal members of our inventive brace pair allows workmen to readily accommodate course laying, internal grouting, and custom surface finishing together with an advanced improvement in worker safety as well.
From a standards point of view, construction of masonry walls places a burden on the mason contractor to support any masonry wall under fabrication that is over eight feet in height. Such walls must be “adequately” braced. Exactly how such bracing is to be performed, however, is left to the discretion of the contractor in accordance with the OSHA standards in effect today. In exercising that discretion for each and every bracing situation, wind factors are of paramount importance. Several of the typical prior art approaches will be discussed below. But first, a brief review of how wind affects the discretionary bracing environment is believed to be warranted.
Wind speed, with winds varying from calm to gale force constantly buffet a wall being laid up by courses of building blocks. The wind, of course, is never steady; rather, it whips around buildings which may be present and comes in bursts and gusts together with wind variations going from steady to shifting forces.
In short, masons must be protected from the cyclic wind loads that are created by the ever changing wind conditions. Otherwise, without adequate bracing, such winds will readily blow down a wall and endanger craftsman in the masonry trades. It is not unknown for workmen to be killed or seriously injured when walls are not adequately braced.
Any wall that has not yet been “cured” sufficiently is at risk unless it is adequately and safely braced. Indeed, such wall destruction happens in spite of the various prior art attempts to use strengthening members and prior art bracing sections as are commonly found in wall construction.
A block wall under construction is looked upon, for evaluation purposes, as comparable to the sail of a water craft. The well known Beaufort Wind Scale is deemed applicable and the various marine Beaufort numbers are deemed to apply to the Masonry Industry. While originally applicable only to wind conditions at sea, that Beaufort scale has been modernized and modified to take into accounts land affects.
The modified table below sets forth some of the relevant wind factors which must be taken into consideration.
TABLE
Beaufort No.
Wind speed
Effects on Land
0
Calm
Smoke rises vertically.
1
1–3
Rising smoke drifts, weather
vane is inactive.
2
4–7
Light Breezes: Leaves rustle, can
feel wind on your face.
3
8–12
Gentle Breezes: Leaves and
twigs move around.
4
13–18
Moderate Breezes: Moves thin
branches.
5
19–24
Fresh Breezes: Trees sway.
6
25–31
Strong Breezes: Large tree
branches move.
7
32–38
Moderate Gales: Large trees
sway.
8
39–46
Fresh Gales: Twigs and
Branches are broken from trees.
Three common prior art methods are employed to try to safely brace walls in view of the varying wind conditions set out above. In the first method, wooden diagonally placed timbers were positioned at one end against the wall and such timbers at the other remote end are tied to a deadmen, or to posts driven in the ground. Vertical, horizontal and diagonal timbers are often nailed or screwed together in a rather helter skelter wooden jumble.
This wooden bracing method may also include wooden struts connected at the midpoint of the diagonal brace, which struts run toward the base of the wall being built. This wooden bracing is not at all acceptable. Such bracing is subject to cyclic loading from the wind forces and tends to become seriously weakened. Indeed, it is felt by some that this jumbled wooden approach of the prior art creates other serious safety hazards.
In short summary, this wooden timber jumble itself poses safety hazards such as sliding upward as the walls tend to move. Actual wooden brace sliding along the surface of a leaning wall may happen and failures result. Additionally, broken planks and splintered wood abounds. Such wooden bracing is both an attractive nuisance, dangerous in operation and “free” lumber is available for unauthorized taking.
Another typical prior art approach employs a vertical metal beam secured to the face of the wall and held in place by a series of bolts passing through the masonry blocks and the vertical beam itself. A Brace-rite system marketed under a Duro-o-wall trademark is one such prior art type, and it is described in detail in the Technical Bulletin 99-2 Unit Masonry manual incorporated herein as though set forth in full at this point.
The above-mentioned Brace-Rite type includes a bolted-through plate which causes serious wall damage and weakens the structural integrity of the wall. Moreover, it mars the outer masonry block surface—especially troublesome and costly when a decorative exterior wall finish is sought. This is a costly approach both to install and then later to remove. In particular, it creates increased finishing costs needed for removal and the subsequent repairs needed to cover the bolted through hole locations. Moreover, the system requires extra costs and suffers the numerous drawbacks of deadmen—which drawbacks are essentially eliminated by our invention.
Another prior art approach employs cables and turnbuckles anchored between deadmen and cable eyes secured at openings through the wall. Again the wall is damaged and the points of connection—although unwieldy—may not provide efficient support. These and other drawbacks of the prior art are set forth in various available publications including “Masonry Bracing” published by the Masonry Contractors Association—a July 2001 is of particular interest and it is incorporated herein as though set forth in full at this point.
The various shortcomings of these and other prior art approaches are overcome by our invention. Indeed, costing out a masonry job based upon prior art supporting techniques is several times higher than when our new and novel bracing system is employed. Additionally, and perhaps most important, is that worker deaths or injuries resulting from inadequate prior art bracing will be markedly reduced.
SUMMARY OF THE INVENTION
In the invention, each right angle brace includes a horizontal, vertical and diagonal member preferably fashioned from rigid steel tubing that may be interconnected by bolts and/or connecting pins into a stiff rigid right angle brace. Suitable coupling at the corners of the brace assures easy folding of these members so that the brace members are readily portable in sections by a single workman.
For example, the inner telescoping members may be separated from the receiving outer triangular telescope brace sections in order to provide for less weight and manual transport considerations. Once inserted, however, such telescoping members are bolted, pinned or otherwise suitably fastened together for on site bracing. In contradistinction to the prior art, the inventive right-angle brace sets are located, adjusted and compressively interconnected back-to-back on opposite sides of a wall under construction. The connector means is locked within the opening and such means may take any one of many different forms. In our embodiment(s) the connector/adjustment means may be spring loaded, winch-like or more simply a threaded steel shaft for adjustably connecting, leveling and interconnecting the braces of a back-to-back pair.
A connector is passed through a hole in the base of the wall and through aligned mating holes in the vertical riser at the right angle corner of each opposing brace of a support set. Such a threaded shaft may simply be secured by mating threaded nuts at the outside 90° corners of the two opposed braces. Manual tightening of such nuts (plus outrigger adjustment) brings the brace sets together in such a manner that the vertical risers of both of the brace sets are vertically aligned against the wall under construction.
Vertical oriented screwjacks located in receiving openings at the remote end of the horizontal outrigger, adjust for any unevenness at the construction site; and, when raised and lowered, assures that the vertical riser of each right angle brace set will be a flush fit securely against the masonry wall being braced. A flush fit by the vertical riser brace member assures workmen safety in a wall braced by our system.
Both the vertical riser and the diagonal legs of our novel right angle brace sets include telescoping rigid struts which allow for height adjustments to such bracing as is periodically mandated by increases in height during wall construction. A simple and novel twist wire is employed as a method of assembling and securing the right angle braces to the wall. This feature of the invention is free of bolts and holes of the prior art that mar or weaken the visible surface of a wall. No deadmen, posts or land anchors of any type are required for the interconnected opposed brace sets equipped with outrigger screwjacks in accordance with the principles of this invention.
The novel features of the disclosed invention provide many benefits. These benefits are achieved by an invention that:
Meets or exceeds OSHA requirements. Is readily useable on small to large projects. Provides vertical adjustability in a simple and ready manner. Is easily transportable. Is easy to set up and/or breakdown thereby minimizing man hours and associated costs required for wall construction. Requires minimum material handling time for setup or removal. Involves minimum wall penetration to reduce man hours and man-lift time for setup and/or removal. Eliminates the use of deadmen, land anchors, anchor posts and the like together with their attendant disadvantages and costly installation and removal.
DRAWINGS
FIG. 1 is a perspective view of one embodiment of a wall brace constructed in accordance with the invention;
FIG. 2 shows an end view of a pair of supports of FIG. 1 placed on opposite sides of a wall;
FIG. 3 depicts workmen rotating a brace set into an upright position for bracing a block wall in accordance with the method steps of this invention;
FIG. 4 shows a connector coupling a pair of opposed brace supports through an opening in a wall being fabricated;
FIG. 5 includes is an enlarged view of an outrigger screwjack of FIG. 1 ; and
FIG. 6 depicts the telescoping feature for the brace sets of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 are views helpful in fully understanding our bracing invention. Each brace 10 as shown is a unitary right angle brace, preferably formed from sturdy square tube steel members, which members are bolted, welded or otherwise assembled into a unitary right angle brace structure 10 . A brace 10 is moved on site in separated member fashion and may be assembled while leaning on the ground. And then, the assembled frames is manually rotated (See FIG. 3 ) and held upright level and flush as will become clearer from the additional description of the invention.
While primarily intended to be employed in opposing pairs (See FIG. 2 ) our invention may, in a particular case, consist of a single right angle brace 10 held flush against a wall by adjustable connecting and leveling means ( 80 and 55 , FIG. 1 , respectively). Most often, however, our preferred embodiment is as shown in FIG. 2 depicting a pair of braces 10 a and 10 b , in back-to-back upright position aligned and held flush and plumb along a common vertical on opposite sides of a wall under construction.
A wall 11 , as well known, is normally “laid up” to various heights by workers placing standard concrete block, layer upon layer, extending upward from a wall's base foundation. Each brace 10 of FIG. 1 has a horizontal member 30 , vertical member 40 and an angled, or diagonal, member 50 . These members may either be single non-telescoped pieces or they may be fabricated from one or more shorter sections which are telescoped together to accommodate differing wall heights and size requirements.
Comparison of the braces of FIG. 1 shows that the telescoped members 40 and 50 of the right hand brace have been elevated in order to accommodate and offer support for the increased height of wall 11 . FIG. 1 also reveals that the telescoped members 40 and 50 of the left hand brace have both been extended as necessary to support the higher height of wall 10 . Workmen on scaffolding (not shown, but provided for by the invention's close fit to the wall 11 ) simply lift the vertical and diagonal telescoping members 40 , 50 as wall 11 increases in height.
In the method of practicing this invention hole 81 is either left or bored at about (or slightly above) the first block course at base 12 of a wall 11 to be fabricated. The steps in our invention will now be described in more detail.
It should be understood that the foundation 12 for a block wall 11 is often wider than the width of the individual blocks 13 which make up wall 11 . FIG. 4 is an enlarged partial view at the base of the wall 11 , which view shows a connector opening 81 for a pair of opposed brace sets on opposite sides of a wall 11 . As shown, the innermost edge 10 e of each brace set 10 of this invention may rest on the foundational overhang, while being interconnected to each other by threaded shaft 70 through opening 81 in the block wall 11 . Rotation of the loosely connected brace set 10 will allow such a set to be placed on that edge 10 e where it may then be secured as described further hereinafter.
Please note that the inner and outer telescoping members ( FIG. 6 ) may be separated. That is to say, that the outer telescope housing 50 o of the diagonal 50 may be slid away from the inner telescope 50 i . The same is true for the vertical members 40 o and 40 i . Thus, these brace members may all be separable in order to lighten the portability load for a workman.
At first the individual members—singularly or in partially folded form—are carried to a site and are often there assembled and leaned on the ground loosely connected to each other through a connecting means—such as threaded shaft 70 —at the base connector opening 81 . Such members may then be pinned, bolted or otherwise fastened together to form a rigid unitary right angle brace 10 of the invention. FIG. 3 depicts a workman in the process of raising an assembled set 10 , previously leaning on the ground, to an upright position.
Method steps, in summary, include tilting the assembled brace set 10 upright—the process being partially shown by FIG. 3 . Then, the upright set is temporarily held in place via a tie wire 60 . Then connector 80 and screwjack 55 , FIG. 1 , are adjusted and tightened so that the upright brace set will provide brace support to one or both sides of a wall 11 .
Getting the rigid assembled brace set 10 upright and plumb involves rotation about an adjustable connecting means 80 , leveling the horizontal and vertical members to their desired positions by height adjustments at element 55 , and then maintaining same free of further manual assistance by a tie wire 60 as described in more detail below.
As a practical matter several courses of blocks will have already been laid on the wall before the bracing system of our invention need be erected for support of the wall. Above eye height, at a position that may easily be reached by a workman on a ladder, a short section of tie wire 60 , FIG. 1 , is inserted in a selected one of the block courses being laid. That wire 60 need only be a short length of wire, perhaps about haywire thickness. Preferably, although it need not be mandatory, this tie wire 60 will be wrapped around an internal vertical riser of reinforcing rod of the type commonly used in block wall construction.
The primary function of this tie wire 60 is simply to allow a workman to place a few twists about the vertical brace member 40 and hold that member 40 —and, thus the entire rigid brace 10 —upright in position against the wall 11 . Twisted tie wire 60 temporarily holds the vertical upright in its proper place, and frees the workman from any further manual attention in holding brace 10 in place.
This invention, FIG. 5 , provides a pair of outrigger screwjacks 55 (one screwjack for each brace set) to be adjusted in height such that the horizontal member(s) 30 are essentially level with the ground. As noted above in connection with the discussion of deadmen, the earth around construction sites is often neither level nor in good repair. The outrigger screwjacks 55 of our invention greatly alleviate such surface problems inasmuch as the screwjacks 55 of our invention include a foot plate 52 which readily accommodates uneven ground.
The amount of upward force that must be applied by screwjack 55 need only overcome the weight of right angle brace 10 and provide adequate support for the loading vectors expected for wind loads. This weight is not very great, and the wind chart set forth earlier will readily yield the load vectors to be accommodated while the brace is being held upright by tie wire 60 , connector 80 and leveler 55 . Accordingly, a simple threaded screwjack riser shaft 54 , FIG. 1 , of about an inch or so in diameter has proven adequate to satisfy these purposes of our invention.
Riser shaft 54 , FIG. 5 , slips within a slightly oversized, circular receiving collar 57 welded to horizontal member 30 . Leveling is accomplished by advancing or retracting wingnut 58 that is matingly threaded to travel upwards or down on riser shaft 54 . Cap 59 covers the exposed end of riser 54 for safety purposes.
Other similar leveling devices, such as manual or hydraulic jacks, or any one of a wide variety of known leveling devices would equally suffice in place of screwjack 55 ; and, such devices remain within the novel features of our invention. Masonry tradesmen in general are familiar with such screwjack leveling devices as they find extensive use on scaffolding. Thus, in our preferred embodiment we have shown a screwjack 55 rather than some other suitable alternative such as those mentioned above.
Briefly returning again to FIGS. 4 and 5 , please note that vertical member 40 has freedom of rotational movement into and away from the wall 11 by a nut/bolt fastener 97 seated within a pair of triangularly-shaped strengthening flanges 99 . This fastener 97 may, of course, also take the form of a pin passing through openings in the flange 99 and held there by any well known securing device, such as a pull ring or clip (not shown, but understood in this art).
For leveling purposes at FIG. 5 , a workman simply spins (advances and/or lowers) the wing tightener 58 on screwjack shaft 54 until the horizontal brace member 30 is essentially level and the vertical member 40 is flush against wall 11 . The workman then finishes securing connector 80 so that the vertical members 40 of our right angle brace invention 10 are snug and flush against the masonry wall 11 . Adjusting connector 80 slightly—plus some final adjustments to screwjack 55 —readily brings the vertical member(s) of our bracing system invention 10 into a slight compressive condition against the surface of wall 11 . If previously loosened, then bolt/nut 97 must also be tightened to bring the brace into a desired state of rigidity for maximum effective support.
At the innermost end, FIG. 4 , of the horizontal member 30 we have elected to weld a pair of spaced apart flanges 99 to the horizontal member 30 . Obviously, however, member 30 may be bolted or otherwise suitably fastened to the spaced apart flange pair 99 . We outfit the other end of that horizontal member 30 with a vertical receiving collar 57 , FIG. 5 . Receiving collar 57 has an inside diameter that readily accepts an upright threaded shaft 54 of screwjack 55 .
Often times work sites face vandalism particularly by juveniles. It would, to idle juveniles, be considered great “fun” to spin the wing nut 58 down on post 54 . A simple coupling like a radiator clamp (not shown) may be fastened below wing tightener 58 to deter such vandalism inasmuch as the vandals may not have screwdrivers with them during their “playful” excursion unto the construction site.
FIG. 6 depicts that inner diagonal member 50 i is slidably seated within outer diagonal member 50 o . With binding bolt 90 loosened, the inner member 50 i may be slid out axially from the outer member 50 o . Bolt 90 may then be made secure and any conventional fastener, 94 such as a cross pin with a ring clip, or a nut and bolt combination may be placed through the mating holes located in both telescoping members 50 i and 50 o.
Binding bolt 90 assists in the above-described telescoping feature. That bolt 90 may be loosened and tightened as adjustments are made during the telescoping operation described herein. Additional erection assistance is provided by a lifting pole 110 that has a saddle 111 at its upper end. Saddle 111 is selected with a width and depth that will readily allow the diagonal member 40 to fit within the saddle 111 . As workmen are tilting the brace upright, FIG. 3 , the lifting pole 110 allows ease of moving the assembled brace into an upright position.
Also note that the top of the inner telescoping member 40 i has a cover plate 96 that may be separate from—or attached to and made a part of—a wall spacer flange 98 . The thickness of the spacer flange 98 compensates for the small amount of separation between the surfaces of the inner and outer members 50 i and 50 o , respectively. Spacer flange 98 fits against the wall, and although there may be a small length of the vertical member 40 i that is not actually flush against the wall, the use of flush in this inventive system takes into account that small degree of separation which does not detract from the brace support features of this invention.
As workmen do masonry work on the scaffolding (not shown) loose wet mortar drops down. Also, as well known, such wet mortar is “pointed”, or scraped away at the block seams, during the block laying and joint finishing process for wall 11 . The cover cap 97 on the top of the vertical member keeps the dropping mortar from filling the vertical tube sections and interfering with the expected and desired sliding freedom between the telescoping members 40 i and 40 o.
Since the height of each newly laid wall section to be braced is foreknown, the telescoped tubes may be appropriately formed with drilled adjustment holes that are aligned so that they may receive connecting bolts or pins. Alternately, of course, a series of spaced length adjustment holes may be placed in each telescoping member pair. The length of a brace member can easily be adjusted as necessary, and the telescoped members (vertical and diagonal) may again be secured together after the required extension to the bracing system has been made.
The method and apparatus of this invention allows scaffolding of conventional type (not shown) to be erected above our inventive bracing system without interfering with the brace sets per se. Our invention increases, in rather dramatic fashion, masonry craftsmen safety while working on block wall 10 .
While my invention has been described with reference to particular examples of some preferred embodiments, it is my intention to cover all modifications and equivalents within the scope of the following claims. It is therefore requested that the following claims, which define my invention, be given a liberal interpretation commensurate with my contribution to the relevant technology.
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Adjustable apparatus for bracing one or both sides of a wall being fabricated from masonry blocks and having an opening near the base of the block wall. Bracing system includes strong rigid members assembled in the form of a right angle brace set having stiff vertical, horizontal and diagonal members, a connector having a length sufficient to extend through the opening affixed at a right angle location of one or both of the brace sets. A pair of such braces—back to back, and spaced on opposite sides of a wall—are interconnected together via this connector. Selected brace members telescope to accommodate increases in wall height and a manually adjustable outrigger screwjack at the remote end of the horizontal member eliminates reliance on prior art deadmen.
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This is a division of application Ser. No. 930,119, filed Aug. 1, 1978, now U.S. Pat. No. 4,204,828.
BACKGROUND OF THE INVENTION
This invention relates to an improved quench system and method for use in spinning multifilament synthetic fiber. More particularly, the system and method use a fog in the quench stack in combination with a flow of air.
By fog is meant fine particles of fluid, such as water suspended in air, specifically excluding fluid such as water droplets not suspended in air. This fog can be mechanically produced with an airless spray nozzle (atomizer) to atomize fluid such as water. Such an airless spray nozzle is disclosed in U.S. Pat. No. 3,366,721 hereby incorporated by reference. By fluid is meant any fluid which can absorb a great deal of heat, such as by the latent heat of vaporization of water or possibly liquid gases. Fluid also means mixtures of water with other fluids beneficial to fibers, such as finishes.
Although it is known to use flowing air to quench freshly spun filaments, and it is known to use airless spray fog or colloidal suspension of fluid, such as water (U.S. Pat. No. 3,366,721) alone to quench filaments, the combination is not taught. Each of these methods when used alone is uneconomical in capital investment or require high flow rates causing filament motion, undesirable for reasons given below.
Because a large volume of air at high velocity is necessary to create the water spray, the prior art method of using flowing air and sprayed water from a compressed air spray nozzle to quench filaments creates great turbulence of the filaments in the quench stack causing at worst filaments fusing together, or at best slight inperfections where the filaments touch or brush one another in the quench stack. Also, turbulence can cause denier variation. These fusions and even denier variation or slight imperfections then cause major problems in subsequent continuous processing of continuous filaments as they break, slough, or wrap on rolls in the drawing, twisting, texturing or like equipment.
Use of steam to condition fiber in the quench stack is also known, but does not utilize the latent heat of vaporization to cool the filaments which is available by use of fog.
Also, use of sprays of water droplets on the yarn is known but cause undesirable non-uniformities along the filament. In fact, such nonuniformity is used to intentionally create weak spots or to create crinkled fiber.
SUMMARY OF THE INVENTION
In the broad concept, the improved method of this invention is to quench freshly spun synthetic multifilament fibers in a quench stack using fog and air compressing spinning synthetic multifilament fiber from its molten polymer through a spinnerette then into a quench stack, introducing flowing air into the quench stack, then introducing fluid, such as water, in the form of fog generated from an airless atomizer into the quench stack along with the flowing air, controlling the air flow, and controlling the formation of the fog, to quench the freshly spun fiber.
A preferred method is to quench freshly spun fibers in a quench stack using air and fog and comprises spinning fiber from its molten polymer through a spinnerette into a quench stack and quenching the freshly spun fiber in the quench stack first with flowing air and then air and fluid, such as water in the form of fog generated from an airless atomizer, and taking up the fiber on a wound package, while controlling the air flow, and controlling the rate of formation of the fog. The atomizer nozzle can be preferably from about 4 to about 8 feet from the spinnerette. Preferably the fibers are from a synthetic polymer. Also, it is preferred to provide one nozzle for each two bundles of multifilament per stack. The air flow is preferably controlled to supply from about 0.01 to 0.15 standard cubic feet per minute per pound polymer per minute and the formation of fog is preferably controlled by atomizing water at a rate of from about 2 ounces of water per minute per pound of polymer per minute to 4.5 ounces of water per minute per pound of polymer per minute at a pressure of about 400 to 720 psi at the nozzle of the atomizer. The nozzle is more preferably located about 6 feet below the spinnerette. By use of this invention, a spinning and quench system designed for high throughput feeder yarn for staple can be converted to produce high quality feeder yarn for continuous filament processing at high throughput rates. The system uses the latent heat of vaporization to obtain a high degree of quenching. The fiber emerging from the interfloor tube has been measured at 20° C. compared to 35° to 40° C. for conventional quench systems.
The quench system of this invention for spinning multifilament fiber, preferably synthetic, using fog and air in a quench stack comprises a spinnerette for spinning synthetic fiber into a quench stack, preferably a cross-flow quench stack, a nozzle for airless atomizing water into fog, the nozzle preferably being located four to eight feet, more preferably, six feet below the spinnerette introducing fog into the quench stack, means for supplying a flow of air to the quench stack, means to exhaust the air flow from the quench stack, means to supply water to the nozzle, means to receive and remove any excess water droplets in the quench stack, means to control the air flow, and means to control the pressure of the water supply to the nozzle. The spinnerette is located at the entrance of the quench stack, while the means for supplying air, means to receive and remove any excess water droplets, means to exhaust air and nozzle all communicate with the quench stack. The means to supply the water communicates with the nozzle. Both the means to control are operatively connected respectively to the air flow supply means and the water supply means. The nozzle atomizes and communicates with the quench stack at a point downstream from said means to supply air and so that no water droplets are formed to directly contact the fiber. The quenching of the fibers is due entirely to the effect of the fog in conjunction with the air flow. Preferably, one nozzle is provided for each two bundles of multifilament fiber per stack. This invention makes possible spinning high quality continuous filament yarn from equipment designed for high throughput staple feeder yarn by simply modifying the quench stack to add the airless atomizer type sprayer to create a fog in the quench stack. This permits a much lower rate of flow of moving air through the quench stack and creates much less filament motion. This reduced filament motion in turn permits practicable downstream continuous processing of the continuous filament yarn because of much fewer feeder yarn fusion points and imperfections where yarn filaments have bounced or contacted one another. Denier quality is also improved. In fact, in a practical application of this invention on a spinning and quench system designed for high throughput staple feeder yarn into a piddler can, it was impossible to take up the yarn from the quench stack onto an acceptable wound package unless the fog was used in conjunction with the flowing air in the quench stack. Without fog introduction into the quench stack, commercially acceptable wound packages were not possible at the high throughputs desired. At those throughputs air flow was so high it caused high filament fusion levels, and very soft, unstable packages that could not be handled normally without sloughs of yarn occurring. Also full size packages could not be wound because ridges, overgrowth and overthrows of yarn would form, causing package deterioration.
Distribution of the quench air in a typical operation is as follows: Fifty percent of the quench air passes across the filaments being quenched and out into the room. The remaining 50 percent is aspirated by the movement of the yarn into the narrow part of the quench stack called the interfloor tube. Of that, 15 percent passes entirely through the tube and exhausts at the lower end of the quench stack and 35 percent is removed by the exhaust system located along the interfloor tube. In other embodiments greater portions of quench air may flow into the room, up to nearly 100 percent.
The new quench system has the upper area (near the spinnerette) operating as a standard cross flow system with a normal air profile, i.e., lower velocity at the top increasing to higher velocity at the bottom. The lower portion acts as a co-current system with room air being introduced in annular manner near the top and being exhausted in an annular manner near the bottom of the interfloor tube. The co-current section has the airless atomizing jet or jets located near the top (below the air introduction point) for the injection of water (or other fluidized medium) under high pressure to form fog. The resulting water as fog and vapor (due to the heat of the polymer filaments vaporizing the suspended fine water particles) are removed from the air exhaust. The use of cooling air prior to contacting filaments with fog puts a tough skin on the filament surface. This avoids the prior art problem of non-uniformities, weak spots, and crinkling of the filaments. Condensation from the cooled interfloor tube is collected at the exit of the tube and drained off to prevent yarn spotting.
This invention offers the following advantages over the prior art:
a. Provides increased heat removal from the fiber during quenching.
b. Combines the best features from both cross flow and co-current flow quench systems.
c. Allows for higher throughputs than either above system is capable of.
d. Reduces amount of fused filaments and filament movement.
e. Increased yarn uniformity.
f. Reduces requirement for high energy consumption of conditioned air.
g. Improved package formation by reducing yarn growth after winding.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a schematic, partial cross section, side view showing a preferred embodiment of the quench system of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the FIGURE molten polymer from extruder 1 flows through conduit 2 to be forced by pump 3 through spinnerette 5 in spin block 4. The filaments 12 of synthetic fiber are extruded into quench stack 6 which has monomer exhaust 7 and monomer exhaust ring 8. Cooling air enters through plenum 9 from source of air 10 and enters quench stack as shown by arrows 11 flowing across filaments 12 and out of quench stack 6 as shown by arrows 13. Some quench air is also drawn along with the moving filaments as shownby arrow 23. Room air may also be drawn along in quench stack 6 as shown byarrow 24. Filaments 12 then pass through fog 26 formed by atomizer 16 whichreceives high pressure water through a pipe 15 from pump 14. Water is supplied from water souce 22. Filaments then pass through the interfloor tube section shown as the narrowed section of quench stack 6. Interfloor tube exhaust 17 for air and water vapor then exhausts a portion of the airdrawn along with the filaments through the interfloor tube as shown by arrow 27. Filaments then contact finish roll 18 and pass around and over separator roll 19 and godet roll 20 to be taken up in takeup means 21 which could be a winder or tow can. Droplets of water which may condense inside on quench stack 6 are caught by drip catchers 28. Water is removed through drains 33. Air may flow into interfloor exhaust 17 from either direction as shown by arrows 25.
Control for water pressure to the atomizer is by pressure control valve 29.Control for air flow is by controller 32 on fan motor 31 which powers fan 30.
EXAMPLE
Using the system and method described above, nylon 6 polymer, having properties shown in Table 1, was extruded through a 140 hole ("Y" shaped) spinnerette to a denier of about 6,000, and taken up as two ends of 3,000 denier, 70 filaments each, at a rate of about 76 pounds per hour per spinnerette. Spinning and quench conditions are shown in Tables 2 and 3. The atomizer was a Nordson having the specifications given in Table 4 and atomizing water was done as specified in Table 4. Take-up was by conventional Leesona 967 winders at 3,000 feet/minute using standard spin finish. Air in the takeup area was maintained at about 48% relative humidity and 72° F. The resulting yarn was subsequently drawn, textured, commingled and taken up as a carpet yarn sales package. The yarnhad properties as shown in Table 5. Yarn was then made into small carpet samples equal in appearance and quality to presently commercial carpet.
Note the air flow rate is about one third of normal for preparation of nylon feeder yarn for making nylon staple yarn for carpet end use. Also, the comparative data in Table 3 show the fusion of filaments is improved by 800% by using fog in combination with flowing air.
TABLE 1______________________________________Properties of Nylon 6 Polymer Type 1 Type 2______________________________________Relative Viscosity 56 60Extractables, % 2.7 2.0Carboxyl ends, per 7.5 12 to 16milliequivalents of polymerAmine ends, per 47 72milliequivalents of polymer______________________________________
TABLE 2______________________________________Spinning Conditions______________________________________Extruder temperature 260° C.Extruder pressure 600 psigPump type 5.6 cc/rev.Pump rpm 55.2Block temperature 260° C.Exit polymer temperature 263° C.Filter pack type Screens______________________________________
TABLE 3______________________________________Quench ConditionsCross Flow QuenchQuench AirTemperature, °F. 65Relative Humidity, % 65Air flow, cfm 400Velocity 60 fpm avg.Monomer exhaust, vacuumInches of water 2 to 4Fused filaments, % .007Comparative DataFused filaments, withwater to atomizer off .056______________________________________
TABLE 4______________________________________Atomizer SpecificationsType Nordson, 16:1 drive pressure to output pressure ratioOrifice, inches .003Turbulence plate, inches .003Pressure, psig. 560Water flow, ouncesper minute per nozzle 3.84______________________________________
TABLE 5______________________________________Yarn Properties Type 1 Type 2______________________________________UndrawnDenier 3,000 3,120Ultimate Elongation, % 315 360Tenacity, grams/denier 1.1 1.7DrawnDraw Ratio 2.8 3.0Drawing Speed,fpm 5,000 6,000Denier 1,330 1,300Ultimate Elongation, % 53 52Tenacity, grams/denier 2.1 3.0Entanglements per meter 33 31Yarn breaks during .63 1.0drawing, per hourYield of yarn on packages 86.5 --versus yarn fromspinning, %______________________________________
INITIAL TRIALS
In initial trials of the use of fog in the quench stack combined with flowing air, a closed quench stack using co-current air flow was used. Several times, when operating the spinning and quenching at 45 pounds/hourof polymer throughput and otherwise standard conditions, as given above, cylindrical packages of nylon 6 yarn could not be taken up on conventionalwinders when the fog was not being introduced about 6 feet down the stack because the yarn being wound would expand and form ridges and slough off of the packages until winding failed. Introducing fog under the same conditions permitted normal winding of full size yarn packages. Increasingair flow without fog would have created much undesirable filament motion inthe quench stack. Also, yarn produced with no fog as compared to yarn produced with fog introduced to the quench stack along with the flow of air was highly inferior in mechanical quality during subsequent processing. That is, the yarn produced with no fog had a great deal more imperfections and nonuniformities along the length of the filaments as shown by problems in drawing. One sample of yarn produced with fog had no wraps during subsequent drawing while an equal amount taken from partial packages of yarn quenched with no fog had 0.21 wraps per pound of yarn drawn. One sample produced without fog could not be drawn because it continually broke when drawn at the same conditions as yarn quenched with fog and flowing air.
Using ten samples of wound sales packages of each type of nylon 6 feeder yarn for carpet end-use, one set quenched with air only and the other set quenched with air and fog under otherwise identical conditions, a comparative evaluation of mechanical quality was made. The packages were evaluated objectively, visually. A value of 1 indicates no overthrown ends, no broken fils and no loops on the package. The inspectors were trained in ordinary daily quality control inspections. The standard for commercial yarn is 2. A value of 5 indicates very poor quality, and any value above 3.5 would be rejected and not sold. The trial average for packages of yarn produced with fog in the quench stack was 1.8. The trial average for packages of yarn produced without fog in the quench stack was 4.4. The yarn produced without fog made unacceptable packages and also would not pass through the standard tufting needles used to tuft carpet due to snags from yarn imperfections.
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A quench system for spinning multifilament synthetic fiber using a fog in the quench stack is disclosed. The system and method comprise
a. spinning synthetic multifilament fiber from the molten synthetic polymer through a spinnerette into a quench stack,
b. quenching the freshly spun fiber in the quench stack with a combination of flowing air and airless atomized water in the form of a fog, and
c. taking up the fiber onto a wound package,
d. while controlling the air flow, controlling the formation of the fog, and removing any excess water droplets formed in the quench stack.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from Provisional United States application Ser. No. 60/140,495, filed Jun. 24, 1999.
FIELD OF THE INVENTION
The present invention relates to methods for the control of ash accumulation and corrosive effects of combustion products, and problems associated with fly-ash disposal or recycling, in catalytic reduction units, by addition of modifying compounds to reduce the detrimental effects of these materials.
BACKGROUND OF THE INVENTION
The EPA has recently promulgated as part of the Clean Air Act a major reduction in nitrogen oxides (NOX) emissions with compliance scheduled for May 1, 2003 in 22 eastern states and the District of Columbia. For the electrical utility industry specifically, a 75% reduction in the current permissible emission has been established which is equivalent to 0.15 lb NOX per million BTU's. The major method of compliance for the utilities will be selective catalytic reduction (SCR) as NOX reductions of 80% to 90% have been proven in Germany and Japan where these regulations have existed for fifteen years.
Predominantly, coal-fired utilities are affected by this regulation. In Europe and Asia where this technology has been employed for a long time, their coals tend to contain low sulfur (less than 1.5% SO 2 ) whereas United States coals are significantly higher in sulfur content. The level of total sulfur ranges from 1.13% total sulfur for coal from the Pittsburgh seam in Washington, Pa. to a level of 8.2% total sulfur for coal from the Bevier seam in Henry, Mo. Operation of the SCR's overseas has presented only minor problems whereas in the U.S., several problems have occurred due to the higher sulfur content.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide novel methods to overcome or mitigate these problems by reducing the detrimental effects of combustion products in these industries.
A further object of the invention is to provide novel methods to overcome or mitigate problems in such catalytic reduction systems by addition of modifying compounds to the system which will modify ash chemistry so as to control ash accumulation and the corrosive effects of combustion products, the modifying compounds preferably comprising magnesium compounds.
Other object and advantages of the invention will become apparent as the description thereof proceeds.
In satisfaction of the foregoing objects and advantages, the present invention provides a method for controlling ash accumulation and corrosive effects of combustion products of catalytic reduction systems which comprises the addition of chemical compounds which will modify the resultant ash chemistry. In a preferred embodiment, the chemical compounds comprise magnesium compounds.
DESCRIPTION OF THE INVENTION
In typical SCR systems, the catalyst is placed in the colder part of the boiler usually before the air heater so that the unit is exposed to temperatures between 450° and 750° F., or otherwise supplemental heat will probably be required. The flue gas containing the nitrogen oxides flows through the honeycomb or plate catalyst in the presence of a slight deficiency of ammonia so that by means of oxidation—reduction reactions, about 85% of the nitrogen oxides are converted to diatomic nitrogen which comprises 78% of the air we breath.
In this process, two detrimental side effects occur. First, on the commercial level, about 5 ppm of ammonia does not react resulting in free ammonia. Second, the same catalyst that helps to convert the NOX into a harmless form, also catalyzes the conversion of SO 2 to SO 3 . These two materials react to form ammonium sulfate [NO 4 ) 2 SO 4 ] and ammonium bisulfate [NH 4 HSO 4 ] which have low melting points and will cause pluggage in the air heater and are also acidic thus causing corrosion. Their melting points are 445° F. and 297° F., respectively, which means that they are molten at the typical air heater temperatures. The sulfates cause the fly-ash to adhere to the surfaces of the catalyst thus resulting in more frequent shutdowns to remove the hardened mass. Plugging of the air heater has been identified as the number one operating problem with SCR's. The costs associated only with the washing of the air heater and net loss of generating revenue is about $50,000 with each shutdown.
Another major problem area is plugging the catalyst. Either in plate or honeycomb form, the openings are only 6 to 12 mm in the ceramic catalyst. Again, compounds with low melting temperatures can fuse or cause the fly-ash to adhere to the catalytic surface.
Several compounds which cause the problems have been identified. They are sodium aluminum sulfate (NaAlSO 4 ), potassium aluminum sulfate (KAlS 4 ) and ammonium phosphate [(NH 4 ) 3 PO 4 )]. The sodium, potassium, aluminum and phosphorous originate from the coal and their levels are dependent on the type and source of coal. The sulfur trioxide (SO 3 ) results from oxidation of the coal ash and causes the formation of deposits on the catalyst.
For many years oil-fired furnaces have been treated with magnesium oxide suspended in oil. One of the main purposes of this treatment is for the MgO to combine with SO 3 to form non-corrosive magnesium sulfate and lower the exit temperature of the boiler without causing sulfuric acid to condense on the air heater. A similar problem is created by the SCR's. Both forms of ammonium sulfate will condense but in particular, the ammonium hydrogen sulfate will condense in a form which can be expressed as an acid salt containing (NH 4 ) 2 SO 4 and sulfuric acid, H 2 SO 4 . In SCR's, magnesium will raise the melting point of the ash above the air heater temperature. The modified ash is more friable and can be removed by soot blowers.
The addition of magnesia will also raise the melting point of ammonium phosphate in the SCR to reduce its tendency to adhere to the catalyst surface. It may also do the same for the alkali aluminum to form spinel which is a very friable material to help prevent the formation of the alkali aluminum sulfate and also make the ash readily removable by soot blowers.
The preferred compounds of the magnesium used in this invention comprise the oxides or the hydroxides. The magnesia or other compound may be added as a powder, aqueous suspension, or oil based suspension.
The site for injection of the magnesium compound is important. From previous work on coal-fired furnaces, it was noted that if the magnesium compound is added too close to the front of the boiler (too high a temperature), the magnesium compound will react with the silica and other ingredients in the coal ash thus causing an excessive requirement for the magnesium compound. However, the injection site must be cool enough for magnesium sulfate to remain in the combined form and not disassociate back to sulfur trioxide gas and magnesia. The magnesia must be injected so as to be uniformly dispersed in the flue gas within a few seconds for proper treatment.
The amount of magnesium compound to be used will be based on the coal ash analysis. The greater the amount of impurities, the higher the amount of magnesium compound or salt addition required. In general, from 1 wt. % up to 80 wt. %, preferably 0.5 to 25 wt. % of magnesium compound or salt may be added, based on the weight % of sulfur shown in the analysis.
The addition of the magnesium compound produces a friable residue in the SCR unit and air pre-heater of a coal fired unit to allow quicker removal of the residue while also contributing to sulfur oxide gases (SO x ) control by reducing the formation of ammonium sulfate double salts such as ammonium magnesium sulfate [(NH 4 ) 2 Mg 2 (SO 4 ) 3 ]. In the air-heater section, the magnesium modifies the ash thus resulting in less pluggage due to ash build-up and also provides alkalinity to reduce corrosion of the unit. In the fly-ash, the magnesium can also reduce the impact of ammonia release when the ash is used in concrete production.
The magnesium may be supplied by an operative magnesium chemical or compound such as magnesium oxide, magnesium hydroxide, magnesium carbonate, etc. Also the form of addition can be powder injection, aqueous suspension, oil-based suspension, etc.
In addition to magnesium chemicals, the addition of about 1 to 50 wt. % aluminum chemicals combined with about 50 to 1 wt. % of the magnesium chemicals is a further embodiment of the invention. A mixture of a magnesium compound or salt with aluminum trihydrate (ATH) provides the chemical basis to form spinel type products, which have been utilized successfully in the oil-fired utilities to produce an easy-to-remove ash. These blends of magnesium and aluminum compounds would thus be of benefit to the SCR industry.
The following examples are presented to illustrate the invention. However, the invention is not considered as limited thereto as obvious variations thereon will become obvious to those skilled in the art.
EXAMPLE I
In this example, three different formulations were tested to determine the effect of magnesium hydroxide on ammonium bisulfate at temperatures of the type encountered in SCR units, and especially the effect on residues which result from cooling.
In each of tests A, B and C, different amounts of magnesium hydroxide were mixed with ammonium bisulfate to obtain different ratios. Then the mixture was heated or burned at 399° C. until the mixture was melted and then allowed to cool. Then a 2% mixture of the resulting ash was formed in 100 ml of deionized water and the pH determined. The tests were as follows:
Test A:
25 grams Ammonium Bisulfate
10 grams Mg(OH) 2
Ratio: 2 gms Mg(OH) 2 /5 gms NH 4 HSO 4
Resulting pH = 10.36
Test B:
25 grams Ammonium Bisulfate
15 grams (Mg(OH) 2
Ratio: 3 gms Mg(OH) 2 /5 gms NH 4 HSO 4
Resulting pH = 10.36
Test C:
25 grams Ammonium bisulfate
7.5 grams Mg(OH) 2
Ratio: 1.5 gms Mg(OH) 2 /5 gms NH 4 HSO 4
Resulting pH = 3.71
These experiments showed that the Mg(OH) 2 addition to ammonium bisulfate, one of the problem compounds in SCR units, under simulated burn conditions, resulted in an ash which could be easily removed and handled and wherein the pH had been substantially elevated above the pH of 1.28 of untreated ammonium bisulfate.
EXAMPLE II
This example was the same as Example I except that the SCR compound to be treated was ammonium sulfate. Test A, B and C compositions and pH results were as follows:
Test A:
25 grams Ammonium Sulfate
10 grams Mg(OH) 2
Ratio: 2 gms Mg(OH) 2 /5 gms (NH 4 ) 2 SO 4
Resulting pH = 9.93
Test B:
25 grams Ammonium Sulfate
15 grams (Mg(OH) 2
Ratio: 3 gms Mg(OH) 2 /5 gms (NH 4 )HSO 4
Resulting pH = 10.44
Test C:
25 grams Ammonium Sulfate
7.5 grams Mg(OH) 2
Ratio: 1.5 gms Mg(OH) 2 /5 gms (NH 4 ) 2 SO 4
Resulting pH = 8.71
The results from this example were consistent with Example I. The heated and cooled mixture was an ash with an elevated pH which could be easily handled and removed.
The invention has been described with reference to certain preferred embodiments. However, as obvious variations thereon will become apparent to those of skill in the art, the invention is not considered to be limited thereto.
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A process for the utilization and strategic addition of ash modifying compounds, into selective catalytic reduction units, to modify the resultant ash chemistry to control ash accumulation and corrosive effects of the combustion products, and problems associated with fly-ash disposal or recycling.
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BACKGROUND AND SUMMARY OF THE INVENTION
This invention pertains to a thin-film, floppy and compliant, electromagnetic read/write head array structure. More particularly, it pertains to such a structure which is intended to be used in compliant, pressure-biased contact with a magnetic imaging medium, with little appreciable medium wear occuring as a consequence of such contact.
A recently emerging magnetographic technology, born from the inventions disclosed in my prior-filed U.S. application which are identified as follows:
MAGNETIC IMAGING METHOD AND APPARATUS, Ser. No. 170,788, Filed 7/21/80 now U.S. Pat. No. 4,414,554;
MULTIPLE HEAD MAGNETIC RECORDING ARRAY, Ser. No. 381,923, Filed 5/26/82;
DIFFERENTIAL-PERMEABILITY FIELD-CONCENTRATING MAGNETIC WRITING HEAD, Ser. No. 381,922, Filed 5/26/82 (now abandoned);
has made possible high-resolution, high-quality, low-cost magnetic imaging. Disclosed in those applications are several different types of thin-film imaging heads, and an array of such heads, which may be used to create and read an endless variety of images, such as lettrs in the alphabet.
One of the important features which is offered by the thin-film structures disclosed in these three prior applications, is that the main supporting substrate in each structure takes the form of a glassy amorphous material known under the trade designation "Metgals". See, particularly, application Ser. No. 170,788, filed 7/21/80, entitled MAGNETIC IMAGING METHOD AND APPARATUS for a more detailed identification of this material. Among other important contributions made by Metglas in the head structures disclosed is that it is an extremely hard material which permits it, with extremely low-wear consequences (regarding a magnetic imaging medium), to be pressure-biased into contact with such a medium for the closest possible magnetic coupling during reading/writing operations. In addition, its flexibility allows a head organization constructed in accordance with those applications to comply easily with curvilinearity in a confronting medium.
While such compliant low-gear contact is strikingly offered by the structures disclosed in the above-referred-to three applications, because of the way in which the individual read/write heads are formed (somewhat like spaced islands or projections) on the face of a Metglas substrate, pressure-biasing during a read/write operation results in some point-pressure telegraphing through the substrate to a contacting medium. Thus, while low-wear performance is clearly offered, it is not as maximized as it could be in the absence of such point-pressure telegraphing.
A general object of the present invention therefore, is to provide, with respect to electromagnetic, thin-film, read/write head structures like those disclosed in the above-identified applications, additional structures which tends to "planarize" (fill-in topography) of that side of the Metglas substrate which bears the projecting head structure, thus to reduce appreciably and likelihood of point-pressure telegraphing like that just outlined.
A related object is to provide such an organization wherein a portion of the additional "planarizing" structure just mentioned is formed using part of the conductive highway system which connects with coils in the read/write head structures.
While the resulting structure, on the side of the substrate where the head coils are formed, has obvious non-planar topography, care is taken, according to the invention, to place the additional fill-in "planarizing" structure in such a manner that normally applied forces, spreading, as is customary, outwardlyt as they transmit through the substrate, converge vectorially no further than the opposite face of the substrate, thus to avoid any significant preferential pressure points.
According to a preferred embodiment of the invention, the proposed head array structure includes a thin-film, floppy and compliant web, or substrate, of the type mentioned above. Individual read/write heads, and associated energizing conductive structure, are distributed like "bumps" on one face of the substrate--the opposite face of which is designed to contact a magnetic imaging medium during a read/write operation. Other "bumps", some of which are formed over the connecting conductive structure for the heads, and others which are isolated like islands from the heads, are distributed over the first-mentioned substrate face in a manner whereby they cooperate with the head bumps to minimize point-pressure telegraphing in the kind of operational situations mentioned above.
Various other objects and advantages are attained by the invention, and these will become apparent as the description which now follows is read in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified, fragmentary, schematic side elevation showing an operational arrangement of a head array structure constructed in accordance with the present invention, pressure-biased for an image-writing operation against a drum-supported magnetic imaging medium.
FIG. 2 is a fragmentary plan detail on about the same scale as, and taken generally from the top side of, FIG. 1 with pressure-biasing mechanism removed from the figure, and with two sets of shading lines used to call attention to certain ares of the figure.
FIG. 3 (second sheet of drawings) is an enlarged fragmentary plan view of a portion of the head array structure shown in FIG. 2, illustrating what is referred to herein as point-pressure-telegraphing minimizing "planarization" structure.
FIGS. 4, 5 and 6 are schematic fragmentary cross sections taken generally along lines 4--4, 5--5, 6--6, respectively, in FIG. 3, illustrating related topographies in the head structure, and disclosing how pressure-biasing forces diffuse through a substrate (in the structure) toward the face thereof which is intended to contact an imaging medium.
DETAILED DESCRIPTION OF THE INVENTION
For the purpose of illustration herein, a preferred embodiment of the invention is disclosed in the setting of a magnetic-image printer, wherein image writing only occurs--such having been found to be an area of particular utility for the invention.
Turing attention now to FIGS. 1 and 2, indicated generally at 10 (FIG. 1) is a portion of a magnetic-image printer, including a rotary drum 12 and an endless, belt-like conventional, magnetic imaging medium 14 carried on the drum. In the particular situation now being described, drum 12, when operating, rotates in the direction of arrow 16 at a speed of about 40-rpm.
Positioned, as will be explained, above drum 12 in FIG. 1 is a read/write head array arrangement 18, including plural, side-by-side adjacent, elongated, strip-like head array structures 20, constructed in accordance with the present invention. As can be seen in FIG. 2, structures 20 are discposed with their longitudinal axes substantially parallel to one another, and at a slight upwardly and to the right inclined angle relative to the direction (shown by arrow 16) in which medium 14 travels relatively beneath the array structures. The reason for this angular inclination will be explained shortly.
Generally describing the head array structures, each of which is substantially duplicative of the others, each includes a flexible Metglas web, or substrate, shown at 22, on the top side of which in FIG. 1 (the confronting side in FIG. 2) there are formed one hundred and twenty-eight electromagnetic read/write heads arranged in sixteen rows of eight heads each. The sixteen rows generally parallel the long axis of the structure, and the whole matrix of heads occupies a rhomboidal region 22a (two such regions being shaded in FIG. 2). The read/write axes for these heads extend substantially normal to the plane of FIG. 2, taking into account the obvious consideration that the head array structures are bent, as shown in FIG. 1 to place the undersides of webs 22 against medium 14.
Extending in FIG. 2 generally upwardly to the right and downwarly to the left of the head matrix in each structure are patterns of conductors, called herein a highway system, for energizing coils in the heads. These conductors extend to terminating connection pads, the outermost of which extend substantially to the dash-double-dot lines in FIG. 2.
The rhomboidal appearance of each head matrix is dictated by the necessity for an angular-offset head arrangement, such as that described in my above-referred-to application, Serial No. 381,329.The disclosure of that application is hereby incorporated by reference into this specification.
Suitably supporting opposite ends of webs 22 are frame pieces 24 which are mounted in the printer in any appropriate manner. These frame pieces are disposed in such a fashion that each web 22 is bent over medium 14 to place in contact with the medium an expanse on the underside of the web substantially co-extensive with the expanse on top of the web where projecting portions of the read/write heads are formed (the shaded expanses in FIG. 2). In FIG. 1, what might be thought of as the "angular" limits of these expanses, with respect to drum rotation, are depicted by dashed lines 26, 28. In FIG. 2 these same expanses are bounded, in a right-to-left sense, by dashed lines 30, 32, and in a top-to-bottom sense, by the lateral margins of each web 22. The respective areas, under the head array structures, in medium 14 which underly the expanses just described are referred to herein as "facial zones" in the medium.
Further describing head array structures 20, formed in accordance with the teachings in my above-mentioned prior U.S. patent applications, on the upper side of each web in FIG. 2, are various layers including electrical conductors and certain magnetic material which, together with the web, make up the plurality of read/write heads in the structure. In FIG. 1, this construction is represented schematically at 34 as a unitary lump on the top side of web 22. The actual construction and topography of this unified lump will be explained shortly. The lateral (right-to-left) limits of lumps 34 correspond with dashed lines 30, 32 in FIG. 2.
Completing a description of what is shown in FIG. 1, disposed in contact on to of lump 34 is a felt biasing pad 36 which is backed up, so-to-speak, by a suitable platen shown at 38. Pressure-biasing the platen and pad downwardly against lump 34 is a biasing spring 40 which acts between the platen shown and a fragment 10a of the frame in printer 10.
As was outlined earlier herein, it is intended that the head array structures of this invention, which are thin-film floppy and complaint devices, be specially adapted for what is referred to as expanse-type, pressure-biased, substantially uniform-pressure contact with a facial zone (identified earlier) in medium 14. To this end, and as will now be explained in detail, forming a part of what has been called a lump 34, along with the specific structural parts that cooperate with web 22 to make up read/write heads, is additional structure that tends to fill in what might be thought of as void expanses on the same side of the web so as to minimize pressure-point-telegraphing through the web to a medium under the pressure-biased operating situation depicted in FIG. 1.
Turning attention to FIG. 3, here there are shown enlarged fragments of portions of two of the head array structures seen in FIG. 2. In order to simplify the figure, a description thereof is given in particular only with reference to substantially one half the length of a portion of one of the head structures, inasmuch as the other half takes the form of a reversed mirror-image replica.
Indicated by dashed circles 42, 44, 46, 48, 50, 52, 54, 56 are the perimetral outlines of eight of the electrical energizing windings provided for eight of the read/write heads in the structure now being described. Extending, as can be seen, from the left side of FIG. 3, independently toward each of these eight windings, and shown also in dashed lines, are unnumbered conductors that form what is referred to herein as a highway system to the respective windings. For reasons which will be explained shortly, one will note that various ones of these conductors, at different locations, include differently shaped lateral bulges, or expanses.
Distributed over the windings and conductors just mentioned, ultimately as a final blanket in the head array structure, is a layer of magnetic material 58 having the perimeter outline shown, which generally repeats the pattern of windings and conductors. This material, where it overlies the windings, cooperates in the way described in the above-referred-to applications Ser. Nos. 170,788 and 381,922 to form parts of the read/write heads. The blanket of material just described extends toward the viewer in FIG. 3, from the near plane of web 22, about the same distance all over the blanket.
Distributed in what might be though of as the void expanses which would otherwise be remaining on the near surface of web 22 in FIG. 3 are different appropriately shaped islands, such as those shown at 60, 62, 64, 66, which are formed to include the same layers making up the other structure just described on the near face of the web. The final exposed layers in these islands are made up of the same magnetic material which produces layer 58, and the projections toward the viewer in FIG. 3 of these islands is substantially the same from the near face of the web as that just mentioned.
The generally circular projecting portions depicted in FIG. 3 are referred to herein as first-mentioned projecting land portions. The other projecting portions, including those which overly the conductors, and those which characterize the islands, are referred to both as second-mentioned projecting land portions, and as point-pressure-minimizing means. Of the second-mentioned projecting portions, those that overly the conductors, as can be seen, connect with those which overly the windings.
Turning attention now to FIGS. 4, 5 and 6, as mentioned earlier, here there are shown three different schematic cross sections taken along the respectively numbered view lines in FIG. 3, showing the topographical relationship between the projecting portions on the top side of web 22, and the web itself. As can be seen in FIG. 4, web 22 has an overall thickness, shown at t 1 , of about 60-microns, and each of the projections above the top surface of the web in FIG. 4 has an overall thickness, shown at t 2 , of about 45-microns. The combined thickness, T, is about 105-microns.
Experience has shown that, in a structure like that which is now being described, where pressure may be applied to a layer of material which lies incompletely (i.e., has margins) within the boundaries of an underlying layer, such pressure produces what might be thought of as diffusing force vectors which extend outwardly from the region of perimeter contact between the two, at about 45° angles into the broader (i.e., more expansive) layer. In FIG. 4, and assuming that pressure is applied downwardly to the structure shown therein on the tops of the projections depicted, diffusion of forces, in the plane of view, is shown by the two pairs of crossing dash-dot lines. It is significant to note that these lines, which represent force vectors in the plane of view, intersect above the bottom face of web 22.
FIGS. 5 and 6, taken from the other points of view mentioned, depicted similar force-vector situations.
What is significant to note is that, relative to the specific positiones of the read/write heads, the pads and configurations of the associated conductive lines including the selected lateral bulges in some of these lines, and the configurations and dispositions of the separate islands described, have all been chosen to assure that all force-vector "situations" between adjacent gapped areas in a head structure result in a crossing of force-vectors no further than the opposite face of web 22. It is this consideration which assures that, during a typical operating situation, like that depicted in FIG. 1, point-pressure telegraphing through web 22, to a contacting recording medium, is substantially eliminated. Put another way, the contact pressure which a medium, like medium 14, experiences is substantially uniform throughout the contact expanse area. Accordingly, extremely long-life low-wear operation is possible.
While a preferred embodiment of the invention has been discussed herein, it is appreciated that variations and modifications may be made without departing from the spirit of the invention.
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A thin-film, floppy and compliant, electromagnetic, read/write head structure which is adapted to be pressed against a magnetic imaging medium during reading and writing. Individual heads and associated structure are distributed like "bumps" on one face of a support substrate--the opposite face of which is the one designed to contact a medium. Other bumps, some connected functionally with the heads, and others isolated from the heads, are distributed over the same first-mentioned substrate face in a manner whereby they cooperate with the head bumps to minimize preferential point-pressure telegraphing (through the substrate to a recording medium) during compliant pressure-biased contact with such a medium.
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BACKGROUND OF THE INVENTION
The invention concerns the heating of electrically conductor flat products, this heating being obtained by scrolling through electromagnitude induction. A known device employed for this contains the following essential components:
A transfer system keeping the flat product to be heated in a heating plane and scrolling it along a longitudinal transfer direction in this plane. The width of the product is laid in a transverse direction also in this plane and its thickness in a direction of flow, each of these directions being perpendicular to others. The transverse position of the product to be heated can be adjusted.
Inductor excitation windings.
Electricity supply sources to supply these windings with an electric current periodically variable according to the time and with controlable amplitude, so that they thus produce a magnetic flow varying like this current.
And magnetic inductor circuit to channel this flow and form a heating flow through the product to be heated more or less along the said direction of flow.
The invention applies to the frequent case where heating must be homogeneous over the whole surface of the product.
Amongst the devices known to obtain this heating, most of them use a magnetic field whose profile is uniform over the greater part of the width of the product. This profile is corrected on the edges to obtain homogeneous heating over the whole width by organizing the distribution of the closing currents. The homogeneity along the lengths results from the longitudinal scrolling of the product.
This is notably the case in the British Pat. No. 1546367. The corrections to the edges are obtained by various devices (coils, or additional magnetic bridges, air-gap modifications, . . . ) which complicate the construction and must be adapted to the induced reaction of the product, this reaction depending on the latter's characteristics: thickness, resistivity.
Another known device said to be "sqaure mesh" does away with the above difficulties. It is described in the document No. FR-A 2538665 (the French Pat. No. EN 82 21906 of Dec. 28, 1982). The inductor consisting of windings and magnetic circuits obtains square meshing of the heating flow with a sinusoidal distribution of the magnetic field along the two directions parallel to the sides of the squares. If the product has a width containing an integer number of times the pitch of the meshing, heating is then homogeneous without any correction to the edges. However if the width of the product does not contain an integer number of times the pitch of the meshing, a heterogeneous temperature develops on the two edges. To reduce this heterogeneity it is possible firstly to modify the excitation current of the meshing elements opposite these edges, secondly to provide a relatively small meshing pitch so that the heat difused by conduction provides acceptable homogenization in this area. However a small pitch of the meshing may be a handicap given that the inductible surface capacity varies in the same way as the fourth power of this pitch, without so much ensuring a sufficient homogenization through conduction in the product if the scrolling speed is relatively high (short transfer time). Additional inductors can thus be added opposite the edges, but this introduces the constructional complexity indicated above.
SUMMARY OF THE INVENTION
The device according to the invention contains the essential components referred to above. Its inductor has a periodical composition both in the longitudinal direction with a longitudinal pitch and in the transverse direction with a transverse pitch, so that the variations in the amplitude of the heating flow in the heating plane outline a rectangular meshing consisting of the juxtaposition of rectangular squares of length equal to this longitudinal pitch and widths equal to this transverse pitch. The magnetic circuit contains in each of these squares at least one central polar part such that the amplitude of the heating flux is cancelled out on the sides of the squares so that the average heating obtained after scrolling of the product to be heated is the same over all the widths of the square comprised entirely in the width of this product. The form of this part is further chosen so that this amplitude is maximum in the center of the square with a more or less sinusoidal arch distribution both in the longitudinal sections and in the transverse sections. The ratio of the transverse pitch to the longitudinal pitch is selected to cancel out the local heating heterogeneity in each of the squares which are entirely contained in the width of the products to be heated. This local heterogeneity is the difference in one direction in the other of the temperature in the center of the width of the square to that of the edges of the square after the product has scrolled.
The inventors have observed that this local heterogeneity develops on output from an inductor when its real transverse pitch diverges from an equilibrium value similar to the longitudinal pitch of this inductor, this heterogeneity then increasing firstly with the divergence from this equilibrium value and secondly with the current supplying this inductor.
A rectangular meshing is described in the application for the French patent referred to above which nevertheless only envisages that the ratio of the transverse pitch to the longitudinal pitch be equal to one, given that the meshing proposed in square as indicated above.
One could conceive of producing, but with very great complexity and with prohibitive costs, a setting of the pitch of a square meshing, in both directions so as to adapt exactly to all the widths of the family of products to be heated.
The aim of the invention is to provide for homogeneous heating of a product of any width without any special correction of the edge and using a device with acceptable production costs.
The device according to this invention is featured by the fact that it contains a first and a second so-called inductor succeeding each other longitudinally, and having respectively a first and a second value different from the longitudinal pitch, and consequently a first and a second equilibrium value of the transverse pitch.
Each of these inductors consist of the juxtaposition of several inductor sections in succession transversally and regularly according to the said transverse pitch, each of these sections extending longitudinally and with its own inductor winding and its own magnetic circuit, and offering the said frequency according to the longitudinal pitch.
Mechanical setting facilities control the spacing between the said inductor sectors consequently the said transverse pitch to the same value in these two inductors. This adapts the device to limited variations in the width of the product to be heated through a variation in this spacing and making this width equal to an integer number of transverse pitches. It is thus possible to have the edges of the products coincide with the edges of the said squares in each conductor, so as to heat the edge areas of this product to the same temperature as its intermediate areas. The common transverse pitch can be controlled between the said first and second equilibrium values of the transverse pitch.
Electrical setting facilities control the ratio of the electric circuits supplying the two inductors. When a difference between the real transverse pitch and its equilibrium value in each conductor tends to produce a said local heterogeneity in the heating specific to this inductor, these setting facilities supply the two inductors with the electrical currents necessary to cancel the local global heating heterogeneity of the device through compensation between the two heterogeneities specific to the two inductors.
In short it would appear that, to remain within acceptable costs, a configuration is adopted according to the invention, varying only in width, so as to always have an integral number of transverse pitches in this width, the device then containing two inductors whose two longitudinal pitches define, with the preceding common transverse pitch, two rectangular meshings. The long side of the rectangle is in the direction of the transfer of one of the inductors and in the direction perpendicular to the transfer for the other inductors. By setting the ratio of the excitation currents in the two inductors it is thus possible to obtain an exact compensation of the heterogeneities created by one inductor by equal sized heterogeneities with opposing sign and created by the other inductor.
Preferably the magnetic circuit of each of the said sectors contains at least one longitudinal bar carrying the said polar parts succeeding each other longiudinally and projecting towards the product to be heated. A winding specific to this bar follows a winding path passing longitudinally in line with a first polar part, then transversally between this part and a second one, then longitudinally to the left of this second one, then transversally between this second one and this third, and so on. In this way the inductor sector is easily produced.
Moreover it is advantageous that the device should also comprise electrical switches so as to connect or disconnect the windings exciting the lateral sectors of the two inductors thus varying the number of transverse pitches to adapt the width of the heating flow to variations in the width of the product to be heated larger than the aforesaid limited variations.
Also each sector should preferably contain two of the said bars installed on either side of the product to be heated.
A further aim of this invention is a heating process for flat products scrolling through electro-magnetic induction, according to which the product to be heated is made to scroll longitudinally in the flow of an inductor offering a dual frequency according to a longitudinal pitch and a transverse pitch, featured by the fact that this product is made to scroll in the flow of two successive inductors with a common transverse pitch which is practically adjustable between the two longitudinal pitches of these two inductors, this transverse pitch is adjusted so that the width of this product coincides with an integer number of transverse pitches thus obtaining the same heating on the two edge areas of this product as on the intermediate areas; firstly the ratio of the currents supplying the two inductors is said to homogenize the heating in each transverse pitch, and secondly the total power adjusted to reach the temperature required.
The advantages and specific features of the invention will be better understood on reading what follows, illustrated by the figures appended.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a square of rectangular magnetic meshing with its long side in the direction DX of the transfer.
FIG. 2 shows the heterogeneity of the heating obtained in the width of the product scrolling in the square in FIG. 1, the temperature reached by the various points in this width being entered in ordinates.
FIG. 3 shows a square with rectangular meshing with its long side in a transverse direction DI perpendicular to the direction of the transfer.
FIG. 4 shows the heterogeneity of the heating obtained in the width of the product scrolling opposite the square in FIG. 3.
FIG. 5 shows the meshings of the heating flows created by inductors IL and IC of two furnaces which follow each other in the direction of transfer, when these meshings are such that the two furnaces must be used at the same power, which implies that the meshing rectangles in the two furnaces have practically the same length to width ratio.
FIGS. 6 and 7 show meshings of the two same furnaces after reduction and increase in the transverse pitch so as to produce a square meshing in the first and second furnaces, respectively, a thick line indicating the only furnace supplied electrically and which has the square meshing.
FIG. 8 shows a front view of the inductor of one of these furnaces, displaying the principle of coiling the inductor windings, the north and south magnetic poles being designated by the letters N and S respectively.
FIGS. 9 and 10 show, in a side view, the magnetic circuits with fixed longitudinal pitches different from the second and first inductors respectively.
FIG. 11 shows a perspective view and end portion of a bar.
FIG. 12 shows the detail, at magnified scale, of FIG. 8 to display the relative arrangement of the parallel parts and windings.
FIG. 13 shows a cross-sectional view of an inductor section showing a polar part according to a drawing X11 in FIG. 12.
FIG. 14 shows a connection diagram of the excitor windings of an inductor, to show that the windings of several lateral sections can be disconnected to adapt to the width of the product to be heated.
FIG. 15 shows a side view of the device, according to the invention, displaying the system of transferring the product to be heated scrolling horizontally.
FIG. 16 shows a cross-section of the view of the short inductor in the device (see FIG. 15), displaying the mechanism setting the transverse pitch.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The inventors have established that if the meshing is rectangular instead of being a square, the heating heterogeneity in a transverse pitch has a sinusoidal distribution whose DT amplitude is given more or less exactly by the expression:
DT=T.(1-a.sup.2 /b.sup.2)/(1+a.sup.2 /b.sup.2)
If T designates the mean temperature obtained, a the short side b the long side of the rectangle.
If, in accordance with FIG. 1, side a is installed over the width of the product (transverse direction DY) and side b the direction of the transfer DX, the maxima of the sinusoid or superheats is on the edges of the rectangles and the minima or underheats in the axis of the said rectangles, as in FIG. 2.
If, in accordance with FIG. 3, a is installed in the direction of the transfer DX and b over the width of the product, the maxima of the sinusoid or superheats are in the axis of the rectangles and the minima or underheats on the edges of the rectangles as shown on FIG. 4.
In the device according to the invention, the basic configuration consists of two furnaces with respectively two inductors IL and IC one of which forms a meshing of longitudinal pitch PL and the other a meshing of longitudinal pitch PC. These two pitches are fixed constructively.
In the transverse direction DY, i.e., in the width of the product, the meshing has a variable pitch PT. This variable pitch PT is comprised between the longitudinal pitches PL and PC and it should be contained an integer n times in the width LA of the product LA=n PT.
Take the specific case in which PL/PT=PT/PC.
The heating heterogeneities are in this case of the same amplitude in both furnaces if they are excited equally, so as to each induce half the total heating power, but have the configuration of FIG. 2 in the PL pitch furnace, and the configuration of FIG. 4 in the PC pitch furnace, so that they compensate each other exactly.
This meshing is shown in FIG. 5.
For all the cases in which the width of the product is between n.PL and n.PC, it is also possible to obtain homogeneous heating. Having installed as previously, an integer number n of pitch PD in the width of the product, the two furnaces are excited differently so as to demand more power from the one producing the least heterogeneity for a given current, and vice versa. The two limit cases are shown in FIGS. 6 and 7.
On FIG. 6, the width of the product is n.PC. One of the furnaces then has a square mesh, producing heating free of heterogeneity. Full power is therefore required of this one whereas the second furnace is not used.
On FIG. 7, the width of the product is n.PL. The unused furnace in the case above becomes square mesh and it is now this one for which full power is required, free of heterogeneity, whereas the other furnace is not used.
In practice, so as to limit the underuse of these two extreme cases, thus to obtain more favorable and economic sizing, no furnace is unused, but with a lower load than that with rectangular meshing so that the heating heterogeneity remains compatible within the accepted tolerance.
If the width of the product is less than n.PC, k longitudinal sections are disconnected from the above meshing in the width of the product, k being determined by the shortest foreseable width of product to be heated, obtained by opening switches such as I1, I1 (see FIG. 14).
It is clear that, given that only the transverse pitch is variable, it is possible to make all the meshes in the same section indissociable from each other. Windings Ei, Ei+1 shown in FIG. 8 belong to two successive sections of rank i and i+1. Their form is linked to this indissociability. The electrical conductor takes on the form of an undulation around the alternating N and S poles in the same row determining three of the four sides CA, CB and CC of a rectangular helix. This same figure shows that the fourth side CE of the helix consists of an conductor of the adjacent sector, owing to the directions of currents indicated, without preventing the relative displacement of the first section in relation to the second so as to vary the transverse pitch.
It can nevertheless be observed that, when the transverse pitch diverges from its minimum value, a perfectly closed rectangular current helix cannot be exactly obtained because two no current intervals remain in the two transverse sides of the rectangle. In particular, when the transverse pitch is equal to the longitudinal pitch one does not obtain exactly the square current helix which would obtain perfectly homogeneous heating. This is one of the reasons for which the said equilibrium value of the transverse pitch is not exactly equal to the longitudinal pitch, this equilibrium value being that by which in practice we get as close as possible to homogeneous heating, and being determined experimentally.
To take a concrete example, the problem is to heat up to 480° C. strips of aluminium 1 mm thick scrolling at a speed of 0.33 m/s and whose width is between 0.85 and 1.85 m. 800 kW must be induced for the maximum width.
The two furnaces are produced one with a longitudinal pitch of 170 mm according to FIG. 9, the other with a longitudinal pitch of 240 mm according to FIG. 10. Each longitudinal row of meshings materialized by an inductor sector with a magnetic circuit in bar form. The polar parts or pole pieces are shown in P. The extreme longitudinal polar parts PE have half the length.
In both cases, each bar consists of a bed of magnetic plates 1, clamped between flanges 2 and braced by parts 3 and 4 as shown in FIG. 11. The winding associated to a bar is shown in FIG. 12. The conductor consists of two copper tubes 5, outside diameter 25 mm, and inside diameter 19 mm, connected parallel and winding around the poles as previously explained.
FIG. 13 is a cross-sectional view of a bar and also shows the insulating shims both electrical 6a and thermal 6b.
FIG. 14 shows the principle governing the electrical connection of one of the inductors. The minimum width of 850 mm is covered by five transverse pitches of 170 mm. To impose a nil value on the magnetic field on the two edges of the product, two additional sections are excited outside the product, one on each edge. These seven sections each forming a row of poles, are supplied through a switch Io which is only opened when the inductor is not in service.
By varying the seven pitches thus defined from 170 to 204 mm, the five active pitches heat all the widths between 850 and 1020 mm.
Adding an eighth row, by closing switch 13 six active pitches can be used heating all the widths between 1020 and 1190 mm when these pitches vary from 170 to 198.33 mm.
WIth the addition of a ninth row (switch 14 closed), it is possible with seven active pitches, to heat all widths between 1190 and 1360 when these pitches vary from 170 to 194.28 mm.
And so on enabling widths to be heated up to 1700 to 1870 mm by evolution of 12 transverse pitches, ten of them active from 170 to 187 mm.
ALong the same principle the following could also be produced:
7 transverse pitches varying from 170 to 204, five of them active, width heated 850 to 1040 mm
8 transverse pitches varying from 170 to 204, six of them active, widths heated 1040 to 1224 mm
9 transverse pitches varying from 170 to 204, with seven of them active, widths heated 1224 to 1428 mm
10 transverse pitches varying from 170 to 204, with eight of them active, widths heated 1428 to 1632
11 transverse pitches varying from 170 to 204, nine of them active, widths heated 1632 to 1836 mm
12 transverse pitches varying from 170 to 204, ten of them active, widths heated 1836 to 2040 mm.
The second device has the advantage of heating larger widths than the first. Nevertheless, for the maximum width of 1850 mm considered, the first device, not using for the large widths the full variation in the transverse pitch, means that with these large widths, the total power is better distributed between the two furnaces thus minimizing the power installation, without however using an additional row.
This example is not exhaustive as to the method of electrical connections. It is basically an illustration. In practice it is advantageous in certain cases to use parallel connections. The power supply voltages are selected to obtain the same current in the windings of the same inductor. The said current setting mechanisms are incorporated into source SE.
According to FIG. 15 the system of transferring the product to be heated seven consists of rollers R1, R2, R3 providing for horizontal scrolling, the product being supported inside the furnaces either by the mechanical tensions applied between the inlet and outlet or, if a product is not ferromagnetic, by the magnetic levitation indissociable from the product (see for example document No. FR-A 2509 562). In this latter case, the rollers R1, R2 and R3 can be suppressed, which is advantageous if the product should not be in contact during its treatment. Each furnace contains two inductors symmetrical to the plane of the product to be heated. These long pitch inductors are shown in IL and I'L, the short pitches ones in IC and I'C. The adjustable lateral guides G1, G2 provide the transverse positioning of the product.
FIG. 16 shows the solution adopted in the example to obtain the variations in the transverse pitch. It is the cross-section of one of the two furnaces and only shows a half-width the other practically being symmetrical. The furnace is shown in the configuration corresponding to the minimum value of the transverse pitch.
The inductor bars BC1 to BC13 and B'C1 to B'C13, designed as described above and shown in FIGS. 9 to 13, are carried by moving supports 21a to 27a, 21b to 27b, except for bars 10a and 10b, identical to the others, which are carried by fixed supports 20a and 20b.
Moreover 21a and 27b are moving and rotated by two screws 31a and 31b, guided radially by guides 20a and 20b, the pitch of the threads being 2 mm for supports 22a and 22b, and also for 21a and 21b, 4 mm for supports 23a and 23b, 6 mm for supports 24a and 24b, 8 mm for supports 25a and 25b, 10 mm for supports 26a and 26b, and 12 mm for supports 27a and 27b. Guides which are not shown preserve the parallelism of the supports.
The configuration is practically symmetrical in relation to the fixed supports 20a and 20b, except that the part not shown contains five pairs of moving bars (whereof 21a and 21b) instead of six.
The two screws 31a and 31b are controlled by the same mechanism comprising, on the same shaft 41, two bevel gears 51a and 51b and a hand-wheel 61.
The product to be heated 7 moves between the bars 11a to 17a and 11b to 17b perpendicular to the plane in the figure.
The dotted line shows the extreme position BCIE of bar BCI after rotation of screws 31a and 31b to obtain the maximum transverse pitch value.
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As known the product to be heated (7) is made to scroll longitudinally in the flow of an inductor (IC) with a dual frequency along a longitudinal pitch and along a transverse pitch. According to the invention this produce is made to scroll in the flow of two successive inductors with a common transverse pitch (PT) which is adjustable (31a) practically between the two longitudinal pitches of these two inductors, this transverse pitch is set to make the width of this product coincide with an integer number of transverse pitches thus obtaining the same heating on the two edge areas (7a, 7b) of this product as on the intermediate areas, and firstly the ratio of the currents supplying these two conductors is set to homogenize the heating in each transverse pitch, and secondly the total power adjusted to reach the temperature required. The invention applies to metallurgy.
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BACKGROUND OF INVENTION
It is well known that ring opening polymerization can be performed on dicyclopentadiene (DCPD), methyl tetracyclododecene, and other norbornene monomers.
For example, Japanese Kokai Patent No. SHO 58[1983]-129013 discloses the manufacturing method of a thermosetting DCPD homopolymer with the aid of a metathesis catalyst using the reaction injection molding (RIM) method. In addition, Japanese Kokai Patent No. SHO 59[1984]-51911 discloses the RIM method of DCPD, methyl tetracyclododecene, and other norbornene monomers.
In these methods, although glass fibers were used to reinforce a norbornene polymer matrix, it was found that if short fibers, such as milled fibers, were used, the increase in the mechanical strength was insufficient. On the other hand, if long glass fibers were used, polymerization was easily impeded.
Hence, there are only few examples in the prior art using a glass mat for the reinforcement of a polymeric matrix. Only U.S. Pat. No. 4,708,969 discloses such a scheme. However, even in this conventional scheme, the glass mat content is only 40% by weight. In addition, the properties, such as flexural modulus, flexural strength, and the like, of the reinforced polymer with glass fibers are not sufficient.
The purpose of this invention is to provide a method of making a glass fiber reinforced norbornene polymer and a reinforced polymer matrix which has excellent mechanical strength and other properties without impeding the ring opening polymerization of the norbornene monomer.
The present inventors have performed intensive research on the method for overcoming the disadvantages of the conventional techniques. It was found that the polyester powder, commonly used as the binder of the glass mat, can seriously impede the polymerization of the norbornene monomer and as a result, the resulting polymer is insufficiently cured and has poor properties.
For the conventional glass mat using a polyester powder as the mat binder, the norbornene polymer is poorly cured and curing is also poor around the polyester powder bonded with the glass fibers. Hence, the adhesiveness between the glass mat and norbornene polymer is poor, the reinforcing effect of the glass mat is reduced, and the mechanical strength cannot be increased.
SUMMARY OF INVENTION
This invention pertains to a method for making a reinforced polymeric matrix and to a reinforced polymeric matrix itself wherein the polymer is polymerized norbornene monomer or a mixture thereof and the reinforcing material is a glass mat bonded with a hydrocarbon polymer selected from polyolefins, vinyl aromatic polymers and norbornene polymers. The norbornene monomer is selected from norbornene-type monomers which are bicyclic or have a higher cyclic structure, such as norbornene itself, dicyclopentadiene, tetracyclododecene, and tricyclopentadiene.
DETAILED DESCRIPTION OF INVENTION
The gist of this invention resides in the use of a specific type of binder to bond glass reinforcing material into a mat using long or continuous, intermediate, or short fibers. Long fibers are generally defined as those that have a longitudinal dimension of greater than 2 inches whereas short fibers have the longest dimension of 1/4 to 1/32 of an inch. Anything in between is considered an intermediate fiber.
This invention, therefore, is directed to a method for making a reinforced polymeric matrix and to the reinforced polymeric matrix itself which is the product of the noted method. The polymeric matrix is a polymer of one or more norbornene-type monomers which have one or more norbornene groups therein and the reinforcing material is a glass mat of individual glass fibers or strands bound into a mat with a hydrocarbon polymer selected from polyolefins and vinyl aromatic polymers.
The polymeric matrix is prepared in a conventional way. In a preferred embodiment, at least two liquid monomer streams are prepared: one containing the metathesis catalyst dissolved in at least one norbornene monomer and the other, a metathesis cocatalyst or activator dissolved in at least one norbornene monomer. Each of these streams can contain other additives as needed. For instance, an elastomer is normally added to both streams to increase viscosity of each and to impart other advantages, an antioxidant is normally added to the stream containing the catalyst, and a halogen source is normally added to the stream containing the cocatalyst. The streams are then mixed in a mixer at about 1:1 volume ratio and then conveyed into a mold wherein a glass reinforcing mat has been previously placed. The mixed streams flow into the mold filling all voids in the mold and in the mat. The mold is normally maintained at an elevated temperature to initiate polymerization by ring opening of the norbornene monomer(s). Polymerization in the mold is completed and a reinforced, thermoset polymeric matrix is extracted from the mold.
In this invention, the monomers used as the starting materials of the norbornene polymers are those having at least one norbornene ring. Polycyclic norbornene monomers with three or more rings are preferred. Using polycyclic norbornene monomers having three or more rings, polymers with high thermal deformation temperatures can be obtained.
In addition, according to this invention, it is preferred that the resulting polymers be of the thermosetting type. Hence, it is preferred that crosslinking monomers be used.
Examples of norbornene monomers include 2-norbornene, 5-methyl-2-norbornene, 5-ethylidene-2-norbornene, vinyl norbornene, and other bicyclic compounds; dicyclopentadiene, dihydrodicyclopentadiene, and other tricyclic compounds; tetracyclododecene and other tetracyclic compounds; tricyclopentadiene and other pentacyclic compounds; tetracyclopentadiene and other heptacyclic compounds; their lower alkyl substituted compounds wherein the alkyl group can be methyl, ethyl, propyl, and butyl; their alkylidene substituted compounds such as ethylidene-substituted compounds; and the like.
Among these compounds, the tricyclic and pentacyclic species are preferred from the viewpoint of easy availability, reactivity, heat resistance, and cost.
The crosslinking monomers herein refer to polycyclic norbornene monomers having two or more reactive double bonds such as dicyclicopentadiene, tricyclopentadiene, tetracyclopentadiene, and the like. When the norbornene monomer and the crosslinking monomer are the same substance, there is no need to use a different crosslinking monomer.
The norbornene monomers having three or more rings can be obtained by the heat treatment of dicyclopentadiene compounds. As an example, one set of heat treatment conditions are as follows: the dicyclopentadiene compound is heated in an inert gas atmosphere at 120-250° C. for 0.5-20 hours. In this heat treatment, the monomer mixture containing tricyclopentadiene and unreacted dicyclopentadiene is obtained.
These norbornene monomers can be used either alone or as a mixture of two or more thereof.
In addition, as long as the purpose of this invention is not hampered, monocyclic cycloolefins, such as cyclobutene, cyclopentene, cyclopentadiene, cyclooctene, cyclododecene, etc., can be used together with one or several species of the aforementioned norbornene monomers in amount of up to 20%, preferably 1 to 10%, based on the weight of all monomers.
Any well-known metathesis catalyst can be used as the catalyst for the ring-opening polymerization of the norbornene monomer. Examples of such catalysts are disclosed in Japanese Kokai Patents Nos. SHO 58[1983]-127728, SHO 58[1983]-129013, SHO 59[1984]-51911, SHO 60[1985]-79035, SHO 60[1985]-186411, SHO 61[1986]-126115, etc. There are no special restrictions for these substances.
Specific examples of the metathesis catalyst include halides, oxyhalides, oxides, and organic ammonium salts of tungsten, molybdenum, and tantalym. Specific examples of the activating agent or cocatalyst include alkylaluminum halides, alkoxyalkylaluminum halides, aryloxyalkylaluminum halides, and organic tin compounds. A particularly useful metathesis catalyst system includes a catalyst selected from organoammonium molybdates and tungstates and a cocatalyst selected from alkylaluminums, alkylaluminum halides, alkoxyalkylaluminum halides and phenoxyalkylaluminum halides containing 1 to 18, preferably 2 to 4 carbon atoms in each alkyl group and 1/2 to 21/2 alkoxy or phenoxy groups in the cocatalysts which contain such group(s).
With an alkylaluminum halide, polymerization starts immediately as the solution containing the catalyst is mixed. This is a problem. In such a case, the start of the polymerization can be delayed by using an activating agent such as an ether, an ester, a ketone, a nitrile, and an alcohol. For examples of such moderators, see Japanese Kokai Patent Nos. SHO 58[1983]-129013 and SHO 61[1986]-120814. In order to ensure uniform impregnation into the glass mat, a catalyst-cocatalyst with a longer pot life at 30° C. is preferred. From this point of view, a pot life longer than 5 minutes, preferably longer than 10 minutes, is needed.
Chloroform, carbon tetrachloride, and hexachlorocyclopentadiene can be added to the catalyst and the activating agent, as well as a halogenated hydrocarbon, as disclosed in Japanese Kokai Patent No. SHO 60[1985]-79035. Silicon tetrachloride, germanium tetrachloride, lead tetrachloride, and other halogenated metals can also be added. Such halogenated metals or halogenated sources are generally selected from chlorosilanes such as bicycloheptenyl methyldichlorosilane, dimethyldichlorosilane, diphenylmonochlorosilane, diphenyldichlorosilane, tetrachlorosilane, which is already mentioned, and the like.
For 1 mole of the monomer, the amount of metathesis catalyst is usually about 0.01-50 millimoles, preferably 0.1-10 millimoles. The amount of activating agent or cocatalyst with respect to the catalyst component is usually 0.1-200 on a molar ratio, preferably 2-10. The halogen source can vary in the range of 0.05 to 10 millimoles, preferably 0.1 to 2 millimoles per mol of the monomer(s).
For both the metathesis catalyst and activating agent, it is preferred that they be dissolved in the monomer. However, as long as the properties of the product are not significantly degraded, they may also be suspended or dissolved in a small amount of a solvent.
According to this invention, a glass mat is used as the reinforcing material. The glass mat is made of glass fibers matted using a mat binder made of a hydrocarbon polymer.
A sufficient reinforcing effect cannot be obtained using glass powder or milled fibers made by cutting or grinding the glass strands.
The species of the glass mat used in this invention include the chopped-strand mat prepared by cutting glass fibers into chopped strands down to 1/32 of an inch followed by matting using a binder or a continuous mat prepared by matting continuous fibers using a binder.
The glass mat can be manufactured using the conventional procedure. For example, chopped strands and a mat binder powder can be mixed, then heat pressed.
The glass mat is then appropriately shaped or cut according to the shape of the mold. In molding, the glass mat is preset in the mold, followed by injection of the reaction solution. Since the viscosity of the reaction liquid is low, a high content of the glass mat can be incorporated and a thermosetting reinforced polymer can still be obtained.
The amount of the glass mat can be appropriately selected according to the desired properties over a wide range varying from a small percentage to high percentage. In order to reinforce the polymer, the amount of the glass mat can be up to 75%, preferably 20-70% by weight with respect to the total weight of the polymer and the glass mat. According to this invention, even when the weight of the glass mat is as high as 70% by weight, a reinforced polymeric matrix with improved properties can still be obtained without inducing hazards to the polymerization.
As far as the glass mat used in this invention is concerned, the glass fibers having a silane coupling agent thereon are preferred. Among the preferred coupling agents, the species processed by an amino-group containing silane coupling agent give particularly good results.
As far as the silane coupling agents are concerned, N-β-(N-vinylbenzylaminoethyl)-γ-aminopropyltrimethoxysilane, its salt, and other such silane coupling agents containing an amino group and ethylene double bonds in their molecules, are preferred. The coupling agent is applied to the glass fibers which form the mat before the hydrocarbon polymer binder is applied to bond the glass fibers into a mat. The amount of the silane coupling agents containing amino groups if utilized is 0.01-3% by weight, preferably 0.05-1% by weight, based on the weight of the glass fibers.
According to this invention, it is necessary to use a hydrocarbon polymer as the binder for bonding the glass fibers to form a mat.
The species of hydrocarbon polymers that can be used for this purpose include polyolefins, vinyl aromatic polymers having vinyl aromatic compounds as their main components and polymers of at least one norbornene monomer. Specific examples of such hydrocarbon polymers include polystyrene, poly α-methylstyrene, polyvinyltoluene, polyethylene, polypropylene, ethylene-propylene copolymer, methyl tetracyclododecene polymer, dicyclopentadiene polymer, norbornene polymer, and other norbornene ring-opened polymers as well as their hydrogenated compounds, ethylene-norbornene copolymer, propylene-norbornene copolymer, ethylene-DCPD copolymer, propylene-DCPD copolymer, and other addition-type copolymers made of olefin and norbornene monomers, dicyclopentadiene-styrene copolymer, dicyclopentadiene-butadiene copolymer, dicyclopentadiene-conjugated diene copolymer, and other thermally polymerized hydrocarbon resins. The binder can be same as or similar to the polymer in the matrix.
Among these hydrocarbon polymers, the vinyl aromatic polymers and polyolefin colymers especially in the form of polyolefin resins are preferred. In particular, in consideration of the handling ease of the glass mat and the properties of the obtained glass-fiber-reinforced norbornene polymer, the vinyl aromatic polymers are especially preferred.
The hydrocarbon polymers can be used in various forms of the mat binder such as a powder, film, mesh, and the like. In consideration of the handling ease, the powder form is preferred. The powder can be prepared either by grinding the pellets using another solid polymer or by suspension polymerization using polystyrene.
The Vicat softening point of the hydrocarbon polymer binder is usually 30-150° C., preferably 40-140° C. As long as the shape does not collapse when the mat is dried, this softening point should be as low as possible. For this purple, the molecular weight of the hydrocarbon polymer should be reduced or the hydrocarbon polymer should be added with a plasticizer, such as chlorinated paraffin, aromatic hydrocarbon, and the like.
The amount of the mat binder with respect to the glass mat is 0.5-20% by weight, preferably 2-8% by weight. If the amount of the mat binder is too small, it becomes difficult to maintain the desired shape of the glass mat. On the other hand, if the amount is too large, it becomes costly and the reinforcing effect of the glass fibers is reduced.
The glass-fiber-reinforced norbornene polymer of this invention has an excellent flexural modulus, flexural strength, and other mechanical properties. When the hydrocarbon polymer is used as the mat binder to prepare the glass mat, the adhesiveness between the norbornene polymer and glass mat is improved without impeding the polymerization.
According to this invention, the properties of the glass-fiber-reinforced polymer can be modified by adding various additives, such as oxidation inhibitor, filler, pigment, colorant, elastomer, dicyclopentadiene thermal polymerized, resin, etc.
The species of oxidation inhibitors include the phenol type, phosphorous type, amine type, and various other oxidation inhibitors for plastics and rubber compounds.
The species of fillers include milled glass, carbon black, talc, calcium carbonate, mica, and other inorganic fillers.
The species of elastomers include natural rubber, polybutadiene, polyisoprene, styrene-butadiene copolymer, styrene-butadiene-styrene block copolymer, styrene-isoprene-styrene block copolymer, ethylene-propylene-diene terpolymer, ethylene-vinyl acetate copolymer, as well as their hydrides. The elastomers are used in amount of 1 to 10%, preferably 2 to 5%, based on the weight of the monomer(s). The polymeric elastomers are referred to herein as hydrocarbon elastomers and include saturated and unsaturated elastomers.
These additives may be premixed with one or both of the reaction solutions, or they may be introduced into the cavity of the mold, not premixed or dissolved in one or both of the reaction solutions.
According to this invention, the polymer prepared by the bulk ring-opening polymerization of the norbornene monomer with the aid of a metathesis catalyst is used. As long as the reaction is virtually a bulk polymerization, a small amount of inert solvent may be added.
As a preferred method of making the bulk ring-opening polymer, the norbornene monomer is divided into two parts added in the containers, respectively. A metathesis catalyst is added into one container and an activating agent is added into the other container. In this way two types of stable reaction solutions are prepared. These two species of reaction solutions are mixed and the mixture is injected into a mold where the bulk ring-opening polymerization occur.
The well-known impact or impingement mixing device used as the conventional RIM molding equipment can be used to mix the two or more of the reaction starting solutions. In this case, rhe containers of the reaction liquids are used as the sources of liquid streams. The streams are instantaneously mixed at the mixing head of the RIM machine and the mixture is then injected into the mold maintained at an elevated temperature where bulk polymerization occurs to form a thermosetting polymer.
Although the mixing device can be used, this invention is not limited to this type of mixing method. For example, if a pot life at room temperature of at least 1 hour is desired, it is possible to inject the mixture into a preheated mold several times after mixing of the reaction solutions in the mixer is completed, as disclosed in Japanese Kokai Pat. No. SHO 59[1984]-51911 and U.S. Pat. No. 4,426,502. In addition, the injection can also be made continuously.
Compared with the impact or impingement mixing device, the mixing device can be made to have a relatively small size. In addition, the operation can be carried out under a relatively low pressure. Hence, the glass mat set in the mold does not flow and the glass content in the moldings can be made uniform. These are the advantages of this approach.
In addition, this invention is not limited to the approaches using only two reaction liquids. Variations that can be easily understood by the workers in the trade can also be used. For example, a third flow stream from a third container with a monomer and the desired additives contained in it, can be added.
In consideration of the property of impregnation, it is preferred that the viscosity of the reaction liquids be made as low as possible as they are injected into the mold. Usually, the viscosity at 25° C. should be lower than 500 cps, preferably lower than 200 cps, or lower than 100 cps with even better results.
Usually, the mold temperature should be higher than 30° C, preferably 40-200° C., or especially 50-120° C. for better results. The molding pressure should be 0.1-100 kg/cm 2 .
The polymerization time should be appropriately selected. Usually, it should be shorter than about one half hour, preferably between one quarter of an hour and 2 seconds, especially 5 minutes and 5 seconds. However, longer time is also possible.
The reaction starting liquids are usually stored and used in the operation in an inert atmosphere, such as nitrogen. However, the mold need not necessarily be sealed with an inert gas.
This invention will now be illustrated greater particularity by the examples which follow, however, it is not limited in any way thereby. The claims appended hereto define the metes and bounds of the invention disclosed herein.
EXAMPLE 1
This example demonstrates preparation of a glass mat.
The starting material of the glass mat was prepared by cutting a 200-filament strand into 1-inch-long chopped strands. Each filament had diameter of 13 μm.
The glass fibers or strands had their surfaces treated using styrylsilane (N-β-(N-vinylbenzylaminoethyl)-β-aminopropyltrimeth-oxysilane hydrochloride salt as the coupling agent and a silicone emulsion as the appreciation medium.
The glass mat was prepared as follows: a polyethylene tetrafluoride sheet was applied on a press plate; a metallic frame measuring 200 mm × 200 mm was set on the sheet. Into this frame, 18 g of the aforementioned chopped strands and 0.54 g (3% by weight) of a mat binder were scattered at random, followed by heat pressing in a nitrogen atmosphere at a pressure of 450 g/m 2 .
Table I lists the types of mat binders, pressing conditions, and operation properties of the glass mats.
TABLE I______________________________________ Vicat MatMat Mat binder Softening Pressing OperatingNo. (powder) Point (°C.) Conditions Property______________________________________A Polystyrene 85 150° C. for Good(*1)powder 20 min.B 100° C. for May collapse 20 min. relatively easily(*2)C 90% of poly- 70 100° C. for Goodstyrene and 20 min.10% of a plasti-cizer powderD Polynorbornene 35 190° C. for Good 5 min.E 10% of DCPD 70 150° C. for May collapseresin 20 min. relatively easily(*3)F Polyester 80 160° C. for Good 5 min.______________________________________ (*1) It can be easily cut with scissors and can be bent. (*2) It partially collapses when being cut with scissors. (*3) It collapses when being bent.
EXAMPLE 2
2-7 plies of the aforementioned glass mat were applied on a flat plate mold measuring 3 mm × 200 mm × 200 mm. With the mold set on its edge, the reaction solution was then injected.
The norbornene monomer, made of 90% of dicyclopentadiene (DCPD) and 10% of a cyclopentadiene trimer (a mixture of 80% of an asymmetric trimer and 20% of a symmetric trimer), was added to two containers. In one container, solution A was prepared by adding diethyl aluminum chloride at a concentration of 40 mm with respect to the monomer, n-propyl alcohol at a concentration of 52 mm, and silicon tetrachloride at a concentration of 20 mm. The viscosity of solution A at 25° C. was about 30 cps. In another container, solution B was prepared by adding tri(tridecyl)ammonium molybdate at a concentration of 10 mmol with respect to the monomer. The viscosity of solution B was nearly the same as that of solution A.
The pot life of the mixture of solution A and solution B was 10 minutes at 30° C.
After solution A was defoamed and the atmosphere was replaced by nitrogen, solution B was added to prepare the reaction solution. The reaction solution was kept at room temperature of 25° C. The aforementioned mold with glass mats positioned therein was heated to 70° C. The aforementioned reaction solution was then injected into it by a gear pump from the bottom of the mold for 10 seconds. Afterwards, ring-opening polymerization in bulk was performed at 70° C. for 5 minutes of the mold contents.
After polymerization, a plateshaped glass-fiber reinforced polymer block was obtained. It was then cut into samples of appropriate lengths and properties were measured, with the results listed in Table II.
TABLE II__________________________________________________________________________ Izod Glass Glass Flexural Flexural impact CuringTest mat No. content modulus strength strength state ofNo. (binder) (%) (kg/mm.sup.2) (kg/mm.sup.2) (kg · cm/cm) polymer__________________________________________________________________________1 A 30 600 20 >80 Fully cured2 Polystyrene 46 1080 29 >80 Fully cured3 60 1220 32 >80 Fully cured4 63 1360 33 >80 Fully cured5 C 60 1200 30 >80 Fully cured Polystyrene6 D 32 580 16 >80 Fully cured7 Polynorbornene 60 1100 23 >80 Fully cured8 E 60 900 20 >80 Fully cured DCPD resin9 F 31 530 11 >80 Poor curing around10 Polyester 60 600 12 >80 polyester powder, causing whitening, indicating poor curing.__________________________________________________________________________
Based on the data herein, in the polymer matrix reinforced with a glass mat wherein a hydrocarbon polymer was used as the mat binder, the flexural modulus and flexural strength are significantly improved. In particular, the effect of the improvement is more significant with higher amounts of the glass reinforcing.
On the other hand, when the glass mat with the conventional polyester powder as the mat binder was used, polymerization was more seriously hampered and the reinforcing effect of the glass fibers became insufficient as amount of the glass was increased.
Observation of the adhesiveness between the polymer and the glass fibers indicates that when the polyester binder is used, curing is poor around the polyester polymer powder. This leads to a whitening phenomenon and a poor adhesiveness.
As far as the Izod impact strength is concerned, although all the results listed in Table II are greater than 80 kg·cm/cm, and there seems to be no difference, this is nevertheless due to the limitation in the measuring power of the tester used. It is believed that the product of this invention would have a better performance in this respect.
It thus can be concluded that the reinforced norbornene polymer matrix has greatly improved mechanical properties, such as flexural modulus and flexural strength, without impeding the ring-opening polymerization of the norbornene monomer. It is possible to make various moldings from this type of glass-fiber reinforced norbornene polymer used for a wide range of applications where strength and heat resistance are required.
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A reinforced polymeric matrix comprising a glass mat and a norbornene polymer surrounding the glass mat, the glass mat is composed of at least one glass fiber treated with a silane coupling agent and a binder adhering the glass fiber(s) to the norbornene polymer; the binder is selected from polyolefins, vinyl aromatic polymers, and ring-opened polymers of at least one norbornene-type monomer containing at least one norbornene group. Process for making a reinforced polymeric matrix comprises positioning a glass mat within a mold, the glass mat having been treated with a hydrocarbon polymer binder; mixing a plurality of streams, one stream containing a catalyst of a metathesis catalyst system, another stream containing a cocatalyst of a metathesis system, and at least one of the streams containing at least one norbornene-type monomer which is liquid at room temperature to form a mixed stream; introducing the mixed stream into the mold around the mat; polymerizing by ring opening the monomer(s) in the mold; and extracting from the mold the reinforced polymeric matrix, wherein the norbornene polymer is thermoset.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to control devices for contactors, motor starters and the like, which couple electrical power to loads. In particular, the invention concerns a trip indicator for signalling and preferably displaying the trip status of a single or multiple contactor/starter arrangement, remotely from the respective contactor or starter.
2. Prior Art
It is frequently necessary to develop a signal or indicator that represents the status of an electrical contactor or similar device. In a control system having a plurality of functionally related loads, or one or more loads that can be coupled to a power line in different configurations, for example, the status of a contactor or group of contactors may affect whether other contactors, controls, alarms or other devices should be activated or deactivated by associated switching means.
In a more specific example, an AC motor controllable for forward and reverse operation or for operation at different speeds typically is coupled to the power line (e.g., a three phase line) via two or more contactors. The respective contactors couple the motor windings to the line in different configurations as needed for the different functions. In the event that a problem occurs, such as a short circuit, a ground fault, excessive heat build up (thermal overload), phase imbalance or the like, one or both of the contactors will trip, thereby disabling the motor for the selected operation. It is desirable to signal and preferably to display the status of a contactor or starter at a remote location so that appropriate action can be taken or not taken, in view of the detected problem. Such action may involve action by maintenance personnel, in which case a simple and convenient display having indicators for the respective trip modes is advantageous. Preferably the display is located in a convenient place for viewing, which generally means a place remote from the contactor.
Error or trip conditions generally fall into one of several categories, such as short term over-current (i.e., short circuit), long term over-current (thermal overload), ground fault, phase imbalance, etc. A thermal overload trip may occur due to excessive current drawn through one or more windings of a mechanically overloaded motor. A thermal overload condition may build up over a long period of time if a motor is loaded too heavily. The appropriate triggering current setpoint for tripping in the event of a short term over-current is appropriately higher than for a long term overload, the long term setpoint being low and short in time enough to trip promptly in the event of a stalled motor or the like, but not so low or short that the contactor trips when a motor is first started, reversed, etc. in the normal course of operation.
A ground fault trip occurs if current sinking is detected through the system ground. Such a condition is potentially dangerous, and the trip setpoint is low. A phase imbalance trip occurs when there is an improper relationship among the phases of a multi-phase AC system.
An automatic control system that controls a plurality of loads by signalling contactors or that controls one load via one or more contactors advantageously can be made responsive to the trip status of the contactor(s). In a production environment, tripping of a contactor controlling a machine downstream along a process line may be arranged by appropriate remote signalling to trigger contactors upstream in the process to be switched off, or for appropriate action to be taken by production personnel. A control system for effecting related switching may be more or less complex, and may include a relay ladder arrangement, a programmable controller or other device. In a basic control system comprising two or more contactors, the trip signal developed by one of the contactors is typically cascaded through other contactors such that if any of the contactors trips, all the contactors switch off.
This presents a maintenance problem. In the event that a problem occurs such as a short circuit, thermal overload, ground fault or phase imbalance, one or more of the contactors detects the condition, generates an error signal, decouples its load from the line and triggers any cascaded contactors to trip. Often the error signal is also used to generate a bell alarm. Although the system has thereby been protected from damage, and the operators have been alerted, the cause of the error condition still must be determined so that appropriate corrective action can be taken. However, in this basic system as described, the operator may be uncertain as to which contactor generated the error signal, and why.
One alternative is to reset the contactors and hopefully to generate the fault condition again, this time observing operation of the loads and perhaps applying test equipment to isolate the cause of the fault. This is disadvantageous for a number of reasons. The fault condition may be due to an intermittent occurrence, such as brief current overloading when two motors happen to be started or reversed at the same time. Such a fault may not reoccur on resetting the system and may be simply a nuisance trip of no consequence.
On the other hand, the fault condition may be due to an electrical failure of substantial consequence. Recoupling the power in the event of a direct short of the line on the load side of the contactor, for example, could damage the load or the line, or could cause a protective device more proximal to the power source to trip. Recoupling the power in the event of a ground fault or phase imbalance may present a danger of electrocution. For all these reasons, simply resetting the system or any individual contactor is not recommended until the initiating contactor and the reason for the trip are identified, and corrective action is taken if necessary.
It is possible without resetting to determine the nature of an electrical fault and to localize the contactor that most likely initiated a trip, for example using a multimeter or the like to test resistance or continuity among various terminals and ground, in short to verify all the wiring and the condition of the load devices. If such action is taken, and no electrical fault is found, uncertainty remains as to whether a nuisance fault occurred and can be ignored, or whether a real problem exists but was inadvertently overlooked. Testing a system sufficiently that the operator is confident can be difficult and time consuming.
It would be possible to provide additional instrumentation, mechanical devices, memory storage elements or similar means associated with the contactors that enable a technician to determine the location and cause of a trip condition. It would also be possible to provide metering elements and/or recording devices that can be checked to determine the operating parameters of the power distribution system and the load, allowing the source and type of fault to be deduced. These alternatives are expensive. Moreover, as a practical matter, the operator may be willing to take the chance that a trip was a nuisance trip rather than a fault of consequence, especially if nuisance trips are not unusual, rather than to take the time to ring out the circuits, to check any instrumentation, recording elements or the like, or even to open the cabinets housing the starters to view any mechanical or electrical indicators therein. What is needed is an inexpensive and convenient means for generating and storing an indication of the source and type of trip, at a location remote from the contactor or motor starter, and preferably without adding any substantial circuitry or instrumentation to the standard contactor.
Some systems provide a status display associated with a controller arranged to communicate with one or more contactors. The display is operable to indicate the contactor status, and therefore the load circuit status, of associated contactors. The Westinghouse Electric Corporation ADVANTAGE™ line of control modules provide a status display of this description, the display comprising colored LEDs. The status light colors are chosen such that normal operations such as "run" use green indicators while trip indicators such as thermal overload, or phase imbalance use red. In one arrangement of the ADVANTAGE control module, blinking of particular lights that normally are used to indicate "run," "stop" and similar modes, or trip status, are blinked to signal the operational status of up to four associated contactors. A display of this type on a control module is helpful to localize the source of a trip, at least to the level of the group of contactors coupled to the control module. The control module comprises a microprocessor that tests the operability of communications with the contactors in addition to controlling the contactors to achieve coordinated operation. The controller is typically located inside a cabinet adjacent the contactors it services.
It would facilitate maintenance procedures to provide trip status indicators in locations remote from the controller. In different applications, the starters or contactors and their controller may located together or apart from one another and from the loads being controlled. In order for a technician to determine the cause of a trip, the appropriate controller must be located before the trip status can be read.
For safety and practical reasons, it would be advantageous to provide means such as an indicator circuit, responsive to a trip status of a contactor or the like, particularly for use with contactors coupled to a control module such as the ADVANTAGE control module. It would furthermore be desirable that such a device be inexpensive and simple, providing a means for indicating or otherwise responding to a trip source and type, that can be placed remote from the contactor circuits, and does not require the addition of extensive supporting circuitry, power supplies and logic elements.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a means for signalling and responding remotely to the trip status of a contactor circuit, associated with the trip signal line and the contactor reset input line, and that imposes signalling information on the trip signal and decodes the information remotely, for example to control operation of indicators or other devices as a function of the information.
It is also an object of the invention to provide a remote trip indicator for displaying the trip status of a contactor circuit in an easy to read fashion, remote from the means for generating a signal representing trip status.
It is another object of the invention to provide a remote trip indicator that obtains all necessary power from the signal lines to which it is coupled.
It is also an object of the invention to provide a remote trip indicator that uses available signals associated with a contactor controller, including a digitally varying trip status signal and an AC coupled reset.
It further an object of the invention to provide a remote trip indicator to achieve the foregoing objects with a minimum of complexity and expense.
These and other objects of the invention are accomplished according to the invention by a trip indicator coupled to a contactor circuit, operable to control motors or similar loads. The trip indicator preferably is remote from the controller or contactor associated with it and is coupled to an externally generated trip signal. The trip signal provides power and signalling information to the trip indicator simultaneously. The signalling information is in the format of serial digital pulses having a variable number of pulses of distinct widths, the pulse signal representing one of a plurality of trip status conditions at the contactor such as thermal overload, phase imbalance, etc.
The trip indicator comprises an input circuit having a diode and a capacitor in series, the input circuit being coupled in parallel across the trip signal and a reset input of the device that generates the trip pulse signal. The capacitor accumulates a charge when the trip signal is high, and delivers charge for powering the trip indicator circuity during the short times the trip signal goes low due to pulses. The capacitor and diode thereby define a power supply capable of powering the trip indicator circuitry, for a limited duration, regardless of the logic stare of the trip signal.
The trip indicator includes a reset circuit coupled to the trip signal. The reset circuit has two distinct operative states, a hold state and a trip state. Switching from one operative state to the other is controlled by the logic level and pulse width of the trip signal. The reset circuit is operable to generate a reset signal coincident with the reset circuit entering the trip state, differentiating and inverting the leading transition on the trip signal to generate an immediate reset. The reset signal is coupled to the reset input of a decoding circuit, thereby clearing the decoder in preparation for pulses to be output on the trip signal line by the controller or contactor circuit.
The decoder can be a counter that accumulates a count of positive edge transitions of the trip signal during the period of time the reset circuit remains in the trip state. In that case the number of positive edge transitions preferably is a binary multiple representing a particular trip status such as a thermal overload, ground fault, phase imbalance or the like. The counter outputs are coupled to drive LEDs such that the each bit of the counter output represents a separate trip status condition such as a thermal overload or phase imbalance. It is also possible to use other forms of decoders such as gating arrays that decode data from the outputs of a counter, flip-flop arrangement, shift register or the like. The decoded outputs can also be used for various purposes related to signalling, in addition to the operation of indicators such as signal lights. For example, one or more devices such as relays or switches can be controlled from the decoded outputs, the data can represent numeric data passed from the device to other devices in a hierarchy of controlled and controlling devices, and other such uses of the signalling path can be made.
The reset circuit switches back to the hold state once the trip signal goes high and remains high for a predetermined period of time, in which event the counter outputs remain stable, displaying the most recent trip status until the reset circuit enters the trip state again and the counter outputs are cleared on the leading edge of the trip signal. The trip indicator thereby provides an easy means for signalling, for example to provide a visual indication for display of trip status (the user need not interpret blink patterns or the like). Although the signalling is done over the single trip signal channel, the trip circuits remain operational because the signalling pulses imposed on the trip signal are short enough that the trip circuits do not respond. No external power supply is needed because all circuitry is powered from the trip signal. The circuit is simple and effective.
BRIEF DESCRIPTION OF THE DRAWINGS
There are shown in the drawings certain exemplary embodiments of the invention as presently preferred. It should be understood that the invention is not limited to the embodiments disclosed as examples, and is capable of variation within the scope of the appended claims. In the drawings,
FIG. 1 is a schematic circuit diagram showing a trip status indicator according to the invention.
FIG. 2 is a timing diagram showing the timing relationship between the trip signal and the reset signal.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the schematic diagram of FIG. 1, the trip indicator according to the invention is shown in a preferred embodiment. The trip indicator has two input terminals 5, 7 that are coupled to the trip output and the reset input of a contactor circuit such as a Westinghouse Electric Corporation ADVANTAGE™ control module or the like, and are coupled to an input circuit 10 of the trip indicator. The trip signal at positive input terminal 5 is normally low, i.e., when the contactor circuit has not switched into the trip state or when there is no data to display or signal. The trip signal goes high during a trip or as a prelude to a signalling pulse stream. In the event of a trip, the trip output goes low, first for a longer (wider) low-going pulse, and then for a variable number of shorter low-going pulses representing serial data.
Generally, the trip signal at terminal 5 couples current to power counter U1 by charging capacitor C1. A timed switching circuit 20 (reset circuit) discriminates for pulses of predetermined width, which pulses either reset the decoder U1, which can be a counter or the like, or cause the decoder to change state. In the event the decoder is a counter, the state change involves advancing from one count to the next on each pulse. For other forms of decoders such as shift register or flip-flop arrangements, other state changes are possible. The pulses in the embodiment shown are decoded to drive unique output indicator lights LED1-LED3 for each binary power, 2 0 , 2 1 and 2 2 . For a larger number of unique outputs, a counter capable of additional powers of two can be used, or a decoding arrangement wherein a combination of bits are decoded can be used, e.g. , via a one-of-sixteen decoder coupled to four binary outputs.
Input circuit 10 has a series diode D1 and a parallel capacitor C1, the capacitor coupled between the V d positive voltage supply to the decoder U1 and terminal 7, which functions as the circuit ground V ss . The input circuit 10 is powered from input terminals 5, 7, and forms a power supply where capacitor C1 is charged through diode D1 when the trip signal is high (positive voltage). Capacitor C1 is charged substantially to the peak voltage of the trip signal. Capacitor C1 supplies power to the counter or other decoder U1 and the reset circuit 20. Capacitor C1 has sufficient capacitance that adequate power is delivered to the trip indicator circuitry during the limited times the trip signal is low (no voltage). When the trip signal transitions from high to low, diode D1 becomes reversed biased, thereby preventing capacitor C1 from discharging back toward terminal 5. Diode D1 is chosen such that its leakage (reverse biased) current is small compared to the current delivered to the remaining circuity, thereby minimizing discharge of capacitor C1.
The circuit as shown couples the trip output of the starter to the reset input of the starter, and a main purpose of this is to couple either a trip indication from the trip output to the reset input, or to couple a reset signal via a manual pushbutton 30 to the reset input. According to the invention, transitions on the trip signal also are applied via reset circuit 20 for resetting the trip indicator decoder. Normally open manual pushbutton switch 30 shorts lines 5 and 7 together, coupling the trip output of the controller (e.g., starter) to the reset input of the controller, and also provides a pulse that may be coupled through to the reset input of counter U1, depending on pulse timing. According to one embodiment of circuit 20 as shown in FIG. 1, two RC charging circuits are disposed on the input and output sides of a switching transistor Q1. Each RC charging circuit defines an RC time constant, the circuit of R1-C2 forming an integrator and C3-R2 forming a differentiator.
The first charging circuit has a resistor R1 in series with a capacitor C2, whereby the voltage on capacitor C2 rises to the maximum voltage of the trip signal according to the factor ε -t/RC following a rising transition on the trip input at terminal 5. Transistor Q1 is a P-channel FET, having a gate coupled to capacitor C2. When the trip input goes low, capacitor C2 is discharged rapidly through diode D2. Transistor Q1 then conducts, coupling the supply voltage V d to capacitor C3 on the drain or output of transistor Q1. Thus, diode D2 and transistor Q1 form a negative edge-triggered switch.
The second RC timing circuit comprises resistor R2 and capacitor C3. The capacitor C3 is in series between transistor Q1 and the reset input of counter Q1. When Q1 begins to conduct, capacitor C3 is not yet charged, and accordingly the voltage V d is coupled to the reset input of the decoder or counter U1. Capacitor C3 charges at a time constant defined by resistor R2 and capacitor C3. Resistor R3 is provided to discharge the second charging circuit when transistor Q1 turns off (not conducting). The normally low output at the junction of C3 and R2 thereby defines a reset signal that provides a pulse to reset decoder or counter U1.
Operation of the circuit is as follows. When the trip signal at input terminal 5 is high for a period of time exceeding five times the time constant of resistor R1 and capacitor C2, capacitor C2 is substantially fully charged, switching transistor Q1 off. When the trip signal subsequently transitions from high to low, thereby forming a negative edge, the first charging circuit rapidly discharges though diode D2, and switching transistor Q1 is forced into conduction. The reset signal, at the junction of capacitor C3 and resistor R2, is thus pulled high, because capacitor C3 is not yet charged, approaching the power supply voltage V d . As capacitor C3 is charged through transistor Q1 and resistor R2, the voltage on the reset input falls off at the time constant of the second charging circuit of R2 and C3.
Assuming a positive transition occurs on the trip signal at terminal 5, the switching transistor Q1 remains in conduction until the trip signal has remained high for a period of time defined by the time constant of the first charging circuit of R1 and C2, namely until capacitor C2 has charged sufficiently through resistor R1 to turn off transistor Q1 (diode D2 being reverse biased).
The reset circuit 20 has two distinct operative states defined by the operation of the negative edge triggered switch. When the trip signal remains high for longer than the period of the first RC combination (R1-C2), the switching transistor is not conducting, and the reset circuit is in a hold state. When the reset circuit is in the hold state, the leading negative edge of the trip signal forces transistor Q1 into conduction and a reset signal is generated to initialize the decoder U1, e.g., to set a counter U1 to a count of zero. When Q1 is conducting the reset circuit is in a reset state, but the reset pulse is kept narrow by virtue of capacitor C3 becoming charged. Thus the decoder/counter U1 is not held in a reset state by continued conduction of transistor Q1. The reset circuit returns to the hold state, enabling a new reset to occur, only after the trip signal remains high for a sufficient period to charge capacitor C2 through resistor R1.
Once the circuit 20 is in the reset state as defined by conduction of transistor Q1, negative edge transitions on the trip signal do not cause additional reset signals to be generated at the input of decoder/counter U1, because Q1 remains in conduction. When the reset circuit is in this state, short low going pulses on the trip signal can be used for signalling. According to the embodiment shown, short pulses can be applied to change the state of the decoder/counter, provided the trip signal does not remain high for the period needed to charge capacitor C2.
It is also possible to omit resistor R1, capacitor C2 and diode D2, provided the signalling pulses are so fast as to cause the decoder/counter U1 to change state without allowing C3 to discharge to the point of an effective reset signal at the input of decoder/counter U1. The timing circuit of R1, C2 and D2 provide further protection from a reset to U1, and provide a strong negative edge triggering function.
In either case, it is possible to impose signalling transitions from high to low on the trip signal a substantial number of times as long as the trip signal does not remain high for the period needed to charge capacitor C2, about five times the time constant of R1 and C2, or as long as an effective reset cannot be generated by C3. As a further limitation, the pulses cannot proceed indefinitely because power supply capacitor C1 may otherwise discharge to below a level at which the circuit can continue to operate. Nevertheless, These short transitions can be used without causing an unwanted reset to the motor starter, and to encode a substantial quantity of signalling information.
In the event of a fault detected by the controller or contactor circuit coupled to terminal 5, such as a thermal overload or ground fault, the output of the controller or contactor typically begins to oscillate high and low as the current level detected wavers around the setpoint of triggering of the controller or contactor circuit, then goes high as the current level detected remains above the setpoint, triggering a trip at the reset input of the contactor circuit (e. g., motor starter), which resets the contactor circuit as it initializes in the protective, contacts-open state. However, according to the invention, the controller or contactor circuit is arranged to output signal pulses on the trip signal, in order to identify the nature of a trip and/or to encode other signalling information, such as an impending trip status (e.g., approaching the trip current threshold), or a deadman timer trigger that is output only while the contactor controller continues to operate properly. Also, after a trip has occurred, as shown by the trip signal remaining high for a predetermined period exceeding the time needed to charge capacitor C2 (which can be shorter than the time needed to reset and open the contactor by generation of an operational reset at terminal 7) the controller signals the indicator circuit in this manner.
Various specific signalling protocols and combinations are possible according to the invention, while remaining within the foregoing timing restraints. The signalling can involve repetitive signalling of the same information, or successive signalling of different types of data together with a header or footer portion identifying the data type. According to a preferred embodiment, the following forms of signalling are used:
1. "Contactor/controller operating properly" is a heartbeat or deadman timer form of signal which can be emitted at intervals, for example of four seconds. The trip signal is switched high for one half of a power cycle, and one of the signal lines (e.g., LED1) is blinked by encoding the corresponding count of one of the outputs (one for LED1 as shown).
2. "Start Diagnostics Result" is signalled upon completing preliminary stamp diagnostic checks (e.g., testing for acknowledgement signals from coupled contactor circuits to ensure they are connected and operative). A one-half to 41/2 cycle high level is maintained on the trip output while blinking LED1 repetitively each half cycle.
3. "Thermal Alarm" uses an approximately one-third second high level on the trip output, with LED1 encoded to thereby blink on and off every one-third second.
4. "Ground Fault Alarm" is signalled by switching to a high trip output level and signalling to turn on LED2 approximately every one-sixth of a second, repetitively over ten cycles. This can occur when a ground fault is detected but the starter is not to be permitted to trip.
5. "Thermal Trip" is signalled by switching the trip signal to the high state and signalling one time to turn on LED1. The trip signal thereafter remains high and the contactor trips.
6. "Ground Trip" similarly is signalled by switching the trip signal to the high state and signalling one time to turn on LED2. The trip signal remains high and the contactor trips.
7. "Phase Unbalance Trip" is signalled in a multiphase system by switching the trip signal high and turning on LED3.
8. "Phase Loss Trip" is signalled in a multiphase system by switching the trip signal high and turning on LED4.
9. The operational status of the indicators can also be signalled by turning on all the LEDs, for example upon power-up. If the decoder is a counter, the foregoing signal types each use a binary multiple (1, 2, 4 or 8), and the indicators can be switched on by the appropriate sum (e.g., 15 or hex `F` for four bits). Where a one-of-N decoding scheme or a series of flip-flops or the like are employed, the lights can be strobed sequentially or a separate switching technique employed to exercise all the lights.
The pulses to be counted or otherwise decoded are applied to the clock input of counter U1, powered from the trip signal by capacitor C1. The clock input of the counter U1 is positive edge triggered such that counter U1 counts the positive transitions on the trip signal, and each transition varies the decoder output (e.g., advances the count output by one count), having started at a predetermined state (e.g., a zero count) due to the reset signal from reset circuit 20. The decoder U1 has a plurality of outputs for identifying the state, three being shown, for example, in FIG. 1 as Q 0 , Q 1 and Q 2 in the example of a binary counter for the decoder. The counter outputs are high true and are connected to respective LEDs, namely LED1, LED2 and LED3, via current limiting resistors R4, R5 and R6. The counter outputs have sufficient current source capability to illuminate the LEDs and provide a visible indication of the count representing the trip status.
The status as thereby identified can be more or less complicated, and preferably is arranged such that each LED corresponds uniquely to one type of trip fault, one particular contactor, etc. In the embodiment of FIG. 1, each LED represents a particular type of trip, namely a thermal overload (LED1), a ground fault (LED2) or a phase fault (LED3). It is also possible to assign other specific indications as discussed above, for example assigning each trip status to a binary code based on combinations of several counter outputs such as:
______________________________________ Q.sub.2 Q.sub.1 Q.sub.0______________________________________Thermal trip 0 0 1Ground trip 0 1 0Phase trip 0 1 1______________________________________
However it is advantageous to assign each trip status type to an individual LED such as an LED triggered via a binary multiple count or the like, achieved intermittently (for example to show impending trip alarms) or steadily (to show the nature of a trip that has occurred), thereby allowing the status to be easily read by looking at a single LED rather than having to look up a numerical code. The device can be arranged with more or fewer outputs, states or sequences of signals, as needed to accommodate the desired number of possible indications.
The trip indicator has a normally open push button (push button) coupled across the input terminals 5, 7. The reset circuit is manually forced into the trip state when the push button is momentarily depressed. This has the same effect as an edge on the trip signal. A reset signal is generated and the decoder/counter is cleared. Assuming the controller or contactor circuit is continuing to output a high (trip) signal, the reset circuit returns to the hold state after the push button has been released for the time defined by R1 and C2.
Terminal 7 is coupled to the reset input of the controller or contactor circuit that is signalling to the indicator. Thus depression of pushbutton 30 shorts together the trip output and reset input of the controller or contactor circuit and resets the controller as well. The controller comes up in a protective state, with controlled contacts open. If desired to test the load circuits again. i.e., after correcting the fault identified by the indicator means of the invention, the user activates the run or start input of the controller or contactor circuit to re-engage power to the loads. Should the fault reoccur, the same process proceeds as discussed above.
FIG. 2 shows a timing diagram of a typical trip signal in relation to the reset signal as generated by the reset circuit 20. Assuming that the trip signal has previously remained high for a period of time sufficient to charge capacitor C2, e.g. , more than five time constants of R1 and C2, and now transitions from high to low, the reset signal occurs on the first negative edge 100. The first negative edge 100 discharges capacitor C2 through diode D2, forcing the reset circuit 20 into the reset state, and generating a high going reset pulse 140 by transistor Q1, capacitor C3 and resistor R2. The reset pulse decays exponentially to the low logic state 150 due to the second charging circuit. The first positive edge 105 of the trip signal occurs following the decay of the reset pulse to below the low logic threshold level of the counter reset input, thereby ensuring that counter U1 is not held in the reset state and that the counter is operable to count the first and subsequent positive edges of the trip signal. However, the period of time between negative transition 100 and positive transition 105 cannot exceed the length of time that power supply capacitor C1 can supply adequate power to the trip indicator circuit.
Subsequent positive edges of the trip signal, shown in FIG. 2 as 115, 125 and 135 advance the decoder state such as the counter output by one count each, and in the example shown the resulting counter output would be four (binary 100), whereby LED3 would be illuminated.
The negative transitions subsequent to the initial one, shown in FIG. 2 as 110, 120 and 130, do not generate a reset signal because the pulse width (e.g., the period of time from 105 to 110) is much less than the time needed to charge capacitor C2 through resistor R1. In the event the pulse width is very short, elements R1, C2 and D2 can be replaced with a direct connection between the gate of transistor Q1 and input terminal 5, because very short pulses will not allow capacitor C3 time to generate a reset to decoder U1. In any event, the reset circuit is caused to remain in the reset or counting state while the decoder advances to the desired state indicated by the pulse signal. The reset circuit returns to the hold state at a period of time defined by approximately five time constants following the last positive edge 135. The decoder/counter outputs remain at the previously accumulated state or count until the reset circuit enters the trip state and the counter is reset by a new low going input transition. Thus, although the contactor becomes tripped and reset, the nature of the respective trip remains visible on the indicators.
The invention having been disclosed in connection with the foregoing variations and examples, additional variations will now be apparent to persons skilled in the art. The invention is not intended to be limited to the variations specifically mentioned, and accordingly reference should be made to the appended claims rather than the foregoing discussion of preferred examples, to assess the scope of the invention in which exclusive rights are claimed.
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A self powered trip indicator remotely reads out parameters such as the type of trip detected in a contactor or motor starter circuit controllably coupling a power line to a load. The contactor circuit imposes signalling pulses on a trip status signal following a transition of the signal to a fault-indicating level, the pulses representing the parameters. The remote trip indicator derives operative power from the trip signal, and decodes the parameter from the pulses, using a decoder such as a counter to accumulate a binary multiple count of pulses, the result being indicated on LEDs coupled to outputs of the decoder. A switching circuit generates a short reset pulse to the counter at a leading transition following a pulse or level of a width exceeding a time limited by an RC combination coupled to the counter reset input. An RC timing circuit on the input side distinguishes the leading transition from other transitions by disabling a subsequent reset for a minimum time after generation of a first reset, during which time the pulses are counted and the result remains stable on the indicator LEDs. The circuit permits a reset after a longer duration between transitions, after which transitions defining shorter duration pulses represent a serial information signal.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a motion compensator to be placed in a well pipe to permit relative movement between an underwater well installation and a floating vessel on the water surface. The motion compensator is particularly useable while conducting a production test of an underwater well. Additionally, the invention relates to a method for using the motion compensator
2. The Prior Art
Motion compensators to permit relative movement between an underwater well installation and a floating vessel are well known.
Motion compensators may take the form of an inner-sleeve telescopable within an outer barrel with seal means disposed between the sleeve and barrel as illustrated in U.S. Pat. Nos. to McNeill 2,606,003; Kofahl 3,179,179; Lacy 3,211,224; and Walker 3,329,221.
Motion compensators may be utilized in a well drill string as illustrated by U.S. Pat. Nos. to Ware 3,194,330; Slator et al 3,599,735; and Kisling III et al 3,764,168 or in a well test string as illustrated by U.S. Pat. Nos: to Hyde 3,354,950; Young et al 3,741,305; Manes et al 3,646,995; Kisling III 3,643,505; and Nutter 3,823,773.
A pressure balanced motion compensator, wherein the forces due to well fluid pressure tending to expand the compensator are balanced by the forces due to well fluid pressure tending to contract the compensator, is disclosed in U.S. Pat. No. 3,354,950 to Hyde.
One persistent problem with motion compensators has been seal failure. As the floating vessel oscillates due to wave action, telescoping elements of the motion compensator move relative to each other to accommodate the oscillation. During the telescoping action, the seal surfaces are exposed to well fluids. The fluids contain abrasive particles. The particles tear up the seals and contribute to seal failure.
Various attempts have been made to prolong seal life and thereby provide a motion compensator that can be used longer. U.S. patent to Hanes et al U.S. Pat. No. 3,647,245 discloses a telescoping pipe joint wherein the seal assembly is impregnated with a lubricant before the joint is positioned within the well pipe. The aforementioned patent to Slater et al U.S. Pat. No. 3,599,735 discloses a telescoping pipe joint wherein, before the joint is positioned within the well pipe, an annular cavity between two seal assemblies is filled with lubricant. The aforementioned patent to Kisling III et al, U.S. Pat. No. 3,764,168 includes a seal tube to isolate the seal wear surface on the telescoping element from well fluids.
However, present motion compensators do not have a sufficient life span for some operations presently being contemplated for offshore wells. Present well tests from floating vessels generally last for 4 hours, however, contemplated production tests are expected to last from 12 to 36 hours. The telescoping elements of a motion compensator utilized during such a production test would undergo much more relative movement than is undergone by the elements of present motion compensators. With more relative movement the likelihood of seal failure increases and there is a corresponding increase in the desire to lengthen seal life by reducing seal wear. Consequently, it is an object of this invention to provide protection to seals in a motion compensator to prolong their life.
Another object of this invention is to provide a pressure balanced motion compensator including means for lubricating its seals during the operation of the compensator so that lubricant may protect the seals and prolong their life.
However, even with the best constructed motion compensator and even with protection provided to the seals, seals will fail. When the seals fail, well fluids can escape from the interior of the compensator to the exterior causing environmental damage, loss of well fluids, and perhaps even loss of well equipment and personnel. Accordingly it is another object of this invention to provide a motion compensator which has means for detecting seal failure.
Another objct of this invention is to provide a motion compensator including means for monitoring its seals so that the condition of the seals during the operation of the motion compensator will be known.
Another object of this invention is to provide a pressure balanced motion compensator including means for monitoring the pressure balancing system which enables determination of the extent of failure of the pressure balancing system so that a determination can be made as to whether to end the operation of the motion compensator or continue its operation.
Another object of this invention is to provide a pressure balanced motion compensator including means for accommodating a seepage of fluids past the pressure balancing seals while maintaining the pressure balancing feature.
Another object of this invention is to provide a pressure balanced motion compensator adapted to be positioned in a well pipe including means for determining when the pressure balancing system fails so that operations may be discontinued before the pipe buckles.
Another object of this invention is to provide a method of operating a motion compensator in a manner to detect seal failure.
Another object of this invention is to provide a method of operating a pressure balanced motion compensator to accommodate a seepage of fluids past the pressure balancing seals while maintaining the pressure balancing feature.
Another object of this invention is to provide a method of operating a pressure balanced motion compensator adapted to be positioned in a well pipe to determine the failure of the pressure balancing system and shut down the system before the pipe buckles.
Another object of this invention is to provide a method of operating a motion compensator to continuously furnish lubricant to the seals of the compensator during its extension and contraction.
Another object of this invention is to provide a method of operating a pressure balanced motion compensator including pressure balancing seals and environmental seals in a manner to continuously furnish lubricant to the pressure balancing seals and environmental seals during extension and contraction of the motion compensator.
Another object of this invention is to provide a method of operating a pressure balanced motion compensator including pressure balancing seals and environmental seals in a manner tending to collapse the motion compensator.
These and other objects, features, and advantages of this invention will become apparent from the drawings, the detailed description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein like numerals indicate like parts and wherein illustrative embodiments of a Motion Compensator are shown:
FIG. 1 is a schematic illustration of a drilling system incorporating a motion compensator;
FIGS. 2A, 2B and 2C are continuation views in quarter-section of a motion compensator; and
FIG. 3 is a fragmentary sectional view of an alternative embodiment of the lower portion of the motion compensator of FIGS. 2A, 2B and 2C.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A floating vessel, such as mobile platform P, may be used when a well is drilled below the surface of a body of water. The wellhead W is located at the ocean floor F and is stationary. Due to wave action the platform P oscillates up and down with respect to the wellhead W. The motion compensator 10 of this invention is designed to accommodate the oscillating motion of the platform P with respect to the wellhead W, especially durint testing operations.
Once the well has been drilled, it may be desired to perform a production test or other operation in the well. To perform the operation, a sub surface test tree 12, as disclosed in Taylor U.S. Pat. No. Re. 27,464, the entire disclosure of which is hereby incorporated by reference, may be lowered to the wellhead W and locked in place by a blowout preventor ram. A string 14 extends downwardly from the sub surface test tree 12 through the well casing 16 into the well. Well pipe 18 extends upwardly from sub surface test tree 12 to the platform P within a riser pipe 20. The motion compensator 10 is disposed within the well pipe 18 to accommodate the oscillating movement of the platform P with respect to the wellhead W during performance of the desired test or operation.
The motion compensator 10 may be located in various positions in the well pipe 18 and still accommodate the oscillating movement of the platform P with respect to the stationary wellhead W. As illustrated in FIG. 1, the motion compensator 10 may be hung from the slips 22 of the rotary table and hang below the platform floor 24. The well pipe 18 then depends from the motion compensator 10 and is attached to the sub surface test tree 12 in the wellhead W. Alternatively, the motion compensator 10 may be located directly above the sub surface test tree 12 and the well pipe 18 would extend upwardly to the platform P from the motion compensator 10. Another alternative would be to suspend the motion compensator 10 from the elevators (not shown) near the top of the platform derrick 26 and have the well pipe 18 depend from the motion compensator 10 to the wellhead. Wherever the motion compensator 10 is positioned, one portion will be attached to the stationary wellhead W through well pipe 18 or other means, and another portion will be associated with the movable platform P.
Other equipment that may be associated with the platform P during the performance of the operation may include valved manifold 28 at the upper end of a well pipe section 30 attached to the motion compensator 10, separator facilities 32, conduit means 34 communicating between the manifold 28 and the separator facilities 32, and a burner 36 for burning the fluid produced during the test once it is passed through the separator facilities 32.
The motion compensator 10 is illustrated in detail in FIG. 2A, 2B and 2C.
The motion compensator includes telescoping means to permit telescoping movement between one end of the compensator adapted to be associated with the stationary wellhead W and the other end of the compensator adapted to be associated with the floating platform P. Two seal systems are provided in the motion compensator. One seal system, the environmental seal system, prevents well fluids within the compensator from leaking to the environment. The other seal system, the pressure balancing seal system, balances the forces due to well fluids within the motion compensator so that only forces in addition to well fluids acting upon the motion compensator, such as platform P movement, will tend to either expand or contract the compensator. To increase the life of the seal systems, the seal means are lubricated and the motion compensator includes port means to permit an injection of lubricant to each seal system.
The means for permitting the telescoping motion are provided by two mandrel means which telescope with respect to each other. The choice of the particular mandrel means to be associated with the stationary wellhead W or with the moving platform P is not important.
In the illustrated motion compensator, a lower tubular mandrel means indicated generally at 38 extends upwardly from sub 38a having threads 40 which permit the tubular mandrel means 38 to be attached to well pipe 18. Mandrel means 38 includes lower sub 38a and several attached sleeve sections 38b, 38c, 38d, and 38e above the sub 38a. Tubular mandrel means 38 will thus be stationary.
Telescoping mandrel means indicated generally at 42 is designed to telescope over tubular mandrel means 38 to accommodate the oscillating motion of the platform P. Telescoping mandrel means 42 includes interconnected, concentric, outer tubular housing means 44 and inner sleeve means 46. Housing means 44 includes several interconnected sections 44a, 44b and 44c. Housing means 44 and the sleeve means 46 are adapted to be disposed around the upper sleeve sections 38e, 38d, 38c and 38b of tubular mandrel means 38. The telescoping mandrel means 42 includes an upper threaded sub 48 so that it may be connected to well pipe 30 associated with the floating platform P.
To prevent well fluids within the motion compensator from leaking to the environment an environmental seal system indicated generally at 50 (See FIG. 2C) is provided between tubular mandrel means 38 and housing means 44. Preferably this environmental seal system 50 comprises a seal assembly carried within a recess 51 in the lower end of the housing means 44 and is adapted to seal between the outer surface 52 of tubular mandrel means 38 and housing means 44. In this location first port means 54 through housing means 44 permit injection of lubricant to the seal assembly 50. Preferably the environmental seal system 50 comprises two seal means 56 and 58 one of which is disposed on each side of port means 54. One seal means 56, the primary environmental seal will be subjected to well fluids in the annular cavity 60 between housing means 44 and tubular mandrel means 38 and will also be subjected to lubricant injected through port means 54. The primary pressure differential created by the well fluids is borne by this primary environmental seal means 56 and it is designed to be the first seal means of the environmental seal system 50 to fail. Second seal means 58 functions as a backup environmental seal when primary seal means 56 fails.
Connector means 62 is in fluid communication with first port means 54 and is adapted to be connected to conduit means 80 (See FIG. 1) extending to platform P. Lubricant flows through conduit means 80 to lubricate the environmental seal system 50 during the operation of the motion compensator.
The pressure balancing seal system (See FIGS. 2A and 2B) provides a means to balance the force of well fluids within the motion compensator. The pressure balancing seal system includes first seal means, indicated generally at 66, between tubular mandrel means 38 and sleeve means 46 and second seal means, indicated generally at 70, between tubular mandrel means 38 and housing means 44. To provide for as much relative movement between tubular mandrel means 38 and telescoping mandrel means 42 as is possible and to facilitate the lubrication of the pressure balancing seal system, the first seal means 66 is preferably located within an annular recess 67 at the upper end of tubular mandrel means 38 and is adapted to seal between the outer surface 68 of the sleeve means 46 and tubular mandrel means 38, while the second seal means 70 is preferably located within a recess 69 at the upper end of the tubular mandrel means 38 and is adapted to seal between the inner surface 72 of the housing means 44 and tubular mandrel means 38.
To lubricate the pressure balancing seal system a lubricant chamber is provided. The lubricant chamber is defined by the first and second seal means 66 and 70 of the pressure balancing seal system, telescoping mandrel means 42, the upper portion of the tubular mandrel means 38, and a reservoir 74. When the motion compensator is collapsed (as shown in FIG. 2) the lubricant chamber is reduced to its smallest volume. The volume of the lubricant chamber increases as the motion compensator extends. Second port means 76 through the telescoping mandrel means 42 permits injection of lubricant to the reservoir 74.
Connector means 78 is in fluid communication with port means 76. Connector means 78 is adapted to be connected to conduit means 82 (See FIG. 1) extending to the surface through which lubricant flows to lubricate the pressure balancing seal system including the first and second seal means 66 and 70, during the operation of the motion compensator.
The seal life of the seal means of each seal system is prolonged by injecting lubricant to each seal means. Because of the injected lubricant, each seal means remains impregnated with clean lubricant and the sealing surfaces are cleaned of abrasive particles. Less heat and abrasion develops between the seal means and the sealing surfaces, thereby reducing seal wear and extending seal life.
To inject lubricant to the seal systems during the operation of the motion compensator 10 conduit means 80 and 82 (See FIG. 1) extend from the platform P to the compensator 10 and are connected to the connecting means 62 and 78 respectively.
The conduit means 82 conducts lubricant from a source 84 to annular lubricant reservoir 74. Lubricant in reservoir 74 lubricates the pressure balancing seal system. Gauge means 86 may be provided to monitor the pressure in reservoir 74.
Similarly, conduit means 80 provides a means for injecting lubricant from a source 88 to the environmental seal system 50. Gauge means 90 may also be provided to monitor the pressure at the lower seal unit 50.
Preferably the seal systems are sized so that the motion compensator is pressure balanced, whereby the well forces tending to expand the compensator are balanced by forces tending to contract the compensator so that only forces other than well fluid pressure exerted on the compensator contracts or expands the compensator. In the illustrated motion compensator the forces due to well fluids within the motion compensator acting over the circular cross-sectional area A1, defined by the inner diameter of seal means 66, tend to expand the joint. If a communicating means, such as port means 92 through the tubular mandrel means 38 (see FIG. 2B), is provided, the forces due to well fluids within the motion compensator 10 acting on the annular area A2 defined by the outside diameter of seal means 70, and the inside diameter environmental seal system 50 tend to contract the joint. The circular cross sectional area A1, is preferably sized relative to the annular cross sectional area A2 so that these forces are equal. With the effect due to well fluids balanced only forces exerted upon the compensator other than well fluids, such as due to the oscillation of the vessel P, would tend to expand or contract the compensator.
Preferably the motion compensator includes interacting spline means so that torque may be transmitted through the motion compensator to positions below the motion compensator. If desired, spline means could interact throughout the entire telescoping movement of telescoping mandrel means 42 with respect to tubular mandrel means 38. However on the illustrated motion compensator, the spline means interacts when the motion compensator is in a collapsed position or when the motion compensator is in extended position. The spline means which interact when the compensator is in a collapsed position include lower engaging means 94 on the lower end of the telescoping mandrel means 42 engageable with slot means 96 associated with the lower sub 38a of tubular mandrel means 38. (See FIG. 2C) The lower sub 38a may include guide teeth means 97, with the slot means 96 extending from the root 97a thereof, to guide engaging means 94 with slot means 96. The spline means which interact when the tool is extended include upper engaging means 98 on the exterior surface of the tubular mandrel means 38 below sleeve section 38c (See FIG. 2B) and slot means 100 on the interior surface of section 44b of housing means 44. The section 44b may also include guide teeth means 101 to guide upper engaging means 98 into slot means 100.
Means are provided to limit the telescoping movement of telescoping mandrel means 42 with respect to tubular mandrel means 38. The limiting means stops movement of telescoping mandrel means 42 when it moves to a select, contracted position with respect to tubular mandrel means 38 and stops movement of telescoping mandrel means 42 when it moves to a select, extended position with respect to tubular mandrel means 38. To stop movement at contracted position, the upper end 38f of tubular mandrel means 38 contacts stop shoulder means 102 of telescoping mandrel means (See FIG. 2A). To stop movement at the extended position, stop shoulder means 104 of tubular mandrel means 38 (See FIG. 2B) engages stop shoulder means 106 of telescoping mandrel means housing means 44 (See FIG. 2C).
To facilitate handling of the motion compensator 10, means are provided to maintain the motion compensator 10 in a collapsed condition. These means may be a plug 108 which extends through ports 110 of housing means 44 to engage lockout recess 112 of tubular mandrel means 38. Before the motion compensator 10 is positioned within well pipe 18, plug 108 is removed, freeing telescoping mandrel means 42 for movement with respect to tubular mandrel means 38. Suitable plugs (not shown) may then be inserted to block ports 110 of housing means 44.
In operation, the motion compensator 10 is utilized to compensate for the oscillating motion of a floating platform P relative to a stationary subsea wellhead W. The motion compensator 10 is installed in well pipe 18 between the wellhead W and the platform P. Associated with the stationary wellhead W is a stationary tubular mandrel means 38. To accommodate for the oscillating motion of platform P, telescoping mandrel means 42 telescopes over tubular mandrel means 38. Lubricant is injected to both the environmental seal system 50 and the pressure balancing seal system.
During the utilization of the motion compensator 10 the seal life of the seal means in each seal systems can be monitored.
To monitor the seal life of the environmental seal system 50, gauge means 90 monitors the pressure of injected lubricant. The pressure of the injected lubricant should be known and is preferably less than the pressure of well fluids within the motion compensator. The injected lubricant lubricates both the primary and backup seal means 56 and 58. Since the primary seal means 56 is subject to abrasive well fluids while the backup seal means 58 is initially subject only to lubricant and sea water, the primary seal means 56 should fail first. When primary seal means 56 fails, well fluids will seap past it and register an increase of pressure upon gauge means 90. The registered increase of pressure indicates failure of primary seal means 56. The relative amount of increase, indicates the extent of failure.
Even though primary seal means 56 of the environmental seal system 50 has failed, the operation of the motion compensator 10 may be continued because backup seal means 58 should still be effective. Preferably the continued operation of the motion compensator 10 is in a manner which inhibits well fluids from contacting backup seal means 58.
To inhibit well fluids from contacting backup seal means 58 once primary seal means 56 has failed, lubricant is conducted to the environmental seal system 50 at a pressure greater than the pressure of well fluids within the compensator. Well fluids will flow into and from annular cavity 60 and the bore of the compensator through port means 92. However, because the pressure of the lubricant is greater than the pressure of the well fluids, the lubricant will fill the lower portion 60a of the annular cavity. The high pressure lubricant fills this lower portion 60a because its volume remains relatively unchanged even though, the volume of the entire cavity 60 changes, and because the lubricant is at a pressure higher than that of the well fluids. With the high pressure lubricant filling the lower portion 60a, well fluids are inhibited from contacting backup seal means 58 thereby prolonging its seal life while permitting continued operation of the motion compensator 10.
When both seal means 56 and 58 of the environmental seal system 50 fail, well fluids within the compensator will leak to the environment. This leakage can generally be visually spotted. However, it is desirable, for environmental reasons, to stop operation of the motion compensator 10 before leakage to the environment occurs. Once primary seal means 56 has failed it is possible to estimate the life of backup seal means 50 so that the operation of the motion compensator 10 can be stopped before leakage to the environment occurs. The life span of the backup seal means 58 once the primary seal means 56 has failed should be approximately the same as life span of the primary seal means 56.
To monitor the seal life of the pressure balancing seal system 64, gauge means 86 monitors the pressure of lubricant injected into the lubricant chamber. The pressure of the injected lubricant is known and is preferably less than the pressure of well fluids within the motion compensator but greater than atmospheric pressure. When one or both of the first and second seal means 66 and 70 fails, well fluids will seep past the failed seal means and register an increase of pressure upon the gauge means 86 thereby indicating a seal failure. The extent of seal failure (e.g. whether there is a mere seepage of well fluids past the failed seal means or whether there is a steady flow of well fluids past the failed seal means) can be determined by the magnitude of the increase in pressure.
When one or both of the first and second seal means 66 and 70 has failed, well fluids entering into the lubricant chamber may prevent complete collapse of the motion compensator 10 and the seepage of fluids past the seal means may cause loss of the pressure balancing feature. The well fluids seeping past the failed seal means should either be accommodated, or the operation of the motion compensator 10 should be stopped.
The accommodation of the seeping well fluids removes the fluids from the lubricant chamber to both permit complete collapse of the motion compensator 10 and to maintain the pressure balancing feature. The seeping well fluids can be accommodated by permitting unrestricted flow of these fluids out of the lubricant chamber to a storage point. For example, source means 84 may be a low pressure accumulator means 84 and the diameter of conduit means 82 and port means 76 could be large enough to permit a free flow of lubricant and seeped well fluids into and out of the lubricant chamber.
When an increase of pressure is registered on gauge means 86, indicating a seal failure of one or both of the seal means of the pressure balancing seal system, the operator can determine whether to continue the test and utilization of the motion compensator or whether to shut down. If the increase of pressure is small, indicating a mere seepage past the failed seal means, he may determine to accommodate the seeping fluids, particularly if the test is near completion. By accommodating the seeped fluid by bleeding it out of the lubricant chamber as fast as it enters the lubricant chamber, the motion compensator 10 will maintain its ability to completely collapse and the pressure balancing feature will be maintained. The accommodated, seeped fluid is not lost to the environment, but is stored in accumulator means 84. The amount of seeped fluids indicate the extent of seal failure. Once the seeped fluids can no longer be accommodated, the operation should be shut down to prevent buckling of the well pipe 18.
The injection of lubricant into the annular reservoir 74 should be accomplished to permit a complete collapsing of the motion compensator 10. Too much fluid in the lubricant chamber, prevents complete collapse of the motion compensator 10 by creating a shock absorber or bumper affect.
There are several methods of preventing lubricating fluid within the lubricant chamber from creating a shock absorber effect.
First, the manner in which lubricant is conducted to the annular reservoir 74 can be controlled. For example, lubricant can be pumped to the reservoir 74 while gauge means 86 is monitored. When the gauge reading exceeds a certain amount the pumping can be stopped. Alternatively, the motion compensator can be collapsed to reduce the annular reservoir 74 to its smallest of volume. Then the reservoir 74 can be filled with lubricant.
Second, the lubricant under a few pounds of pressure can be maintained in the annular reservoir 74 and accommodated when the motion compensator is collapsed. To maintain and accommodate lubricant within the annular reservoir 74, source means 84 may be a low pressure accumulator means 84 and the diameter of conduit means 82 and of port means 76 could be large enough to permit unrestricted flow of lubricant into or out of annular reservoir 74. When the motion compensator 10 expands, lubricant from accumulator means 84 flows into the annular reservoir 74. When the motion compensator contracts, excess lubricant in the reservoir 74 is accommodated, and the shock absorber affect avoided, by being expelled from the reservoir 74 and flowing back to accumulator means 84. Alternatively, an annular free piston means 114 (shown in dotted form in FIG. 2A) could be disposed within the annular reservoir 74 to provide low pressure accumulator means within the lubricant chamber. Lubricant would be injected into the lubricant chamber between piston means 114 and the pressure balancing seal system. The reservoir 74a above piston means 114 would be filled with low pressure gas. The lubricant within the lubricant chamber would exert the same pressure across the pressure balancing seal system as is exerted by the gas. When the motion compensator extends, piston means 114 moves to a position increasing the volume of reservoir 74 while maintaining the volume of lubricant constant. When the motion compensator contracts, the lubricant is accommodated by piston means 114 moving to a position reducing the volume of the reservoir 74a above the piston means 108 and permitting the lubricant to flow into the reservoir 74b below the piston means 114.
The pressure balancing seal system can be monitored to determine whether the lubricant in reservoir 74 has been used up so that more must be added. When lubricant is pumped into chamber 74 guage means 86 is monitored. If the pressure within the reservoir 74, as indicated by gauge means 86, increases quickly, lubricant remains within the reservoir 74 and further injection of lubricant into the reservoir 74 is unnecessary. If however, the pressure within the reservoir 74 does not increase quickly, little lubricant remains 74 and lubricant should be injected into the reservoirs 74 to lubricate the pressure balancing seal system 64.
To transmit torque through the motion compensator 10, the compensator is extended or collapsed until the respective spline means engage and interact. The compensator is maintained in this position, and torque transmitted therethrough, by rotating the Kelley (not shown) and the well pipe 18 connected to the motion compensator.
As illustrated in FIG. 3, an alternative arrangement may be provided for the environmental seal system and its lubricating port means. Since the rest of the motion compensator is unchanged FIG. 3 illustrates only the lower portion of the motion compensator and like numerals have been used for like parts.
The environmental seal system indicated generally at 120 prevents leakage to the environment and is disposed between tubular mandrel means 38 and housing means 44. It is preferably located within an annular recess 121 of housing means 44 and adapted to seal with the exterior surface 52 of tubular mandrel means 38. The seal system 120 preferably includes upper primary seal means 122 and lower backup seal means 124.
Port means 126 through housing means 44 permits injection of lubricant to the environment seal system 120. Port means 126 opens into annular cavity 60a above but adjacent to the seal system 120. Lubricant may be maintained in this lower portion 60a of annular cavity 60 to lubricate the environmental seal system 120.
The operation of the motion compensator, with the alternative environmental seal system 120 and port means 126 is similar to the operation of the first embodiment of the motion compensator after the primary seal means 56 of the environmental seal system 50 has failed. Lubricant is maintained in the lower portion 60a of the annular cavity 60 to lubricate the environmental seal system 120, by injecting lubricant through port means 126 at a pressure in excess of the pressure of the well fluids within the motion compensator. In this manner, although the well fluids will seep into the annular cavity 60 through port means 92 they will be inhibited from contacting the environmental seal system 120.
The failure of both seal means 122 and 124 can be detected by observing a leakage of fluid past the seal system 120 to the environment.
Because the pressure of lubricant injection through port means 126 is greater than the pressure of well fluids within the bore of the motion compensator, the motion compensator has a tendency to collapse (e.g., the force tending to collapse the motion compensator equals the pressure of injected lubricant times A2, the annular cross-sectional area defined by the outside diameter of seal means 70 and the inside diameter of environmental seal system 120, while the force tending to expand the motion compensator equals the pressure of well fluids within the bore times A1, the circular cross-sectional area defined by the inner diameter of seal means 66. Since A1 is designed to be equal to A2, and since pressure of injected lubricant is greater than the pressure of well fluids, the force tending to collapse the compensator is greater than the force tending to expand the compensator). Operating the motion compensator so that it has a tendency to collapse may be preferable because there would then be less likelihood that the well pipe 18 would buckle.
It would be apparent that in the embodiment illustrated in FIG. 3, more lubricant is required to lubricate the environmental seal system than is required for the embodiment illustrated in FIGS. 2A, 2B and 2C. The FIG. 3 embodiment required more lubricant because, even before the primary seal 122 fails, a portion of the lubricant is lost through port 92 while in the FIG. 2A, 2B and 2C embodiment no lubricant is lost until the primary seal 56 fails.
From the foregoing it can be seen that the objects of this invention have been obtained. A motion compensator has been provided wherein means are provide which permit the seals between the telescoping parts of the compensator to be lubricated resulting in less heat and abrasion on the seal surfaces and increasing the operating life of the motion compensator. By observing the gauges which monitor the pressure of lubricant, it can be determined when the seals fail so that corrective steps, can be conducted before much damage has occurred. Additionally a method of utilizing a motion compensator has been provided which permits determining when the seals have failed, determining the extent of failure, and continued operation of the compensator even after some of the seals have partially failed.
The foregoing disclosure and description of the invention are illustrative explanatory thereof and various changes in the size, shape and materials, processes, as well as in the details of the illustrated construction may be made within the scope of the appended claims without departing from the spirit of the invention.
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Disclosed is a motion compensator to permit relative movement between an underwater well installation and a vessel on the water surface. The motion compensator includes telescoping elements, seals between the telescoping elements and ports to permit lubrication of the seals. A method of using the motion compensator is also disclosed. This abstract is neither intended to define the invention of the application which, of course, is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
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FIELD OF THE INVENTION
[0001] The present invention relates to an improved process for the preparation of active cephalosporin antibiotic derivative. The present invention more particularly relates to an improved process for the preparation of cefuroxime sodium of the formula (I).
DESCRIPTION OF THE PRIOR ART
[0002] Cefuroxime is a valuable broad spectrum antibiotic and having activity against wide range of gram-positive and gram-negative microorganisms. Cefuroxime sodium is physiologically acceptable non-toxic salt of cefuroxime and may be administered to human or used as a veterinary medicine.
[0003] U.S. Pat. No. 4,775,750 discloses the process for the preparation of the compound of formula (I), which involves carbamoylation of (6R,7R)-7-[Z-2-(fur-2-yl)-2-methoxyiminoacetamido]-3-hydroxymethylceph-3-em-4-carboxylic acid in presence of triethylamine and a solvent, and in situ preparation of cefuroxime sodium using sodium-2-ethylhexanote. The product obtained from this patent suffers in non-acceptable color and low purity. Reprocessing is needed to get sterile cefuroxime sodium.
[0004] U.S. Pat. No. 4,277,601 describes the process for the preparation of cefuroxime sodium as its THF solvate in situ manner. The process described in this patent involves the usage of multiple organic solvent system and thereby making the process complicated. Moreover, recrystallisation is needed to get the sterile cefuroxime sodium.
[0005] The synthesis of cefuroxime disclosed in U.S. Pat. No. 3,966,717 and U.S. Pat. No. 3,974,513 comprises 8 synthetic steps starting from 7-ACA. Such high number of steps, which causes low overall yield, is due to the introduction of two productive groups.
[0006] A process for the preparation of cefuroxime starting from 7-ACA has been described in Chemistry and Industry 1984, 217, which do not involve any protective groups. The preparation involves the condensation of 3-hydroxymethyl-7-amino cephalosporanic acid with (fur-2-yl)-2methoxyimino acetic acid using an organic base to produce (6R, 7R)-7-[(Z)-2-(fur-2-yl)-2methoxyiminoacetamido]-3-hydroxymethylceph-3-em-4-carboxylic acid. Carbamoylation of resulting acid with isocyanate of formula RNCO wherein R is a labile substituent to get (6R,7R)-3-carbamoyloxymethyl-7-[Z-2-(fur-2-yl)-2-methoxyiminoacetamido]-ceph-3-em-4-carboxylic acid (cefuroxime).
[0007] WO 00/71547 describes a process for the preparation of cefuroxime, which involves enzymatic hydrolysis of 7-glutaryl ACA, which is not industrially viable.
[0008] With our continued search and intense investigation, we finally achieved a process for the preparation cefuroxime sodium, which overcomes all difficulties and makes the process industrially viable and yield the title compound in required quantity and quality. In addition, the present invention provides a new process for the conversion of cefuroxime to cefuroxime sodium using a mixture of water soluble sodium salts
OBJECTIVES OF THE INVENTION
[0009] The main objective of the present invention is to provide a process for the preparation of cefuroxime sodium of the formula (I), which has better quality such as color and solubility.
[0010] Another objective of the present invention is to provide direct manufacturing process for the preparation of sterile crystalline cefuroxime sodium of the formula (I) from cefuroxime acid.
[0011] Still another objective of the present invention is to provide a process for the preparation of cefuroxime sodium of the formula (I) in good yield, high purity and with desirable particle size.
[0012] Yet, another objective of the present invention is to provide a simple method for the preparation of cefuroxime of the formula (II) in pure form.
SUMMARY OF THE INVENTION
[0013] Accordingly, the present invention provides an improved process for the preparation of cefuroxime sodium of the formula (I),
[0014] which comprises the steps of:
[0015] (i) dissolving the cefuroxime of the formula (II)
[0016] in a water miscible solvent/water at a temperature in the range of 10° C. to 50° C.,
[0017] (ii) charcoalising the solution of step (i) followed by micron filtration,
[0018] (iii) treating the filtered charcoalized solution of step (ii) with a mixture of water soluble sodium salts of two weak acids in suitable alcoholic solvent at a temperature in the range of 10° C. to 50° C. and
[0019] (iv) isolating and drying the precipitated cefuroxime sodium of the formula (I) in pure form.
[0020] Another embodiment of the present invention is to provide a process for the preparation of cefuroxime of the formula (II), which comprises the steps of:
[0021] (a) condensing 3-hydroxymethyl-7-amino cephalosporanic acid of formula (IV) with activated (fur-2-yl)-2-methoxyimino acetic acid of formula (V) in the presence of an inorganic base in a solvent at a temperature in the range of −40° C. to 10° C. and isolating the product by adjusting the pH to 1.5 to 2.5 using an acid to produce (6R,7R)-7-[(Z)-2-(fur-2-yl)-2-methoxyiminoacetamido]-3-hydroxymethylceph-3-em-4-carboxylic acid of formula (VI) and
[0022] (b) carbamoylating the compound of formula (VI) with isocyanate of formula (VII) wherein R is a labile group in the presence of a solvent at a temperature in the range of −60° C. to 0° C. to get cefuroxime of the formula (II).
[0023] The process is shown in scheme-I as given below:
DETAILED DESCRIPTION OF THE INVENTION
[0024] In an embodiment of the present invention, cefuroxime of formula (II) was dissolved in water miscible solvent/water such as acetone, THF, acetonitrile at a temperature in the range of 10° C. to 50° C.
[0025] In still another embodiment of the present invention, the mixture of water soluble sodium salt of weak acid is selected from sodium lactate/sodium acetate, sodium 2-ethyl hexonate/sodium acetate and the like. The reaction may be carried out in an alcoholic solvent selected from methanol, ethanol, isopropyl alcohol or mixtures thereof, at a temperature in the range of 10° C. to 50° C. The advantage of using the mixture of water soluble sodium salt of two weak acids is that the yield is higher and the color of the product obtained is better.
[0026] In still another embodiment of the present invention, the compound of formula (I) was isolated from reaction mass by adding suitable water miscible solvent such as acetone, methanol, ethanol, isopropyl alcohol or mixtures thereof.
[0027] In yet another embodiment of the present invention, 7-amino cephalosporanic acid of formula (III) was dissolved in solvents such as methanol, acetone, dichloromethane, THF, water or mixtures thereof, to that sodium hydroxide solution was added at a temperature in the range of −90° C. to 0° C., to produce compound of formula (IV).
[0028] In still another embodiment of the present invention, the activation of fur-2-yl methoxyimino acetic acid of formula (V) is carried out using PCl 5 , DMF/POCl 3 , oxalyl chloride, SOCl 2 /DMF, diphenylchlorophosphoridate, dialkyl chlorophosphoridate, in the presence of a solvent selected from halogenated alkanes, ethyl acetate, tetrahydrofuran, aromatic hydrocarbons, acetone, acetonitrile, dialkylethers or mixtures thereof at a temperature in the range of −40° C. to 10° C.
[0029] In still another embodiment of present invention the compound of formula (IV) was reacted with the active derivative of fur-2-yl methoxyimino acetic acid of formula (V) in step (a), in the presence of inorganic base such as sodium bicarbonate, sodium hydroxide, potassium carbonate or sodium carbonate in the presence of solvents such as methanol, acetone, dichloromethane, THF, water or mixtures thereof to produce the compound of formula (VI).
[0030] In yet another embodiment of the present invention, the acid used for adjusting pH in step (a) is selected from hydrochloric acid, sulphuric acid or ortho phosphoric acid.
[0031] In yet another embodiment of the present invention, the labile group represented by R is selected from chlorosulphonyl, mono, di or trichloroacetyl, bromosulphonyl, trichloro ethoxycarbonyl, trimethylsilyl or chlorobenzenesulphonyl group.
[0032] In still another embodiment of the present invention the compound of formula (VI) was reacted with the compound of formula (VII) to produce the compound of formula (II) in step (b), in the presence of a solvent selected from THF, methanol, dichloromethane, acetone, water or mixtures thereof.
[0033] In one more embodiment of the present invention the cefuroxime sodium of the formula (I) obtained is sterile crystalline syn isomer.
[0034] The present invention is exemplified by the following examples, which is provided for illustration only and should not be construed to limit the scope of the invention.
EXAMPLE (1)
[0035] Step (i): Preparation of (6R,7R)-7-[(Z)-2-(fur-2-yl)-2-methoxyiminoacetamido]-3-hydroxymethylceph-3-em-4-carboxylic Acid.
[0036] (i) To a mixture of dimethyl acetamide (145 ml), dichloromethane (22 ml) and dimethylformamide (28 ml) in a dry flask, (fur-2-yl)-2-methoxyimino acetic acid ammonium salt (73 gm) was added and cooled the reaction mass to −40° C. To the reaction mass POCl 3 (60 gm) was added at −40° C. and stirred the reaction mass at −20±2° C. for 45 minutes. The mass was cooled to −30° C. and kept at that temperature for condensation.
[0037] (ii) To a mixture of water (400 ml) and methanol (400 ml) in another flask, 7-amino cephalosporinic acid (100 gm) was added and cooled the slurry to −50° C. To the reaction mass sodium hydroxide solution (29 gm NaOH in 200 ml water) was added at 50° C. and stirred for 60 minutes at 40±2° C. After completion of reaction the pH of reaction was adjusted to 7.0 to 8.0 using dilute HCl. Temperature of this reaction mass was raised to 0° C. by the addition of saturated sodium bicarbonate solution (800 ml) followed by (fur-2-yl)-2-methoxyimino acetic acid mass from step (i) at 0-2° C. After completion of reaction, pH was adjusted to 2.0 using dilute HCl (80 ml). The product formed was filtered, washed with water followed by dichloromethane and dried the product under vacuum at 45° C. to get the title compound of formula (VI) (116-118 gm-) in pure form.
[0038] Step (ii): Preparation of (6R,7R)-3-carbamoyloxymethyl-7-[(Z)-2-(fur-2-yl)-2-methoxyiminoacetamido]-ceph-3-em-4-carboxylic Acid (Cefuroxime Acid):
[0039] (6R,7R)-7-[Z-2-(Fur-2-yl)-2-methoxyiminoacetamido]-3-hydroxymethyl ceph-3-em-4-carboxylic acid (100 gm) obtained from step (i) was dissolved in THF (480 ml) at 0° C. and cooled to −50° C. To the cooled solution chlorosulphonyl isocyanate (59 gm in 100 ml THF) solution was added at −50° C. and stirred at the same temperature for 60 minutes. The reaction mass was poured into precooled water at 10° C. Stirred the mass at 10° C. till completion of reaction. The reaction mass was washed with ethyl acetate and then aqueous layer was subjected to charcoal treatment. The pH of aqueous solution was adjusted to 2.0 using dilute HCl. The product formed was filtered and washed with water followed by isopropyl alcohol to produce the title compound of formula (II) (105 gm).
[0040] Step (iii) Preparation of (6R,7R)-3-carbamoyloxymethyl-7-[(Z)-2-(fur-2-yl)-2-methoxyiminoacetamido]-ceph-3-em-4-carboxylic Acid Sodium (Cefuroxime Sodium):
[0041] (6R,7R)-3-carbamoyloxymethyl-7-[Z-2-(fur-2-yl)-2-methoxyimino acetamido]-ceph-3-em-4-carboxylic acid (100 gm) was dissolved in a mixture of acetone (650 ml) and water (800 ml) at 25° C. Activated carbon was added and stirred for 15 minutes at 25° C. The carbon was filtered and washed the bed with acetone/water. The solution was then passed through series of micron filters in a sterile area. The solution was warmed to 35° C. A mixture of sodium lactate solution (23 gm) (60% solution in water) and sodium acetate (16.5 gm) in ethanol (25 ml) was added to the reaction mixture slowly at 35° C. and stirred for 30 minutes. To the thick slurry acetone (900 ml) was charged at 35° C. The product obtained was filtered and washed with ethanol followed by acetone. The product was dried under vacuum to get sterile cefuroxime sodium (98 gm) in pure form.
EXAMPLE (2)
[0042] Preparation of (6R,7R)-3-carbamoyloxymethyl-7-[Z2-(fur-2-yl)-2-methoxy iminoacetamido]-ceph-3-em-4-carboxylic Acid Sodium (Cefuroxime Sodium):
[0043] (6R,7R)-3-carbamoyloxymethyl-7-[Z-2-(fur-2-yl)-2-methoxyimino acetamido]-ceph-3-em-4-carboxylic acid (100 gm) was dissolved in a mixture of acetone (650 ml)/water (800 ml) at 25° C. Activated carbon was added and stirred for 15 minutes at 25° C. The carbon was filtered and washed the bed with acetone/water. The solution was then passed through series of micron filters in a sterile area. The solution was warmed to 35° C. A mixture of sodium lactate solution (23 gm) (60% solution in water) and sodium acetate (16.5 gm) in methanol (450 ml) was added to the reaction mixture slowly at 35° C. and stirred for 30 minutes. The product obtained was filtered and washed with methanol (200 ml) followed by acetone. The product was dried under vacuum to get sterile cefuroxime sodium (98 gm) in pure form.
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The present invention relates to an improved process for the preparation of the sterile cefuroxime sodium of formula (I).
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The present invention is directed to a new strain of a group of lactic bacteria having probiotic activity. This strain was isolated from a natural corn silage without chemical or biological additives. Specifically, the invention provides a new strain of enterococci, Enterococcus faecalis GALT, capable of surviving in and colonizing the gastrointestinal tract of humans and animals, and their use as probiotics.
The present invention is also directed to compositions, uses, and methods for inhibiting the growth of pathogenic microorganisms, either in the process of manufacturing food, previous to consumption, or in uses and methods for the treatment and prophylaxis of disorders associated with the colonization of the gastrointestinal tract in humans and animals, and to uses and methods for improving the immune response (natural and acquired) in humans and animals. More specifically, the invention is related to compositions and methods for inhibiting pathogenic growth and for improving the immune response of humans and animals through the use of the inventive microorganism.
BACKGROUND OF THE INVENTION
The ingestion of pathogens, especially bacterial pathogens, including viruses and other disease-causing microorganisms, is a common problem in most animals. It is well known that pathogens cause diseases in animals, with numerous harmful effects including weight loss, diarrhea, abdominal obstruction, and renal failure. In the case of immunosuppressed or underfed animals, the effects of diarrhea may be even fatal. Pathogens are often transferred among animals under poor hygienic conditions, and even when suitable care is available, contagion may not be avoided.
Extreme health risks result when humans consume pathogens in contaminated food products such as sprouts, lettuce, meat products, unpasteurized milk or juice, water contaminated with sewage waters, etc. The problem is particularly frequent in beef and the dairy sector. Pathogens present in the udder of cows or in the milking equipment may be a source of contamination for raw milk. Beef may be contaminated in the slaughterhouse, and pathogen organisms may be subsequently mixed with large amounts of meat during grinding. Serious and life-threatening infections may occur when humans eat meat, especially ground beef, which has not been cooked enough so as to kill any pathogen present in the beef. This problem is difficult to solve because contaminated meat often looks and smells perfectly normal. Further, the number of pathogenic organisms necessary to cause a disease condition is extremely small, making detection very difficult. Pathogens that cause diseases in the intestinal zone are known as enteropathogens. Examples of these bacteria include Staphylococcus aureus , specific strains of Escherichia coli ( E. coli ), and Salmonella spp. While most of the hundreds of E. coli strains are harmless and live in the intestines of animals, including humans, some strains such as E. coli 0157:H7, 0111:H8, and 0104:H21, produce great amounts of powerful toxins closely related or identical to the toxin produced by Shigella dysenterieae . These toxins may cause severe pain in the small intestine, often producing harmful effects in the intestinal zone and in extreme cases, diarrhea. E. coli 0157:H7 and other enterohemorrhagic strains may also cause acute hemorrhagic diarrhea, characterized by severe abdominal obstruction and abdominal bleeding. In children, this may develop into a rare but fatal disorder called hemolytic uremic syndrome (“HUS”), characterized by renal failure and hemolytic anemia. In adults, it may develop into a condition known as thrombotic thrombocytopenic purpura (“TTP”), which involves HUS in addition to fever and neurological symptoms, and may have a mortality rate as high as of 50% in the elderly.
A reduction in the risk of diseases caused by food-borne pathogens may be achieved by controlling potential contamination sources. The beef industry has recognized the need of increasing the control of pathogens prior to harvest, particularly the control of E. coli 0157:H7 and other hemorrhagic serotypes, to avoid contamination of products, potential contact with humans, and transmission of pathogens during meat processing. In particular, raw or undercooked hamburgers (ground beef) have been involved in many outbursts or documented epidemics as containing E. coli 0157:H7 and other hemorrhagic serotypes.
Thus, there persists a recognized need for providing compositions and methods for reducing or eliminating the growth of enteropathogens such as E. coli 0157:H7 and other hemorrhagic serotypes, for the benefit of human and animal health.
Therefore, for the benefit of consumers, there is an important need of reducing or eliminating the growth of enteropathogens in animal meat and milk before their harvest. Such reduction or elimination of pathogens in animals intended consumption will provide a better protection for beef consumers, in dairy, and other food products against the risk of consuming said pathogens.
A very common solution to this problem has been the provision of antibiotics to the animals; however, this solution is not only costly, but may also lead to the generation or selection of antibiotic-resistant bacterial strains. Also, as is known, the treatment with antibiotics, in particular oral antibiotics, may modify or destroy the gastrointestinal flora. These antibiotics may exert a negative effect on the general health. Said negative or undesirable effect, consists in partly destroying the healthy bacteria naturally living in the body. For example, in the intestine there are healthy bacteria that usually live there: biphidobacteria and lactobacilli, that are part of the intestinal flora. Said intestinal microbiota constitute a natural defense for protection against stomach and intestine infections; infections which finally will cause problems such as diarrhea.
On numerous occasions, patients on antibiotics have diarrhea, due to destruction of the bacteria that naturally live in the intestine, and protect them against infections.
Likewise, women on antibiotics for a bacterial infection may suffer from mycosis (fungi) at vaginal level, as the antibiotics also kill the bacteria acting as natural defense (lactobacilli).
It has thus been shown that the gastrointestinal microbiota play a number of vital roles in maintaining normal function of the gastrointestinal tract and overall physiological health. For some experts, the key to good health resides in the intestine, whose role in the human body has been compared to that played by the roots of a tree. And, in fact, the intestine is not just an absorption organ. It is the most relevant site of action of the immune system and of non-specific protective mechanisms, as it is precisely in the intestines where they are most active. Its immunocompetent cells recognize pathogenic agents and activate the production of T lymphocytes that, in turn, differentiate into plasma cells and segregate non-specific antibodies.
When we are born, the gastrointestinal tract is sterile but shortly after a complex set of approximately 400 different types of microorganisms settles down permanently which work in harmony at maintaining the health. This microflora—the intestinal flora—weights over one kilogram, it may comprise up to 100 billions of different microorganisms which have an overall metabolic activity similar to that of a human liver. Once the microflora has settled, it may be negatively affected by factors such as consumption of very refined food poor in fibers, antibiotic treatments, and stress, among others.
For example, growth and metabolism of the many individual bacterial species living in the gastrointestinal tract depend mostly on the available substrates, mainly derived from the diet. See, for example. Gibson et al., 1995 . Gastroenterology 106: 975-982; Christi, et al., 1992 . Gut 33: 1234-1238; Gorbach, 1990 . Ana. Med. 22: 37-41; Reid et al, 1990 . Clin. Microbiol. Rev. 3: 335-344. These disclosures have led to different approaches intended to modify the structure and metabolic activity of the gastrointestinal tract through the diet, especially including probiotics, which are live microbial food supplements.
As it is known that pathogens live in many different areas of the digestive system of animals, it has been found beneficial to supply and/or reinforce the naturally-occurring organisms in these areas which are effective for inhibiting pathogenic growth throughout the digestive tract, such as in the rumen, small intestine, and large intestine.
Probiotics, when introduced into the gastrointestinal tract, may influence the gastrointestinal microflora and play a beneficial role in the human or animal host. The term “probiotic” derives from Greek “for life”. It was first used to describe substances secreted by microorganisms capable of stimulating the growth of other microorganisms (Lilly and Stillwell, 1965, Probiotics: growth-promoting factors produced by microorganisms. Science . February 12; 147:747-8).
In 1992, Havenaar suggested, as a definition for probiotics, “a viable mono- or mixed culture of microorganisms, which applied to animals or man, beneficially affects the host animal by improving the properties of the indigenous microflora” (Havenaar et al., 1992, Selection of strains for probiotic use. In: Probiotics, the Scientific Basis (Fuller R., ed.), pp. 209-224. Chapman and Hall, London, UK). Havenaar's definition was the first using the term probiotic for both humans and animals.
Taking into account the current applications and proven effects of probiotics, Salminen et al (1999), Probiotics: how should they be defined. Trends Food Sci. Tech.; 10:107-110), proposed a new definition: “probiotics” are preparations of microbial cells or components of microbial cells that exert a beneficial effect on health and comfort of the host. This definition includes microbial cells (viable or non-viable) and parts of cells as probiotics, but not metabolites such as antibiotics. This definition also indicates that the application of probiotics is not restricted to its use in food.
“Probiotics” are considered as viable microbial preparations that promote the health of an individual by preserving a healthier microflora in the intestine. A microbial preparation is commonly accepted as a probiotic when it as a known effect and mode of action. Probiotics bind to the intestinal mucosa, colonize the intestinal zone and also prevent settling of deleterious microorganisms into the intestine. An essential requirement for its action is that they should reach the intestinal mucosa in an appropriate and viable way without being destroyed at the upper part of the gastrointestinal tract, especially by influence of the low pH values prevailing in the stomach.
It is known that the low pH values in the stomach in addition to the antimicrobial action of pepsin provide an efficient barrier against the entry of bacteria into the intestinal zone. The pH of the stomach ranges from 2.5 to 3.5, but may reach values as low as pH 1.5, or as high as pH 6 or higher after food ingestion. The type of food affects stomach emptying. Normally, food remains in the stomach from two to four hours: however, liquids leave the stomach in about 20 minutes. Extensive in vitro tests have been used for selecting gastric tolerance, including lactic acid producing bacteria tolerant to acids (Charteris et al, 1998, Development and application of an in vitro methodology to determine the transit tolerance of potentially probiotic Lactobacillus and Bifidobacterium species in the upper human gastrointestinal tract. J. Appl. Microbiol . May; 84(5):759-68; Clark et al, 1993, Selection of bifidobacteria for use as dietary adjuncts in cultured dairy foods: III. Cult. Dairy Prod. J. 29:18-21; Chou and Weimer, 1999, Isolation and characterization of acid- and bile-tolerant isolates from strains of Lactobacillus acidophilus. J Dairy Sci . January; 82(1):23-31).
Another barrier that probiotic bacteria must overcome is the small intestine. The adverse conditions of the small intestine include the presence of bile salts and pancreatin. The transit time of food through the small intestine generally comprises between one and four hours. Lactic acid bacteria resistant to bile salts may be selected by assaying their survival capacity in the presence of bile salts and their growth on selective media with varying levels of bile (Gilliland et al, 1984, Importance of bile tolerance of Lactobacillus acidophilus used as a dietary adjunct. J Dairy Sci . December; 67(12):3045-51; Ibrahimand Bezkorovainy, 1993, Survival of bifidobacteria in the presence of bile salt. J Animal Sci. 62:351-354; Clark and Martin, 1994, Selection of bifidobacteria for use as dietary adjuncts in cultured dairy foods: II—tolerance to simulated pH of humans stomach. Cult. Dairy Prod. J. 6:11-14; Chung et al, 1999, Screening and selection of acid and bile resistant bifidobacteria. Int. J. Food Microbiol. 47:25-32). A concentration of 0.15-0.3% of bile salts is a suitable concentration for selecting probiotics for human use.
After surviving the passage through the upper gastrointestinal tract, probiotic bacteria need to attach to the intestinal epithelium in order to colonize and remain in the gastrointestinal tract. The complexity of the intestinal mucosa and its microflora make it very difficult to study bacterial attachment in vivo.
Live probiotic microorganisms may provide advantages either during the preparation of fermented probiotic food or in the digestive tract of the host. After fermentation, texture and flavor of the raw materials are perceptibly improved; harmful effects of some feed components may be reduced, for example food intolerance and allergies caused by certain oligosaccharides and proteins; levels of amino acids and vitamins may be improved, which enhances the nutritional value of food; and sugars and other components that promote food decay may be removed, leading to a longer potlife and improving the safety of food products. Also, there is evidence that the bioavailability of calcium, zinc, iron, manganese, copper, and phosphorus is greater in fermented yoghurt as compared to milk. Studies have also showed an increase in riboflavin and niacin in yoghurt, vitamin B6 Cheddar cheese, vitamin B12 in quark and folic acid in a variety of products including yoghurt, quark, Cheddar cheese, and sour cream. Enzymatic hydrolysis of probiotic microorganisms has also demonstrated to enhance bioavailability of proteins and fats. Bacterial protease may increase the production free amino acids that may benefit the nutritional condition of the host, especially if said host has an endogenous protease deficiency.
In the food manufacturing industry, the lactic bacteria used as protecting cultures must have the ability to adapt themselves to the prevailing conditions in the corresponding product and must also show competitive ability. In most beef products, lactic bacteria must tolerate relatively high salt concentrations, and should be able to develop in the presence of nitrite at relatively low temperatures. Biological preservation of food is an important alternative to preservation with non-biodegradable chemical compounds which are toxic for humans.
It has also been disclosed that consumption of food containing viable probiotics produces health benefits including (1) alleviation of intestinal disorders such as constipation and diarrhea caused by an infection by pathogenic organisms, antibiotics, or chemotherapy; (2) stimulation and modulation of the immune system; (3) anti-tumoral effects resulting from inactivation or inhibition of carcinogenic compounds present in the gastrointestinal tract by reduction of intestinal bacterial enzymatic activities such as O-glucuronidase, azoreductase, and nitroreductase; (4) reduced production of toxic final products such as ammonia, phenols and other protein metabolites known to influence hepatic cirrhosis (5) reduction of serum cholesterol and arterial pressure; (6) maintenance of mucosal integrity; (7) alleviation of lactose intolerance symptoms; (8) prevention of vaginitis.
Examples of probiotic organisms include, but are not limited to, bacteria capable of growing, at least temporarily, inside the gastrointestinal tract, of displacing or of destroying pathogenic organisms, as well as providing additional advantages to the host.
It is known that certain bacteria, in particular bacteria isolated from healthy human or animal gastrointestinal tracts, as well as certain lactic acid bacteria such as Lactobacillus , have a prophylactic and therapeutic effect in gastrointestinal diseases, such as gastrointestinal infections. For this purpose, the administration of preparations containing these microorganisms (viable) to humans or animals is also known. After administration, these probiotic bacteria (also called eubiotic) compete with the pathogenic bacteria for food and/or binding sites on the gastrointestinal wall, such that their number is reduced and infections are thus reduced or prevented.
For many years, lactic acid bacteria have been used as fermenting agents for food preservation by reason of their low pH and the action of the fermentation products generated during their fermentation activity which inhibits the growth of harmful bacteria. To this end, lactic acid bacteria not well characterized yet have been used for preparing a variety of food products such as dry fermented meat products, cheese, and other fermented dairy products.
Recently, these lactic acid bacteria have attracted some attention because it has been found that some strains exhibit valuable characteristics for digestion in humans and animals. In particular, specific strains of the genera Lactobacillus or Biphidobacterium capable of colonizing the intestinal mucosa and assisting in the maintenance of wellbeing of humans and animals were found.
The best-known probiotics are lactic-acid generating bacteria (that is, lactobacilli and biphidobacteria), extensively used in yoghurts and in other milk products. These probiotic organisms are non-pathogenic and non-toxic, they maintain viability during storage, and survive the passage through the stomach and the small intestine. As the colonization of the host by probiotics is not permanent, they must be consumed on a regular basis in order to achieve persistent health-promoting characteristics. Commercial probiotic preparations generally comprise mixtures of lactobacilli and biphidobacteria, but species of yeast such as Saccharomyces have also been used.
In this aspect, several patent applications disclose specific strains of Biphidobacterium, Lactobacillus and, to a lesser extent, Enterococcus ( E. faecium ) and their beneficial effects on diarrhea, immuno-modulation, hypersensitive reactions or infections by pathogenic microorganisms.
In spite of the above-mentioned beneficial effects of these probiotics, as the bacteria that may be administered for treating gastrointestinal disorders also have preferred adhesion and/or growing sites in the gastrointestinal tract, and these sites may be different from the growing sites of the deleterious microorganisms to be controlled, administration of certain types of probiotic bacteria may not be of help against certain types of gastrointestinal infections.
Thus, Lactobacillus, Lactococcus , or Micrococcus may be located in the mouth, and preferably in the small intestine extending even to the ileum. Accordingly, administration of these bacterial genera will not be of great use against infections by pathogenic microorganisms, such as E. coli, Salmonella, Clostridium, Shigella , and Campylobacter , because they develop in other parts of the gastrointestinal tract, such as the colon.
On the other hand, biphidobacteria and enterococci grow in the anaerobic part of the gastrointestinal tract. Biphidobacteria are preferably located in the colon. Species of Enterococcus are preferably located in ileum and colon.
Another difficulty observed with many strains of enterococci useful as probiotics (for example, E. faecium ), is that they show a natural resistance to the antibiotics of clinical use in man. Currently, the trend is not to incorporate bacteria with multiple resistance to antibiotics as additives of food products. There is a possibility of transferring said resistance to saprophytic bacteria colonizing the intestine. In addition, due to a condition of immunosupression (AIDS; chemotherapy in cancer, congenital immunologic dyscrasia, etc) or to an abdominal trauma, this antibiotic resistant probiotic bacteria that colonized the intestine may advance to the peritoneum or to the blood and originate infections difficult to treat due to their multi-resistance.
Accordingly, there persists a need for providing a therapeutic method as an alternative to prescription of highly efficient antibiotics and which would work in acute, as well as preventive, treatment scenarios with inhibitory activity against pathogenic bacteria, including those that are resistant to those antibiotics currently used for infections in humans and animals. In addition, the new agent should have inhibitory activity against other pathogenic organisms such as parasites and fungi.
There is also a need for this therapeutic method to be efficient against infections by pathogenic microorganisms not localized in those parts of the gastrointestinal tract where Biphidobacterium and Lactobacillus are localized, and that it also capable of being administered in combination with antibiotics.
An additional need is to provide a new probiotic strain which is not resistant to antibiotics of clinical use such as glycopeptides (vancomicin, teicoplanine), carbapenemes (impipenem, meropenem) and ampicillin and with a broad inhibitory spectrum against Gram positive and Gram negative bacteria, as well as against other parasitic, fungal and viral pathogens.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows the profile of cell proteins described in Example I.
FIG. 2 shows the cluster analysis of RAPD-PCR patterns generated with M13 and D8635 primers, as described in Example I.
DEPOSIT INFORMATION
An isolated strain of Enterococcus faecalis GALT was deposited in The Spanish Collection of Type Cultures, 46100 Burjassot (Valencia). Spain, as E. faecalis CECT7121, on Dec. 1, 2005
SUMMARY OF THE INVENTION
The present invention is directed to a new strain from the group of lactic bacteria, capable of surviving and colonizing the gastrointestinal tract in humans and/or animals and having a probiotic activity which is beneficial for the health of humans and animals.
Particularly, the invention provides a new strain of enterococci, E. faecalis GALT isolated from a natural corn silage without chemical or biological additives, useful as a probiotic.
Therefore, according to a first aspect of the invention, a new probiotic strain belonging to the group of lactic bacteria, preferably of the genus Enterococcus , is provided. This strain was selected for its ability to survive and colonize the gastrointestinal tract of humans and/or animals, and to exert a beneficial probiotic activity for the health of humans and/or animals.
In another aspect, the invention provides a new probiotic strain from the group of lactic bacteria, preferably a strain of Enterococcus , which is not resistant in vitro to antibiotics of clinical use for this genus.
This selected microorganism has a particular beneficial impact on humans and/or animals, both on their gastrointestinal tract and/or their immune system. It has a particular impact on intestinal pathogens such as strains of Salmonella typhimurium , of Escherichia coli enteropathogens, of Shigella dysenterieae , and other pathogenic enterobacteria capable of infecting man, or parasites such as helminthes ( Toxocara canis ), protozoa ( Cryptosporidium spp, Giardia lambia, Entamoeba histolytica, Toxoplasma gondii, Dientamoeba fragilis ) or yeasts ( Candida spp.).
Therefore, a further aspect of the invention is directed to the use of the bacterial strain E. faecalis GALT and/or of its culture supernatant and/or of its metabolites for the preparation of a composition intended for the treatment and/or prophylaxis of disorders associated with colonization of the gastrointestinal tract by pathogenic microorganisms.
Unless the context clearly indicates otherwise, reference to “strain” is meant to include the strain itself, as well as the culture supernatant and/or a metabolite thereof.
Thus, in another aspect, the invention refers to the use of the bacterial strain E. faecalis GALT and/or a culture supernatant thereof and/or a metabolite thereof, for preparing a composition intended for use as a regulator of the immune response in humans and animals.
By the term “regulator of the immune response” is meant a bacterial strain as defined herein and/or a culture supernatant thereof and/or its metabolites capable of stimulating certain immune functions which are important for the health of humans and/or animals, or to modulate other immune functions that could potentially be involved in immune disorders, such as inflammation, allergy, etc.
The microorganism of the invention shows bioprotective activity with fermented and non-fermented plant, milk and meat food products.
Thus, according to another aspect, the invention is directed to the use of the isolated strain E. faecalis GALT and/or a culture supernatant thereof and/or a metabolite thereof, for food preservation, comprising adding a sufficient amount of the isolated strain E. faecalis GALT to the food product to be efficient as a bioprotector.
The invention also provides a method for maintaining or improving the health of the gastrointestinal tract, or of the immune system of humans and/or animals comprising the step of administering to said subject a composition containing the isolated strain E. faecalis GALT.
Further, the invention provides a method for the treatment and/or prophylaxis of disorders associated with colonization of the gastrointestinal tract of humans and/or animals by pathogenic microorganisms, comprising the step of administering to said man or animal a food or feed composition containing the isolated strain E. faecalis GALT.
The invention also provides a method for regulating the immune response in humans and/or animals, comprising the step of administering to a man and/or animal a composition containing at least the isolated strain E. faecalis GALT according to the present invention.
According to still another aspect, the invention is related to a method for preserving food consisting in adding a sufficient amount of the isolated strain E. faecalis GALT and/or a culture supernatant thereof and/or a metabolite thereof as a bioprotector.
Combined with food, the beneficial probiotic effects of this microorganism consist particularly in a pleasant flavor, a healthy digestion and intestines, and improvements in the immune function.
Thus, according to still another aspect, the invention is related to a food composition comprising the strain E. faecalis GALT having high probiotic activity in humans and/or animals and capable of surviving and colonizing the gastrointestinal tract of humans and/or animals ingesting it.
Accordingly, the invention is related to a food composition intended for the treatment and/or prophylaxis of disorders associated with colonization of the gastrointestinal tract of humans and/or animals, containing the isolated probiotic strain E. faecalis GALT and/or a culture supernatant thereof and/or a metabolite thereof, associated with an edible carrier or a pharmaceutical matrix.
Also, the invention is related to a food composition intended for regulating the immune response in humans and/or animals, containing the isolated strain E. faecalis GALT and/or a culture supernatant thereof and/or a metabolite thereof, associated with an edible carrier or a pharmaceutical matrix.
In a further aspect, the invention provides a bioprotective food composition containing the isolated probiotic strain E. faecalis GALT and/or a culture supernatant thereof and/or a metabolite thereof, associated with an edible carrier or a pharmaceutical matrix.
The food composition preferably contains a sufficient amount of the isolated strain, E. faecalis GALT and/or a culture supernatant thereof and/or a metabolite thereof, to be efficient at providing said prophylactic effect when the composition is administered to a human or animal.
DETAILED DESCRIPTION OF THE INVENTION
The presence in corn silage of lactic bacteria capable of surviving and colonizing the gastrointestinal tract of humans and/or animals, and of providing a beneficial probiotic activity for the health of a human or an animal, was investigated. These bacterial strains show good adhesion to the mucosal cells of the small intestine.
Three strains of Lactobacillus and four strains of Enterococcus faecalis were screened for “bacteriocine” type compounds. The strain of E. faecalis designated GALT was further investigated.
The strain of the invention does not have hemolysins that destroy red blood cells of human (4 blood types), sheep and horse origin. It does not produce gelatinase, Dnase, and decarboxylases (Example 1 (a)-(b)).
The strain E. faecalis GALT of the invention produces a protein-type antimicrobial substance (broad spectrum inhibitory bacteriocine). The inhibitory component, partially purified enterocine designated EPP, was obtained by precipitation with ammonium sulphate, and after elution with Sep-Pak 018. EPP it was heat-inactivated during 15 min at 121° C. or by treatment with 2-mercaptoethanol as well as with Triton X-100. EPP is partially hydrophobic and further maintains its activity in the range of pH 4-8. EPP has a molecular mass of 5,000 Da.
EPP showed bactericidal action on L. monocytogenes, S. aureus , Gram positive strains resistant to antibiotics of clinical use and bovine-mastitis producing strains. Further, EPP showed bacteriostatic action on different strains of E. coli.
When analyzed by RP-HPLC cromatography, EPP shows inhibitory activity in the sample eluted with 40% acetonitrile. The strain E. faecalis GALT of the invention is a saprophytic environment lactic bacterium, without virulence factors; i.e. it does not produce proteases and hemolysines, it does not show antibiotic multiresistance, and has in vitro inhibitory activity against numerous strains of Gram positive bacteria such as Listeria monocytogenes, Staphylococcus aureus, Streptococcus pneumoniae, Enterococcus faecalis ( E. faecalis GALT shows immunity to its inhibitory activity), E. faecium, E. durans, E. gallinarum - casseliflavus, Str. agalactiae, Str. dysgalactiae, Str. uberis, Clostridium perfringens, C. sporogenes, Bacillus subtilis , and B. cereus . It also acts against some Gram negative bacteria such as certain strains of E. coli, Shigella sonnei , and Shigella fexneri . However, the lactic acid bacteria used as starters in fermented food such as certain strains of Lactobacillus, Leuconostoc , and Pediococcus are resistant to the action of E. faecalis GALT strain (Example II).
Further, it shows inhibitory action against Gram-positive strains with multi-resistance to antibiotics and also against the most important agents of bovine mastitis and endometritis in mares.
In this way, the strain of the invention may form a protecting barrier against pathogenic bacteria such as the different types of intestinal pathogens of Escherichia coli, Salmonella spp, Staphylococcus aureus, Candida spp, as well as against parasitic infections by Toxocara canis, Giardia lambia, Entamoeba spp, Cryptosporidium . spp.
The strain of the invention is also characterized in that it does not show multi-resistance in vitro to commonly used antibiotics in human clinics such as ampicillin, vancomycin, teicoplanine, tetracycline, and chloramphenicol. It has not a high level of resistance to gentamycin (120 μg) and streptomycin (300 μg) (Example 1 (c)).
The strain E. faecalis GALT of the invention may be used in any therapy either for preventing colonization by harmful organisms; or for reestablishing gastrointestinal flora after antibiotic treatment. When E. faecalis GALT is ingested at a high concentration by humans and/or animals, this bacterium colonizes the intestine creating the necessary environment for a useful and homogeneous flora. Administration of E. faecalis GALT to said human and/or animal may also act against the deleterious effects of antibiotics, as well as complete the recovery of humans and animals, avoiding recycling of intestinal bacteria in the case of diarrheas. On the other hand, it prevents contagion of pulmonary diseases in weak humans and animals, for example those recently weaned or separated from their mother (pig breeding)
An early investigation on the potential uses of probiotics was carried out in vitro and consisted in the study of tolerance to gastric acidity with various pH values (Example 1 (d)) and different concentrations of bile salts encountered in the duodenum (Example 1 (e)). Assays show that E. faecalis GALT is able to survive the acid environment of the stomach, and the presence of bile salts and the digestive process.
The strain E. faecalis GALT according to the invention colonizes raw food of different animal origin and resists adverse environmental conditions (heat, pH acids, high NaCl concentrations) and may survive in fermented products. (Examples 2-4). In this way, it plays an important role in the natural preservation of meat products by controlling the development of various pathogenic or harmful bacteria (coliforms, staphylococci). The strain tolerates the relatively high salt concentrations of meat products and develops in the presence of nitrite and relatively low temperatures, showing a great resistance to technological processes.
Biological preservation of food is an important alternative to preservation with non-biodegradable chemical compounds, which may be toxic to humans. In this way, the strain of the invention may be included in food products as a biological preservative, thus avoiding the use of non-biodegradable chemical preservatives that are toxic to humans.
Also, the strain according to the invention may be incorporated into food products, thus forming a new kind of functional food product, as it is an enriched food providing not only nutritional benefits to those ingesting it but also other advantages allowing for better health conditions. E. faecalis GALT according to the invention colonizes the intestine thereby positively modifying the intestinal flora and improving the immune system function and, accordingly, the general health of the organism.
The strain E. faecalis GALT of the invention acts not only on innate immunity, as other probiotic strains, but also on specific or acquired immunity. E. faecalis GALT activates peritoneal macrophages in culture and induces production of both IL-12 and IL-10. E. faecalis GALT can also establish a good balance between anti-inflammatory cytokine IL-10 and pro-anti-inflammatory IL-12 (either suppressing inflammatory responses or enhancing them) in order to maintain such an important function as immune homeostasis in the host. When E. faecalis GALT is pre-administered intragastrically in immunized mice with bacterial vaccines (Diphtheria-Tetanus-Pertussis), it produces an increase of the proliferative response memory of specific T lymphocytes thus stimulating the production of type Th1 (INF-γ) and Th2 (IL-5).
The invention will be described with more detail by reference to the following examples of different embodiments, but the invention is in no way to be considered as limited to any specific embodiments.
EXAMPLE I
Biochemical Characterization of Enterococcus faecalis GALT
a) Hemolytic Activity
The study of hemolytic activity of E. faecalis GALT was carried out using human (all four blood types), ram and horse red blood cells. A E. faecalis GALT culture of 18 h in brain-heart infusion was used for isolations on base agar Columbia supplemented with blood of different origin (5%, v/v), Plaques were incubated under anaerobic conditions (Gas-Pack system) at 35° C., and monitored for 24 h and 72 h after incubation. Surrounding the colonies, the presence of a clear zone of hydrolysis (β hemolysis), partial action (α hemolysis) or absence of hemolytic activity (γ hemolysis) were analyzed. The strain E. faecalis GALT did not hydrolyze red blood cells of different origin (γ hemolysis) which is why there is no production of hemolysins.
b) Production of Gelatinase
The production of gelatinase by E. faecalis GALT was determined by addition of mercurial chloride to a culture on agar with gelatin. The study of the production of thermonucleases, such as DNAse, was carried out according to Giraffa et al. (1995) from a culture of E. faecalis GALT in Todd Hewitt broth with 1% yeast extract and boiled broth (boiled broth culture). Decarboxylases were evaluated according to the method of Joosten and Northolt (1989), Detection, growth, and amine-producing capacity of lactobacilli in cheese. Appl. Environ. Microbiol. 55, 2356-2359, modified by Maijala (1993), Formation of histamine and tyramine by some lactic acid bacteria in MRS-broth and modified decarboxylation agar. Letters in Applied Microbiology 17, 40-43. The following amino acids were used: ornithine, histidine, tryptophan, lysine, phenylalanine, and tyrosine. Gelatinase, DNase, decarboxylases were not detected in the strain E. faecalis GALT according to the invention.
c) Resistance to Antibiotics
The study of resistance of E. faecalis GALT to antibiotics was carried out using the diffusion through agar technique with monodiscs (Lab. Britania): ampicillin (10 μg), gentamicin (120 μg), streptomycin (300 μg), erythromycin (15 μg), vancomycin (30 μg), teicoplanine (30 μg), tetracycline (30 μg), chloramphenicol (30 μg), using Mueller-Hinton agar as culture medium (NCCLS, 2004). The production of the beta-lactamase enzyme (Nitrocefin) was also investigated. E. faecalis GALT does not show resistance in vitro to the above-mentioned antibiotics, except for erythromycin. The strain E. faecalis GALT according to the invention does not produce beta-lactamasa enzyme.
d) Resistance to Human Fluids—Gastric Acidity
The survival of E. faecalis GALT at pH 2.5 was measured in the study of tolerance to gastric pH. E. faecalis GALT cultures in brain-heart infusion at pH 7.3 and at pH 2.5 (approximate count at 10 7 UFC/ml) were used.
In the course of incubation during 8 h at 35° C., the value of optic density (A620) was measured and at 1 h intervals, and the population of viable bacteria was evaluated at pH 2.5 using brain-heart agar (24 h at 35° C.). It was determined that the viable population of E. faecalis GALT decreased to a value of 6.53 log UFC/ml after 7 h of incubation when the pH of the culture was of 2.5.
Experiments were carried out twice in duplicate.
The assays show that E. faecalis GALT is capable of surviving the acid environment of the stomach, in the presence of bile salts and the digestive process, and is capable of colonizing the intestine.
e) Resistance to Human Fluids—Bile Salts
0.1 ml of a culture of the strain E. faecalis GALT was inoculated after 18 hours in brain-heart infusion into a medium with agar, bile (40%) and esculin; growth and attack on esculin were observed after 18 h of incubation under normal atmosphere at 35° C.
The strain E. faecalis GALT of the invention grew rapidly and was darkened by esculin. Therefore, the strain E. faecalis GALT of the invention shows tolerance to bile (40%).
f) Whole Cell Protein Profile
As an additional phenotypical characterization, a whole cell protein SDS-PAGE profile (WCP) was carried out (Merquior et al., 1994). The relationship between the profiles corresponding to E. faecalis CECT7121 and E. faecalis ATCC 29212 (reference strain) was studied by densitometric analysis employing Image Pro and Origin 6.0 software (Germany). Homology percentage values were calculated using Dice's coefficient (Dice, 1945). E. faecalis CECT7121 presented a protein profile with aprox. a 78.5% homology with the E. faecalis ATCC29212 strain ( FIG. 1 ). The whole protein cell profiling study confirmed the strain E, faecalis CECT7121 at the species level and showed its characteristic WCP.
FIG. 1 shows the profile of cell proteins (SDS-PAGE)
g) Polymerase Chain Reaction Using Random Amplified Polymorphic DNA (RAPD-PCR)
RAPD-PCR (polymerase chain reaction using random amplified polymorphic DNA) patterns proved to be useful for species identification and for the detection of inter-strain variations.
The chromosomic DNA profile was analyzed from isolates of different culture media of strain E. faecalis CECT7121 by RAPD-PCR and compared to other strains of Enterococcus of clinic origin ( E. faecalis EVR2000) and collection ( E. faecalis ATCC 29212) grown in brain heart infusion.
DNA was extracted according to the method of Persing et al. (1993), Diagnostic Molecular Biology, Principles and Application. Washington D.C.: ASM. The random primers used for DNA amplification in concordance with Suzzi et al. (2001), A survey of the enterococci isolated from an artisanal Italian goat's cheese (semicotto caprino) J. Appl. Microbial., 89, 267-274, were:
1- M13:
5′ GAGGGTGGCGGTTCT 3′ (SEQ ID NO: 1)
2- D8635:
5′ GAGCGGCCAAAGGGAGCAGAC 3′(SEQ ID NO: 2)
Amplification, electrophoresis, pattern recognition, and normalization were performed as described previously by Suzzi et al. (2001). For each strain, the normalized profiles obtained with the four different primers were assembled one after the other into a combined profile using Gel Compar version 4.1 software. These combined patterns were imported into the Bionumerics version 1.5 software (Applied Maths) and were analyzed by using the Pearson product moment correlation coefficient and the unweighted pair group with mathematical average clustering algorithm (UPGMA).
Culture Media Used with E. faecalis CECT7121
1—brain heart infusion (Lab. Britania, Argentina)
2—triptic soy broth (Lab. Britania, Argentina)
3—skim milk 10% (p/v) (Difco, USA)
4—M17 broth (Difco, USA)
5—MRS broth (Lab. Britania, Argentina)
6—Mueller Hinton broth (Lab. Britania, Argentina)
The results obtained were:
RAPD-PCR D8635:
2. Isolates of E. faecalis CECT7121 strains from different isolation media showed identical profiles.
3. Non-related isolates E. faecalis ATCC 29212 and E. faecalis EVR 2000 were detected, having a similarity percent of less than 60%.
RAPD-PCR M13:
The results obtained by this method were redundant to those obtained by RAPD-PCR D8635.
With the methods employed it was possible to discriminate non-related isolates with a low percentage of similitude, and to pool all the isolates of E. faecalis CECT7121 from different isolation media having an identical profile with a similarity percent of 100% (taking both methods into account).
FIG. 2 . shows the cluster analysis of RAPD-PCR patterns generated with M13 and D8635 primers
EXAMPLE II
In Vitro Antibacterial Activity of E. faecalis GALT
Screening for inhibitory activity was carried out using a modified version of the “double layer technique” (Tagg et al., 1975, Bacteriocins of Gram-positive bacteria. Bacteriol. Rev. 40, 722-756). E. faecalis GALT cultures were assayed after 18 h incubation in brain-heart infusion. Plates with brain-heart, previously inoculated with 5 μl of material, were incubated under anaerobic conditions (24 h at 30° C.). Then, each plate was covered with 7 ml soft agar (7 g/L) inoculated with 0.1 ml of the indicator strain (about 10 7 UFC/ml). Plates were incubated during 18 h, under aerobic or anaerobic conditions, according to the requirements of the indicator strain.
The strain E. faecalis GALT showed in vitro inhibitory activity against Gram-positive bacteria: Listeria monocytogenes, Staphylococcus aureus, Streptococcus pneumoniae, E. faecium, E. durans, E. gallinarum - casseliflavus, Str. agalactiae, Str, dysgalactiae, Str. uberis, Clostridium perfringens, C. sporogenes, Bacillus subtilis , and B. cereus . It also showed activity against some Gram-negative bacteria, such as certain strains of E. coli, Shigella sonnei , and Shigella fexneri . However, the lactic acid bacteria used as starters in fermented food, such as certain strains of Lactobacillus, Leuconostoc , and Pediococcus , are resistant to the action of E. faecalis GALT.
EXAMPLE III
Bactericidal Effect of E. faecalis GALT on L. monocytogenes in Goat Milk
In order to analyze the effect of this strain on deteriorating or pathogenic bacteria present in milk, the inhibitory activity on the pathogen L. monocytogenes resistant to environmental conditions was used as a model.
The inhibitory ability of E. faecalis GALT was investigated when competing with autochthonous bacteria of goat milk, against L. monocytogenes CEB 101 and L. monocytogenes ATCC 49594 (derived from the strain Scott A, which in studies carried out by other authors in milk and cheese, showed higher resistance to the inhibitory action of enterocin-producing strains). The system employed in the research excluded the influence of other inhibitory factors such as very acid pH and hydrogen peroxide.
For the production of the inhibitory component, a culture incubated 18 h at 35° C. of E. faecalis GALT in brain-heart infusion was centrifuged at 10,000×g during 10 min and suspended in an equal volume of PBS. Raw goat milk was skimmed at 35° C. by centrifugation in aliquots of 250 ml which were inoculated with 1% and 2% (v/v) of a suspension of E. faecalis GALT. In order to allow for the competition between autochthonous bacteria of milk and the inoculated strain, mixtures were incubated at 30° C. during 9 h.
For the inhibition studies of L. monocytogenes , the different aliquots of goat milk inoculated with E. faecalis GALT (1% and 2%), were acidified to a pH of 4.2 with 1N HCl to curdle the caseins, and centrifuged at 20,000×g during 15 min. Each supernatant was filtered with a 0.22 μm diameter membrane (Millipore) and pH was adjusted at 6.0 with 1N NaOH. Fractions of 10 ml of this filtrate were obtained and inoculated with L. monocytogenes CEB 101 and ATCC 49594 to obtain a final count of viables of about 10 4 UFC/ml. Catalase (150 Ul/flip was added to the inoculated filtrates and they were incubated during 24 h at 30° C.
Then, the two strains of L. monocytogenes were isolated and enumerated from selective Oxford agar (Oxoid), at 30° C. during 48 h.
Inhibition studies were also carried out with 10 strains of wild-type L. monocytogenes isolated over the last five years from raw goat milk (GM) obtained from different farms where home-made semihard cheese is manufactured (Buenos Aires Province).
Each strain was inoculated in 10 ml of 2% E. faecalis GALT filtrate, previously incubated during 9 h at 30° C. After 24 h of incubation with the filtrate, each strain was measured.
Also, the inhibition test in the strains of wild-type L. monocytogenes was carried out with the 2% E. faecalis GALT filtrate and using the well diffusion technique.
All the strains of Listeria came from a culture grown to logarithmic phase, in brain-heart infusion incubated at 30° C. All experiments were repeated 3 times, in duplicate, and the results were statistically analyzed using Student's t test.
When the inhibitory effect of the filtrate against Listeria monocytogenes ATCC 49594 and CEB 101 was analyzed, the decrease of viable counts observed in L. monocytogenes ATCC 49594 and CEB101 was significantly and directly influenced (p<0.001) by the inoculum of 2% E. faecalis GALT strain, wherein the decrease of viables in both strains of Listeria was greater than 2.5 log UFC/ml and in L. monocytogenes CEB101, 3.25 log UFC/ml.
The 10 wild-type strains recovered from different farming facilities were sensitive to the action of the E. faecalis GALT filtrate when inoculated at 2% and previously incubated during 9 h at 30° C.; diameters of inhibition obtained by the well diffusion technique varied from 11.3 and 12.9 mm.
Count variations were significant for all strains when incubated during 24 h (p<0.01).
The decrease of the viable population was greater than 1.8 log UFC/ml for all wild-type strains under study.
Inoculation of raw goat milk with a 2% suspension of E. faecalis GALT could control the growth of diverse strains of L. monocytogenes recovered from raw milk intended for use as starting material for home-made cheese.
The strain E. faecalis GALT competed with the native microorganisms from goat milk, that was a favorable substrate for the production of inhibitory activity.
In these experiments, inhibitory factors, such as lactic acid, acid pH, and hydrogen peroxide, were eliminated by neutralizing the milk cultures and by the use of catalase.
The strain E. faecalis GALT was able to compete with the native microorganisms from goat and cow milk and showed bactericide activity against L. monocytogenes , a contaminating pathogen resistant to environmental conditions present in goat and cow milk. The system excluded the influence of other inhibitory factors such as very acid pH, lactic acid and hydrogen peroxide.
EXAMPLE IV
Inhibitory Activity of E. faecalis GALT Against Bacterial Flora of Ready-To-Eat Vegetables
The effect of the addition of E. faecalis GALT on the growth dynamics of bacteria associated to ready-to-eat vegetables was analyzed during storage at 8° C.
A 9 h culture of E. faecalis GALT in brain-heart infusion was centrifuged during 10 min at 10000×g. It was washed and suspended in Ringer solution and added to 3 different mixtures of vegetables so as to obtain a final count of about 106 UFC/g. For each salad variety a control group was established using Ringer solution.
The trays containing ready-to-eat vegetables were covered with polyethylene film, under a normal atmosphere. Each of them had a shelf life of 5 days. Trays were obtained from 2 supermarket gondolas, one day after packaging. They were transported refrigerated to the laboratory and opened immediately, mixed and divided into different groups for further study.
Three varieties of salads were analyzed:
A. 10 trays (320 g each) with white cabbage, red cabbage and carrot. B. 10 trays (320 g each) with red cabbage, celery and carrot. C. 10 trays (320 g each) with celery, collard and radicchio.
For each salad variety, contents of trays were mixed and distributed in polypropylene bags stored at 8° C. (500-per bag). These were divided into two groups: inoculated with E. faecalis GALT and control without addition of this strain, three bags in each group. Bacterial counts were carried out for each mixture at different times: one day after manufacture (0) and 2, 4, and 7 days later.
For the bacterial count, 25 g of each group of vegetables were mixed with 250 ml of Ringer solution and homogenized during 2 minutes (Stomacher Lab-Blender 400). After ten-fold dilutions, counting was carried out in plates by duplicate in different media. For total viable mesophilic aerobic bacteria (TVMAB) casein agar, peptone, glucose, yeast extract was used; for enterococci, fGCTC agar; for lactic acid bacteria, fresh MRS agar with the addition of 0.02% p/v sodium azida and 200 ppm of cycloheximide; for total coliform (TC) and fecal (FC) bacteria: crystal violet-red-neutro-bile-glucose agar, with incubation during 24 h under aerobic conditions, at 37° C. and at 44° C., respectively; for S. aureus , base Baird Parker agar with emulsion of egg yolk and tellurite.
Determination of pH was carried out at 0, 2, 4, and 7 days of storage using a portable pH meter (Orion Research, Inc., model 610). Statistical analysis of the data was performed giving priority to the two-factor ANOVA test for group and time. SPSS 10.0 software was used, except for the test of simple effects, performed with Excel.
E. faecalis GALT has inhibitory activity against the deteriorating bacterial flora (total coliforms and fecal, staphylococci) present in ready-to-eat vegetables during storage at 8° C.
EXAMPLE V
E. faecalis GALT as Biopreservative in Fermented Meat Products
In the food industry, the lactic bacteria used as protecting cultures must be able to adapt to prevailing conditions in the corresponding product and should also have competitive ability. In most meat products, lactic bacteria must tolerate nitrite concentrations and relatively low temperatures.
Enterococci colonize raw food of different animal origin and resist adverse ambient conditions (heat, acid pH, high concentrations of NaCl). In fermented products, enterococci survive and may multiply, thus competing with the bacteria used as “starters”.
In fermented meat products, the most important microbiota is comprised by diverse lactobacilli species ( L. sakei, L. curvatus , and L. plantarum ), coagulase-negative staphylococci and E. faecium.
Bacteriocin-producing enterococci strains can play an important role in natural preservation of meat products by controlling the growth of different pathogenic or deteriorating bacteria.
Salamin is characterized as a thin cured dry sausage that has been subjected to partial dehydration process to favor long-term preservation.
The evolution of the most representative bacterial groups was studied during the manufacturing process of home-made salamin in a small establishment near de city of Tandil. Variation of pH and lactic acid were also analyzed.
Two batches of salamin were manufactured: one inoculated with E. faecalis GALT and one control batch. The mixture was cold-grinded (−1° C.) and stuffed in collagen casing. Then the salamins were taken to a drying chamber with temperature and moisture controlled at 18-20° C. and 90-95%, respectively, until the pH reached a value of 5.1.
Then the temperature was set at 12-14° C. and the moisture at 70-80% until curing was completed.
Inoculation: salamins were inoculated with 106 UFC/ml E. faecalis GALT obtained from an 18 h culture in brain-heart infusion and further centrifugation and washing of bacterial sediment with 8.5 g/l NaCl.
Sampling: sampling for the bacteriologic and lactic acid analysis was carried out at the following times: 0 (after stuffing); end of drying (ED; pH 5.1); 7 days and end of curing (EC; 21 days).
Microbiological Analysis: 15 g aliquots of salamin were homogenized with a “Stomacher 400” (Lab System) during 2 min with 135 ml of sterile diluent (1 g/L bacto-peptone (Disco), 8 g/L NaCl (Merck), pH 7.0). Seeding was performed from a decimal dilution series in different selective media for counting of bacterial groups.
a) Enterobacteriaceae
Deep seeding was performed in crystal violet-red-neutro-bile-glucose agar (VRBG; Merck). After 24 h of incubation at 30° C., violet colonies surrounded by a precipitation haze (positives) were confirmed by Gram staining and cytochrome oxydase and catalase biochemical tests.
b) Micrococcaceae
Agar plates with salt and mannitol (Disco) were used for surface seeding. After incubation (25° C., 4-5 days), colonies were confirmed by Gram staining.
c) S. aureus
Petri dishes with Baird-Parker agar and fresh egg-tellurite (Difco) were surface-seeded and incubated at 35° C., 48 h. Black, shiny colonies surrounded by precipitation haze were confirmed by Gram staining and catalase, coagulase, and DNAse assays.
d) Lactobacillus
MRS agar plates were deep-seeded (pH 5.4) using the double layer technique. After incubation at 30° C. during 3 days, confirmation of colonies was performed using Gram staining and catalase.
e) Enterococcus
Counting was carried out in fGCTC agar, with incubation at 35° C. during 24 h. Confirmation of colonies was performed by Gram staining, catalase, growth at 45° C. and hydrolysis of pyrrolidonyl-beta-naphthylamide.
Phenotypic characterization of E. faecalis was carried out for 4 random-selected colonies not showing fluorescence or that did not hydrolyze starch. Monitoring of E. faecalis GALT was performed measuring the inhibitory activity against L. monocytogenes CEB 101 using the double-layer technique.
A search for plasmids was carried out in recovered E. faecalis strains that inhibited the growth of the starter strain.
Determination of pH: pH of samples was determined in similar points of probe insertion (Orion Research Inc.) at time 0 (once stuffing was completed), 15 h, 36 h, 48 h, 60 h, 7 d and 14 d.
Determination of lactic acid: a 5 g sample was thoroughly homogenized in a meat grinder, 20 ml of 1 M perchloric acid was added. It was mixed on magnetic mixer during 10 min and transferred to a beaker containing 40 ml of distilled water, where pH was adjusted to 10-11 with 2N potassium hydroxide, under continuous stirring.
The volume was completed to 100 ml with distilled water. It was cooled during 20 min to separate fats and precipitate potassium perchloride. Finally, it was filtered and determination of lactic acid was performed in solution using the API 50 CHL system (BioMérieux).
For statistical analysis, a two-factor variance analysis was used (group and time). In order to analyze if the variation between different times was group-dependant, the simple effect test was used. The SPSS 10.0 program was employed, except for the test of simple effects, which was performed with Excel. Concentration of enterobacteria turned out to be similar to time zero in both batches. The batch inoculated with E. faecalis GALT showed significantly lower values than the control series during the process: ED (p<0.001), 7 d (p<0.001), and EC (p<0.001). Values for S. aureus in the inoculated batch were low and also lower than the control: ED (p<0.05), 7 d (p<0.005), and EC (p<0.001). Bacterial load decreased only in the inoculated batch during the stuffing process (p<0.01). Bacterial counts of the Micrococcaceae family in the batch inoculated with E. faecalis GALT were lower than control for ED time (p<0.001) and 7 d (p<0.01), but not for other times.
In the case of Lactobacillus , no significant differences were recorded in the number of bacteria in both series during the period of aging. Concentration of enterococci in the control group was significantly higher only for time zero (p<0.01). In the control group, initial counts increased significantly for ED time and then remained constant (p<0.05).
Accordingly, E. faecalis GALT is useful as a biopreservative for fermented meat products.
EXAMPLE VI
Another pre-requisite for a successful research and development of probiotics is the knowledge about indigenous intestinal microflora that offers protection against infections, as a disturbance of this flora might increase susceptibility to infections.
E. faecalis GALT shows no systemic pathogenic power. When inoculated i.p. in mice, its DL50 value was 1 logarithm lower than that for strains belonging to a collection of E. faecalis without known virulence factors.
E. faecalis GALT shows no phenotypical expression of virulence factors, it resists gastric pH, produces a broad spectrum enterocine, and it adheres to and persists on intestinal tissue of BALB/c mice.
E. faecalis GALT protects against challenges with Salmonella enteriditis serotype. The probiotic ability of E. faecalis GALT is shown in studies carried out using BALB/c mice (n=10) inoculated i.g. during 6 days with 200 μg of E. faecalis GALT (3×10 8 cells/ml) and challenged i.g. with 200 μg of Salmonella enteriditis serotype (5×10 4 cells/ml). Animals of the study group and control group (physiologic solution) were observed during 15 days. In intestines of mice from the control group, 8.37 log UFC/g of S. Enteriditis serotype were counted and an important displacement of coliform authochtonous bacteria was observed with no detection of E. coli . In those who received E. faecalis GALT before the challenge, no pathogenic strain was detected (counts in Salmonella - Shigella agar) but presence of enterococci (4.21 log UCF/g) and coliform (7.25 log UFC/g) was observed. These observations are consistent with the death of all mice belonging to the control group and survival of all the animals that received E. faecalis GALT. The results show the ability of E. faecalis GALT as it was innocuous and protected a 100% of animals against challenge with S. Enteriditis serotype.
E. faecalis GALT protects against challenges with E. coli 0157H7 (using the same model).
E. faecalis GALT protects against challenges with Shigella sonnei (using the same model).
E. faecalis GALT protects against challenges with Shigella fexneri (using the same model).
E. faecalis GALT protects against challenges with eggs from Toxocara canis.
Ten male Swiss mice were used for each group of inoculated and control. Obtention of embryonated Toxocara canis eggs: eggs were incubated in a solution of 0.1N sulphuric acid and 1% formalin during 40 days at room temperature (Oshima technique, 1976). Challenge was performed inoculating mice with 100 embryonated T. canis eggs.
Mice were sacrificed 48 h after the challenge. The intestinal implant of E. faecalis GALT was analyzed, as described for the previous protocol, and the presence of T. canis in lung was investigated. No T. canis was detected in lungs of mice protected with E. faecalis GALT.
EXAMPLE VII
Modulation Studies for Specific Immune Response
a) Inhibition Assays for Proliferation of T lymphocytes
It is well-known that there exist differences between the action of commensal and pathogenic bacteria on cells from the immune system. Common bacteria from the intestinal tract do not stimulate proliferation of mononuclear cells and play an important role in maintaining hyporeactivity to foreign antigens. On the contrary, pathogenic bacteria activate immune cells present in their entrance pathway and therefore favor their proliferation and triggering of an inflammatory reaction.
When the activity of E. faecalis GALT on a culture of splenic T lymphocytes was analyzed in BALB/c mice, the proliferative level of Concavaline A (ConA, mitogen) stimulated lymphocytes was higher than when stimulated with a mixture of E. faecalis GALT and Con A (p<0.001). These results show the inhibitory activity of E. faecalis GALT on the proliferative action of the Con A mitogen on T lymphocytes.
b) Cytokine Induction Assays
E. faecalis GALT induces production of pro-inflammatory as well as anti-inflammatory type cytokines on a culture of peritoneal macrophages.
An efficient control of microbial infections not only requires immune activation after pathogenic invasion, but also demands the onset of appropriate unique immune responses generated for a certain group of pathogens. Thus, certain infections require Th1-type responses, while others may be better controlled with a Th2-type immunity. Antigen presenting cells (dendritic, macrophages, and others) may adjust the balance of Th1-Th2 according to the results of their interactions with cytokine IL-10 and IL-12 differentially producing-microbes. IL-10 is related to the priming of Th2 response, while IL-12 potentially induces interferon-gamma producing Th1 cells (INF-γ).
In order to examine the stimulating effect of E. faecalis GALT on peritoneal macrophages in culture, the ability of these cells to produce pro-inflammatory and anti-inflammatory cytokines was evaluated. The presence of IL-6, IL-10, and IL-12p40 (ELISA) was evaluated in supernatants of cultures stimulated with E. faecalis GALT (5×10 5 -5×10 7 cells/ml) and incubated for 24 hours at 37° C. and 5% of CO 2 .
E. faecalis GALT induced, depending on stimulus concentration, the production of IL-10, IL-12, IL-6, but no of IL-18. The results achieved indicate that E. faecalis GALT is an excellent candidate to be used as a modulator of the immune response as it induces production of IL-12 (inflammatory response) as well as of IL-10 (anti-inflammatory response).
E. faecalis GALT, when preadministered intragastrically in mice further immunized with bacterial vaccines (Diphtheria-Tetanus-Pertussis), induces an increase of the proliferative response memory of specific T lymphocytes by stimulating the production of type Th1 (INF-γ) and Th2 (IL-5) cytokines.
c) Inhibition of Proliferation of Myeloma Cell Line Assays.
The effect of E. faecalis GALT on the proliferation of myeloma cell line P3×63-Ag8.653 (tumoral cells) and Vero cells was comparatively established. The myeloma cell line P3×63-Ag8.653 was grown in RPMI1640 medium supplemented with 15% of bovine fetal serum, 50 IU ml −1 of penicillin, 50 mg ml −1 of streptomycin and 1% of L-glutamine. Vero cells were grown in Dulbeccois Modified Eagle medium supplemented with 10% bovine fetal serum, 50 IU ml −1 of penicillin, 50 mg ml −1 of streptomycin and 1% of L-glutamine. Cell cultures were incubated at 37° C. and 100% of humidity in an atmosphere with 5% of CO 2 . A cell proliferation kit (Roche Molecular Biochemicals) was used to study strain effect of the strains (10 6 , 10 7 and 10 8 UFC ml-1) on myeloma cell proliferation. The MTT assay was performed in 48-well microtiter plates and the optic density of each well was measured at 620 and 690 nm. The results were satistically analyzed.
The results of the MTT assays showed that, independently from the dose employed, the E. faecalis GALT strain did not modify the proliferation level of Vero cells. However, E. faecalis GALT inhibits proliferation of myeloma cells up to a 75%, in a direct dose-dependant fashion of bacteria used in the MTT assay.
d). Immunomodulatory Effect
The effect of E. faecalis CECT7121 on proliferation of murine LBC T lymphoma was analyzed. To this end, LBC cells (5.10 5 cells/ml, 100 ul) were incubated with an equal volume of RPMI (control), heat-killed E. faecalis CECT7121, heat-killed E. faecalis CECT7121 without plasmid (cured E. faecalis CECT7121) both in a range of concentrations of 5.10 2 -5.10 8 UFC/ml, o with an E. faecalis CECT7121 lysate (20 μg/ml). Cell proliferation was determined by incorporation of 3 H thymidine after 24 hs of culture. LBC cell proliferation was inhibited by the E. faecalis CECT7121 lysate (p<0.05, ANOVA), by E. faecalis CECT7121 at 5.10°-5.10 8 UFC/ml (p<0.01) and by cured E. faecalis CECT7121 5.10 8 UFC/ml (p<0.01, ANOVA). The correlation between the observed inhibition of proliferation and induction of apoptosis was verified using agarose gels for detecting nucleosomal DNA fragmentation and staining with acrydine orange and ethidium bromide. These results indicate that E. faecalis CECT7121 has an antiproliferative effect on the LBC cell line and induces apoptosis of tumoral cells. This effect would be mediated not only by the structure of the E. faecalis CECT7121 cell wall, but also to some extent by plasmid-encoded molecules.
EXAMPLE VIII
Vehiculization of E. faecalis CECT7121 Bacteriocin for its Addition to Food
In order to consider Bacteriocin production useful at industrial level, it is considered essential that the growing substrate for the production strain for producing said bacteriocin is of food grade and low cost. Based on this, subproducts from the dairy industry may be used as alternative growth and production media.
Development and production of bacteriocin in lactoserum and lactalbumin (from cheese manufacturers and commercial lyophilizates) were tested in E. faecalis CECT7121
Drying (electrospray, ultrafiltration) of preparations was also performed in order to achieve a greater stabilization of the same.
Formulations:
Production of bacteriocin in:
Lactoserum
Lactalbumin
It was established that lactoserum (LS) is a suitable medium for the development and production of bacteriocin in E. faecalis CECT7121. Optimal production conditions are achieved when LS is heated to 110° C. during 10 min before its use. Other conditions that favor bacteriocin production is the addition of 1% glucose and any type of 0.25% peptone. The optimal initial inoculum of the strain in LS is of 4%, with incubation for 18 h at 30° C. without stirring.
Optimal production was achieved with 5% lactalbumin supplemented with 1% glucose, pH stabilized at 6.60 without addition of peptone. The initial inoculum is of 8%, with incubation during 18 h, no stirring.
Although some embodiments and preferred embodiments of the invention are described herein, said embodiments should only be considered as illustrative. It should be evident for those skilled in the art that modifications may be made without departing from the spirit of the invention and the scope of the appended claims.
BIBLIOGRAPHY
Dice L R. Measures of amounts of ecologic association between species 1945 Ecology 26: 297-302.
Merquior V L C, Peralta J M, Facklam R R, Teixeira L M 1994 Analysis of electrophoretic whole-cell protein profiles as a tool for characterization of Enterococcus species. Curr Microbiol, 28:149-153.
Persing, D. H., Smith, T. F., Tanover, F. C. and White, T. J. 1993. Diagnostic Molecular Biology, Principles and Application. Washington D.C.: ASM.
Suzzi G, Caruso M, F. Gardini, A. Lombardi, L. Vannini, M. E. Guerzoni, C. Andrighetto and M. T. Lanorte. 2000. A survey of the enterococci isolated from an artisanal Italian goat's cheese (semicotto caprino) J. Appl. Microbiol., 89, 267-274.
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An isolated strain of Enterococcus faecalis GALT deposited under number CECT 7121 of the group of lactic bacteria is disclosed, which is capable of surviving and colonizing the gastrointestinal tract of humans and/or animals and showing beneficial probiotic activity for the health of humans and animals. The strain E. faecalis GALT and/or a culture supernatant and/or metabolites thereof shows no in vitro multiresistance to antibiotics of common use in human clinics as glycopeptides, such as vancomycin, teicoplanine; carbapenemes, such as impipenem, meropenem; and ampicillin. The strain E. faecalis GALT contains no red blood cell-destroying hemolysins of human, ovine and equine origin; and it does not produce any gelatinase, DNase and decarboxylases.
The strain E. faecalis GALT is useful for the preparation of a composition intended for the treatment and/or prophylaxis of disorders associated with colonization by pathogenic microorganisms of the gastrointestinal tract; for use as a regulator of the immune response in human and animals, as well as for the preparation of a composition.
The invention is also directed to methods and uses of the strain E. faecalis GALT.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to construction materials for upholstery and, more specifically, to a kind of cushion blocks for use in setting a build-up surface, such as wooden flooring, wooden wall or wooden ceiling.
[0003] 2. Description of the Related Art
[0004] Build-up wooden flooring is commonly seen in upholstery. When paving a build-up wooden flooring, wooden strips coupled to one another by engaging the coupling flange of one wooden strip into the coupling groove of another wooden strip and then the flooring board thus obtained is fastened to the floor wall or wooden racks at the floor wall by iron nails. This wooden flooring paving procedure is complicated and time-consuming. Further, the nailing work requires a special technique. Only an experienced person can do the job well. Because wooden strips are fixedly fastened to the floor wall or wooden racks by iron nails and abutted against one another, they cannot expand freely. Therefore, the wooden strips tend to curve upwards or to break when absorbed a certain amount of moisture from the air. Recently, bamboo strips are popularly invited for flooring. However, bamboo strips have relatively higher absorptive power than wooden strips. The curving or breaking problem due to absorption of moisture will occur more easily in bamboo strips.
SUMMARY OF THE INVENTION
[0005] It is one object of the present invention to provide a cushion block for a build-up flooring, wall, ceiling and the like which is easy to install without special techniques and, saves much flooring cost.
[0006] It is another object of the present invention to provide a cushion block for a build-up flooring, wall, ceiling and the like which compensates the expansion of wooden strips due to absorption of moisture.
[0007] To achieve these objects of the present invention, the cushion block comprises a first coupling device at one end thereof, a second coupling device at an opposite end thereof corresponding to the first coupling device, the first coupling device and the second coupling device being made such that multiple cushion blocks are connectable in a line in a linking direction by engaging the first coupling device of one cushion block into the second coupling device of another cushion block, a retaining device protruded from one side thereof and adapted to secure strips to the corresponding side of the cushion block, and a deformable body connected between the first coupling device and the second coupling device and deformable in the linking direction to compensate expansion of strips due to absorption of moisture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a perspective view of a cushion block according to a preferred embodiment of the present invention.
[0009] [0009]FIG. 2 is a top plain view of the cushion block according to the preferred embodiment of the present invention.
[0010] [0010]FIG. 3 is a sectional view taken along line 3 - 3 of FIG. 2.
[0011] [0011]FIG. 4 illustrates the connection of multiple cushion blocks according to the preferred embodiment of the present invention.
[0012] [0012]FIG. 5 is an applied view of the present invention.
[0013] [0013]FIG. 6 is side view in section in an enlarged scale of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Referring to FIG. 1, a cushion block 10 is a flat rectangular block molded from synthetic resin (for example, polyacrylic resin or polyethylene resin) in integrity, having a base 20 disposed at one end, two male coupling devices 40 arranged in parallel at the other end, a deformable body 30 connected between the base 20 and the male coupling devices 40 , two female coupling devices 50 arranged in parallel in an outer side of the base 20 remote from the deformable body 30 , a retaining device 60 located on the top side of the base 20 and spaced between the deformable body 30 and the female coupling devices 50 , and two pairs of springy supporting devices 70 located on the top side of the base 20 and symmetrically disposed at two sides of the retaining device 60 .
[0015] The retaining device 60 projects upwards from the top side of the base 20 . Except the retaining device 60 , the top sides of the other parts of the cushion block 10 are maintained in flush (the springy supporting devices 70 are normally disposed in a sloping position partially protruding over the top side of the base 20 , however they become in flush with the top side of the base 20 when forced downwards).
[0016] According to the present preferred embodiment, the thickness of the cushion block 10 is about 1 cm (the height of the protruding retaining device 60 excluded). The length of the cushion block 10 (i.e., the length front the outer end of the male coupling device 40 to the outer end of the female coupling devices 50 ) is about 10 cm. The width of the cushion block 10 is about 7 cm. For easy understanding of the present invention, the direction passing through the male coupling devices 40 and the female coupling devices 50 is defined as “linking direction”.
[0017] The base 20 is shaped like a flat rectangular block. The deformable body 30 extends outwards from one vertical peripheral side of the base 20 to the male coupling devices 40 opposite to the female coupling devices 50 , and is formed of a latticed grid having rhombic meshes 31 in it. Each rhombic mesh 31 has two opposite acute angles aligned in the linking direction, and two opposite obtuse angles aligned in direction across the linking direction. Further, Each acute angle of each rhombic mesh 31 forms a substantially C-shaped arched portion 32 having the open side facing the inside of the respective rhombic mesh 31 . Because of the latticed grid structural design, the deformable body 30 can be compressed and stretched in the linking direction. Further, the deformable body 30 does not wear easily with use because it is molded from synthetic resin.
[0018] The male coupling devices 40 are respectively outwardly extended from one side of the deformable body 30 remote from the base 20 , each having three vertical positioning ribs 41 symmetrically disposed at two sides, a vertical through hole 42 , and a retaining notch 43 disposed at an outer side at a lower elevation than the top side of the cushion block 10 .
[0019] The female coupling devices 50 are recessed coupling devices formed in the side of the base 20 and extended to one vertical peripheral side of the base 20 opposite to the deformable body 30 and adapted to accommodate the male coupling devices 40 respectively, each having four vertical positioning grooves 51 symmetrically disposed at two sides, and an upright springy hook 52 adapted to engage the retaining notches 43 of the male coupling devices 40 .
[0020] The retaining device 60 is an elongated retaining bar raised from the top side of the base 20 and extending across the linking direction between two opposite vertical peripheral sides of the base 20 . The cross section of the retaining device 60 is a T-shaped cross section, i.e., the retaining device 60 has an elongated top flange 62 , defining two elongated coupling grooves 61 at two sides below the top flange 62 .
[0021] The bottom side of the base 20 is a hollow structure (see FIG. 3). Two springy tongues 72 are formed of a part of the top wall of the base 20 by making two substantially U-shaped crevices 71 in the top wall of the base 20 at two sides of the retaining device 60 . The top side of each springy tongue 72 obliquely upwardly extends from the fixed end toward the free end (see FIG. 3). The crevices 71 and the springy tongues 72 form the aforesaid springy supporting devices 70 .
[0022] Referring to FIG. 4, by means of fastening the male coupling devices 40 of one cushion block 10 to the female coupling devices 50 of another, a plurality of cushion blocks 10 are connected in a series, forming an elongated rack 80 for supporting wooden strips. When fastening the male coupling devices 40 of one cushion block 10 to the female coupling devices 50 of another, the three vertical positioning ribs 41 at one side of each male coupling device 40 can selectively be forced into engagement with the front three or rear three of the corresponding four vertical positioning grooves 51 of the matching female coupling device 50 . Therefore, each two cushion blocks 10 can be alternatively connected between two sizes. After insertion of the respective male coupling devices 40 into the respective female coupling devices 50 , the upright springy hooks 52 of the respective female coupling devices 50 are respectively hooked in the retaining notches 43 of the respective male coupling devices 40 .
[0023] Referring to FIGS. 5 and 6, multiple cushion blocks 10 are used with multiple wooden strips 90 to make a wooden flooring. The wooden trips 90 are rectangular strips, each having a longitudinal coupling tongue 91 and a longitudinal coupling groove 92 respectively extended along the two opposite long sides, two longitudinal. locating grooves 93 respectively extended along the two opposite long sides below the longitudinal coupling tongue 91 and the longitudinal coupling groove 92 , and two longitudinal locating flanges 94 longitudinally disposed in the two opposite long sides below the longitudinal locating grooves 93 . The length of each wooden strip 90 is about 1 meter. The maximum width (including the width of the longitudinal coupling tongue 91 ) of each wooden strip 90 is about 10 cm corresponding to the length of each cushion block 10 . The thickness of each wooden strip 90 is about 1.5 cm.
[0024] When paving the desired down flooring, arrange multiple cushion blocks. 10 into parallel racks 80 at a pitch corresponding to the length of the wooden strips 90 , and then mount the wooden strips 90 on each two adjacent racks 80 , enabling the two ends of the major axis of each wooden strip 90 to be supported on one half of the area of the top side of a respective cushion block 10 between the retaining devices 60 of two symmetrical pairs of cushion blocks 10 . When set into position, the longitudinal coupling tongue 91 of one wooden strip 90 is engaged into the longitudinal coupling groove 92 of another, and the longitudinal locating grooves 93 and longitudinal locating flanges 94 of the wooden strips 90 are respectively forced into engagement with the elongated top flange 62 and elongated coupling grooves 61 of the retaining devices 60 of the cushion blocks 10 . Because the cushion blocks 10 are deformable in the linking direction, inserting one wooden strip 90 in between the retaining devices 60 of two cushion blocks 10 causes the two cushion blocks 10 to be reversely expanded outwards in the linking direction for enabling the respective wooden strip 90 to be set into position. When the respective wooden strip 90 set into position, the respective cushion blocks 10 return to their former shape, thereby causing the retaining devices 60 of the respective two cushion blocks 10 to hold down the respective wooden strip 90 . Normally, the springy supporting devices 70 of each cushion block 10 have the respective top side partially protruding over the top side of the respective cushion block 10 . When the wooden strips 90 pressed on the top side of the cushion blocks 10 are set in position, the springy supporting devices 70 impart an upward pressure to the wooden strips 90 , thereby causing the longitudinal locating flanges 94 to be positively stopped against the elongated top flanges 62 of the retaining devices 60 at the bottom side, preventing vibration of the wooden strips 90 .
[0025] The length and width of the desired wooden flooring may not able be divided by the length and width of the wooden strips 90 . In this case, the wooden strips 90 for the border area may have to be cut to a particular size. During wooden flooring paving work, the two cushion blocks 10 at the ends of each rack 80 may be cut (for example, along the bottom side of the respective retaining device 60 ) subject to the cutting status of the bordering wooden strips 90 . When abutting one short side of each wooden strip 90 against the wall of the room, the corresponding racks 80 are arranged with one corresponding long side abutted against the wall of the room, thus the corresponding wooden strips 90 can wholly be supported on the corresponding racks 80 without cutting.
[0026] [0026]FIG. 5 shows simply one wooden flooring paving example according to the present invention. According to this wooden flooring paving example, the wooden strips 90 are longitudinally and transversely aligned. Alternatively, the wooden strips 90 can so arranged that the respective long sides are aligned, and the respective short sides are staggered. Other paving methods as used in the bonding of bricks may be employed. For example, the pitch between two racks 80 can be one half of the length of the wooden strips 90 , i.e., three racks 80 are arranged in parallel to support the ends and middle part of the respective wooden strips 90 .
[0027] The aforesaid example explains the paving of a wooden flooring. However, the invention can also be used in paving any type of the build-up surface, such as bamboo flooring, wooden ceiling, wooden wall panel, etc. When a wooden flooring or wooden ceiling is constructed according to the present invention, elongated open spaces are left in the wooden flooring or wooden ceiling between the wooden strips and the floor or wall surface and between each two adjacent racks for electric wiring.
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A cushion block for using in a build-up surface formed by strips is disclosed to have two male coupling devices at one end, two female coupling devices at an opposite end corresponding to the male coupling devices, a retaining device protruded from one side thereof and adapted to secure the strip to the corresponding side of the cushion block, and a deformable body connected between the male coupling devices and the female coupling device. The male and female coupling devices are so made such that multiple cushion blocks are connectable in a line in a linking direction by engaging the male coupling devices of one cushion block into the female coupling devices of another. The deformable body is deformable in the linking direction to compensate expansion of the strips due to absorption of moisture.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a method for reducing the computational complexity of a Viterbi decoder and, more particularly, to a method for reducing the computational complexity of a Viterbi decoder at all code rates of a convolutional code.
[0003] 2. Description of Related Art
[0004] In current communication systems, a transmitter transmits a radio signal to a remote receiver. When the radio signal passes through a wireless channel so as to cause a fading and result in errors. Accordingly, the transmitted signal is typically performed with a convolutional encoding before being modulated to the RF signal. After demodulating the received radio signal, the remote receiver performs the convolutional decoding to thereby reconstruct the transmitted signal. Such a way can reduce the channel fading effect and noise interference. The convolutional encoding is referred to as a channel encoding, which is performed by a channel encoder. In general, a convolutional code has three parameters: the number of input bits k, the number of output bits n, and constraint length. The input and output bit parameters k and n are typically represented by the code rate k/n, where k, n are a positive integer. The constraint length indicates the number of memory element of the convolutional code. The convolutional decoding uses a Viterbi algorithm in order to provide an optimal coding gain. Therefore, the current communication systems mostly implements the Viterbi decoder to perform the convolutional decoding. The convolutional code can enhance the capability of error correction by increasing the constraint length. However, the decoding computation at the receiving side is increased with the increased constraint length. To overcome this, U.S. Pat. No. 5,539,757 granted to Cox, et al. for an “Error correction systems with modified Viterbi decoding” has disclosed a method to relatively reduce the computation of the Viterbi decoder by efficiently using the relation of the branches. However, the method can be applied only at a specific code rate, 1/n, which cannot satisfy a user with a desire for a code rate k/n other than the code rate 1/n.
SUMMARY OF THE INVENTION
[0005] The object of the invention is to provide a method for reducing the computational complexity of a Viterbi decoder, which can be used in the Viterbi decoder at all code rates of a convolutional code and effectively reduce the computation required for a convolutional decoding.
[0006] To achieve the object, there is provided a method for reducing the computational complexity of a Viterbi decoder. The method comprises the steps of: (A) decomposing a trellis diagram with a convolutional code at a code rate k/n into 2 v−k radix-2 k butterfly units, where k, n, v are a positive integer, and k indicates a number of input bits, n indicates a number of output bits, and v indicates a constraint length; (B) decomposing each radix-2 k−r butterfly unit into four radix-2 k−r−1 butterfly units; (C) determining a branch symmetry among the radix-2 k−r−1 butterfly units based on a generator sequence for the convolutional code; (D) determining if r is equal to k, and when r is not equal to k, adding r by one and executing step (B); and (E) using the branch symmetry to reduce a branch metric computation required by a convolutional decoding at the code rate k/n.
[0007] Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic diagram of a convolutional encoder with a convolutional code at a code rate k/n in accordance with the invention;
[0009] FIG. 2 is a trellis diagram of a convolutional code at a code rate k/n in accordance with the invention;
[0010] FIG. 3 is a diagram of radix-2 k butterfly units in accordance with the invention;
[0011] FIGS. 4 (A) and (B) are original and simplified diagrams of a radix-2 k−r butterfly unit in the rth level in accordance with the invention;
[0012] FIG. 5 is a schematic diagram of four radix-2 k−1 butterfly units in the first level in accordance with the invention;
[0013] FIG. 6 is a schematic diagram of four radix-2 k−r butterfly units in the rth level in accordance with the invention;
[0014] FIG. 7 is a schematic diagram of four radix-2 1 butterfly units in the (k−1)th level in accordance with the invention;
[0015] FIG. 8 is a schematic diagram of one radix-2 1 butterfly unit in accordance with the invention;
[0016] FIG. 9 is a table of a generator sequence and branch symmetries among the butterfly units in accordance with the invention;
[0017] FIG. 10 is a flowchart of a method for reducing the computational complexity of a Viterbi decoder in accordance with the invention; and
[0018] FIG. 11 is a schematic trellis diagram obtained by applying the method of FIG. 10 to an example of code rate k/n=¾ and constraint length v=4 for decomposition in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] The method for reducing the computational complexity of a Viterbi decoder, which is suitable for all code rates of a convolutional code which is decoded by the Viterbi decoder. The method uses the butterfly structure to gather the corresponding branches in the trellis diagram to a same butterfly unit, and finds the symmetries of all branches in the trellis diagram in accordance with the generator sequence. Accordingly, the branch metric values for partial branches are required in computation, and the remainders can be obtained in accordance with the branch symmetries. Thus, the reduced computation is achieved. Upon the best mode as using the method, the Viterbi decoder can reduce the required branch metric computation to ¼ k of the original computation.
[0020] As shown in FIG. 1 , the encoder with the convolutional code at the code rate k/n has k+v registers, for v is a positive integer and indicates the constraint length or the number of state bits. In a unit of time, the k bits input data denoted by u 1 u 2 . . . u k are input to the encoder. There are n modulo-2 adders to generate n output bits y 1 y 2 . . . y n . In this case, the relation between the input bit and the output bit is determined by the generators. If the generator for the i-th output bit y i is g i =[g 1 i g 2 i . . . g k+v i ], the i-th output bit y i can be defined by the following equation:
y i =g 1 i ·u 1 ⊕ . . . ⊕g k i ·u k ⊕g k+1 i ·s 1 ⊕ . . . ⊕g k+v i ·s v , (1)
where i is a positive integer smaller than or equal to n, and ⊕ indicates a modulo-2 adder.
[0021] In addition, a trellis diagram is another approach that is commonly used to show the convolutional code with the code rate k/n. In the trellis diagram, each branch shows a set of output bits, and each state is defined by referring to the state bits in the register, which is represented by the following equation:
S=s 1 s 2 . . . s v−1 s v . (2)
As shown in FIG. 2 , the trellis diagram in each stage has N=2 v state values, and the states are numbered in decimal, where s v indicates a most significant bit (MSB) while s 1 indicates a least significant bit (LSB). If notation j indicates the current stage state set containing the states numbered 1 to N, state j′ indicates a next stage state set with respect to the current stage state set j, and the sets j and j′ have an N state respectively. The oldest k input bits are removed from the registers as k input bits enter in the registers every time, thereby generating a state transition, i.e., the state is changed from the state denoted as s 1 s 2 . . . s v of the set j into the state denoted as u 1 . . . u k s 1 . . . s v−k of the set j′. As shown in FIG. 2 , each state has 2 k state transitions, and each transition has a corresponding branch. Accordingly, for a Viterbi decoding, each set has 2 v+k branch metric values to be computed. However, the number to be computed presents an exponential growth as the constraint length v is increased. To overcome this, the invention finds the branch symmetries of the branches in the trellis diagram to thereby simplify the computation and achieve the purpose of reducing the computational amount required for the Viterbi decoding.
[0022] Because an effective approach to find the symmetries of the branches in the trellis diagram does not exist, the invention discloses a butterfly structure to overcome the aforementioned problem.
[0023] Referring again to FIG. 2 , it is observed that the 2 k branches emitted from a same source state have a certain relation because the content of the register for the 2 k branches emitted is determined only by the different input bits, i.e., the relation of the branches can be found from the bits u 1 . . . u k . In addition, the 2 k branches entering in a same destination state also have a certain relation because the content of the register for the 2 k branches is determined only by the bits s v−k+1 . . . s v of the source states, i.e., the relation of the branches can be determined by the bits of the source states.
[0024] All relative states and branches are collected to form a butterfly unit, as shown in FIG. 3 . Namely, the trellis diagram of FIG. 2 can be decomposed into 2 v−k butterfly units. The butterfly unit shown in FIG. 3 is defined as a radix-2 k butterfly unit that has 2 k states. Each of the 2 k states is joining 2 k branches.
[0025] All states in the radix-2 k butterfly unit have the same bits s 1 . . . s v−k , which is notated by xx in the figures for the convenience. Accordingly, equation (1) can be rewritten into:
y i =g 1 i ·u 1 ⊕g 2 i ·u 2 ⊕Λ⊕g k i ·u k ⊕X i ⊕g v+1 i ·s v−k+1 ⊕Λ⊕g k+v i ·s v , (3)
where X i is generated from the same portion s 1 . . . s v−k , i.e., the same component presented in every branch,
X i =g k+1 i ·s 1 ⊕g k+2 i ·s 2 ⊕Λ⊕g v i ·s v−k . (4)
[0026] Therefore, upon the relation of the branches of FIG. 3 , the trellis diagram of FIG. 2 can be decomposed into 2 v−k radix-2 k butterfly units. Namely, the corresponding branches are all gathered to a same radix-2 k butterfly unit, and the branch symmetry is obtained by referring to the states joining the branches in every radix-2 k butterfly unit. The relation of the branches is not affected because X i indicates the same portion of the bits in every branch. From equation (3), it can show that the relation of the branches is influenced only by the 2k members, g 1 i ,g 2 i Λg k i ,g v+1 i ,g v+2 i Λg k+v i , in the generator. Namely, for every bit on the branches, there are 2 2k symmetries in total. Because a branch symmetry is obtained from the intersection of bit symmetries, a great number of bit symmetries can cause the difficulty of obtaining the branch symmetry. The invention can continuously and regularly decompose a radix-2 k butterfly unit in every level to thereby reduce the influence of the generator on the branch symmetries in the butterfly unit.
[0027] In order to simplify the following illustrations, the butterfly unit in every level is illustrated by a simplified diagram. FIGS. 4 (A) and (B) show original and simplified diagrams of a radix-2 k−r butterfly unit in the r-th level. As shown in FIG. 4 (A), each of the radix-2 k−r butterfly units in the r-th level has 2 k−r states, and each state joins 2 k−r branches. The butterfly unit in every level hereinafter is illustrated in a simplified form.
[0028] First decomposition divides the radix-2 k butterfly unit into four radix-2 k−1 butterfly units based on the bits (u 1 ,s v ) of the states in the radix-2 k butterfly unit, and distributes all branches, which are the same at the bits (u 1 ,s v ) in the states, to a same radix-2 k−1 butterfly unit. As shown in FIG. 5 , the branch relation in a same radix-2 k−1 butterfly unit is not influenced by the bits (u 1 ,s v ). In addition, the states joining the branches among the four radix-2 k−1 butterfly units are the same except at the bits (u 1 ,s v ), and thus the relation of the branches of the four radix-2 k−1 butterfly units is determined only by the bits (u 1 ,s v ). Besides, the symmetry type of the four radix-2 k−1 butterfly units is influenced only by the members (g i 1 ,g i k+v ) of the generators that are mapped by the bits (u 1 ,s v ). For example, if g i 1 =0 and g i k+v =0, the symmetry of the four radix-2 k−1 butterfly units is B 1 k−1 =B 2 k−1 =B 3 k−1 =B 4 k−1 . If g i 1 =0 and g i k+v =1, the symmetry of the four radix-2 k−1 butterfly units is B 1 k−1 =B 2 k−1 =B 3 k−1 ′=B 4 k−1 ′, for B 3 k−1 ′ and B 3 k−1 are complementary, and B 4 k−1 ′ and B 4 k−1 are complementary.
[0029] Similarly, for a butterfly unit in the r-th level, a radix-2 k−r+1 butterfly unit is decomposed into four radix-2 k−r butterfly units by settling the bits (u 1 ,s v−r+1 ) of the states, as shown in FIG. 6 . In addition, the relation of the four radix-2 k−r butterfly units is determined by the members (g i r ,g i k+v−r+1 ) of the generators. Accordingly, a last radix-2 2 butterfly unit is decomposed into four radix-2 1 butterfly units, as shown in FIG. 7 , and the relation of the four radix-2 1 butterfly units is determined by the members (g i k−1 ,g i k+v+2 ). Finally, as shown in FIG. 8 , each of the four radix-2 1 butterfly units remains only four branches, and the states joining the four branches are different only at the bits (u k ,s v−k+1 ). Therefore, the relation of the four branches can be determined by the members (g i k ,g i v+1 ) of the generators.
[0030] When the relation of the four branches in the radix-2 1 butterfly unit is considered as four butterfly units {B 1 0 ,B 2 0 ,B 3 0 ,B 4 0 } obtained by the k-th decomposition, it is known that the members of the generators influencing the symmetries in the levels have the same influence on the symmetries of the butterfly units in the levels, which can be generally shown in the table of FIG. 9 . As shown in FIG. 9 , no matter what the generator sequence is, the butterfly units in the levels can have ¼ symmetries. In the invention, the 1/x symmetry indicates that only one of the x branches is necessarily subjected to the branch metric computation, and in accordance with the symmetry, the branch metric values for the remaining (x−1) branches can be obtained. Therefore, the (¼) k symmetry owned by the bits of each branch can be found by means of such a butterfly structure. It is noted that such a symmetry only indicates the symmetry owned by a single bit of the branches in the butterfly units in the levels. The complete symmetry of the branches is obtained by intersecting the symmetries of the bits corresponding to the branches. Thus, the branch symmetry is influenced by the similarity of bit symmetries. The bits of the branches have more similar symmetry, and the symmetry of the branches in the trellis diagram is more preferred.
[0031] FIG. 10 is a flowchart of a method for reducing the computational complexity of a Viterbi decoder in accordance with the invention. The method includes the steps as follows.
[0032] Step A: a trellis diagram with a convolutional code at code rate k/n is decomposed into 2 v−k butterfly units with radix-2 k . Each butterfly unit, as shown in FIG. 3 , has 2 k states, and each state joins 2 k branches. The values of the states contain a same portion s 1 . . . s v−k to thereby distribute the corresponding branches to a same radix-2 k butterfly unit.
[0033] Step B: each radix-2 k−r butterfly unit is decomposed into four radix-2 k−r−1 butterfly units in order to reduce the influence of the generators on the branch symmetries.
[0034] Step C: each bit symmetry is determined in accordance with the generators for the convolutional code, and the bit symmetries respectively of the n bits are intersected to thus obtain the branch symmetry of the four radix-2 k−r−1 butterfly units.
[0035] Step D: it determines if r=k; when r is not equal to k, it indicates that a single radix-2 k−r−1 butterfly unit can be further decomposed. Namely, a symmetry among the radix-2 k−r butterfly units is determined only by the members (g r i , g k+v−r+1 i ) of the generators corresponding to the bits (u r ,s v−r+1 ). In this case, r=r+1, and step B is executed for the further butterfly unit decomposition. When r=k, it indicates that the last level is decomposed completely.
[0036] Step E: the branch symmetry is used to reduce the branch metric computation required for decoding the convolutional code at the code rate k/n.
[0037] FIG. 11 is a schematic trellis diagram obtained by applying the method of FIG. 10 to an example of code rate k/n=¾ and constraint length v=4 for decomposition in accordance with the invention. As shown in FIG. 11 , a trellis diagram corresponding to the convolutional code at state set j has 16 state values numbered 0-15 in total. Each of the state values has eight state value transitions. The trellis diagram can be divided into two radix-2 3 butterfly units. Each butterfly unit has eight state values, and each state value has four state value transitions. Accordingly, if the generators are g 1 =[1111101], g 2 =[1111001], g 3 =[1010111] and g 4 =[1110101], when r=1, the bit symmetries among the radix-2 k−1 butterfly units are shown as follows.
Bit y 1 (g 1 1 =1, g 7 1 =1): B 2 1 =B 2 2 ′=B 2 3 ′=B 2 4 ; Bit y 2 (g 1 2 =1, g 7 2 =1): B 2 1 =B 2 2 ′=B 2 3 ′=B 2 4 ; Bit y 3 (g 1 3 =1, g 7 3 =1): B 2 1 =B 2 2 ′=B 2 3 ′=B 2 4 ; and Bit y 4 (g 1 4 =1, g 7 4 =1): B 2 1 =B 2 2 ′=B 2 3 ′=B 2 4 .
[0038] The four bits have the same symmetry so that the branch symmetry B 2 1 =B 2 2 ′=B 2 3 ′=B 2 4 is obtained by intersecting the bit symmetries. When r=2, the bit symmetries among the radix-2 k−2 butterfly units are shown as follows.
Bit (g 2 1 =1, g 6 1 =0): B 1 1 =B 1 2 ′=B 1 3 =B 1 4 ′;
Bit (g 2 2 =1, g 6 2 =0): B 1 1 =B 1 2 ′=B 1 3 =B 1 4 ′;
Bit (g 2 3 =0, g 6 3 =1): B 1 1 =B 1 2 =B 1 3 ′=B 1 4 ′; and
Bit y 4 (g 2 4 =1, g 6 4 =0): B 1 1 =B 1 2 ′=B 1 3 =B 1 4 ′.
[0039] The four bits have different symmetries so that only the branch symmetry B 1 1 =B 1 4 ′, B 1 2 =B 1 3 ′ is obtained after the intersection. When r=3, the bit symmetries among the radix-2 k−3 butterfly units are shown as follows.
Bit y 1 (g 3 1 =1, g 5 1 =0): B 0 1 =B 0 2 ′=B 0 3 ′=B 0 4 ;
Bit y 2 (g 3 2 =1, g 5 2 =0): B 0 1 =B 0 2 ′=B 0 3 =B 0 4 ′;
Bit y 3 (g 3 3 =0, g 5 3 =1): B 0 1 =B 0 2 ′=B 0 3 ′=B 0 4 ; and
Bit y 4 (g 3 4 =1, g 5 4 =0): B 0 1 =B 0 2 ′=B 0 3 ′=B 0 4 .
[0040] The four bits have different symmetries so that only the branch symmetry B 0 1 =B 0 2 ′, B 0 3 =B 0 4 ′ is obtained after the intersection.
[0041] The branch symmetries owned by the butterfly units in the three levels are combined so as to provide the convolutional code with a 1/16 symmetry. Accordingly, on implementing a Viterbi decoder with the convolutional code, the required branch metric computation is reduced by the butterfly structure to 1/16 of the original computation, and the remaining can be obtained in accordance with the branch symmetries. For example, as shown in FIG. 11 , the trellis diagram has 16 states in total, each state having eight branches, and in this case, it is required that total 128 branch metric values are originally computed for every level of the trellis diagram. Accordingly, the invention uses the decomposition of the butterfly structure to first divide the trellis diagram into two radix-2 3 butterfly units. The four radix-2 2 butterfly units contained in each radix-2 3 butterfly units needs only to compute the branch metric values of the branch B 1 2 , the others can be obtained through the symmetry B 1 2 =B 2 2 ′=B 3 2 ′=B 4 2 . In addition, as to the branch B 1 2 , only the branches B 1 1 and B 3 1 in the radix-2 butterfly unit are computed, without computing all branch metric values of the branch B 1 2 , and the remaining can be obtained through the symmetry B 1 1 =B 4 1 ′, B 2 1 =B 3 1 ′. Similarly, as to the branches B 1 1 and B 3 1 , only the branches B 1 0 and B 3 0 in the radix-1 butterfly unit are computed, and the remaining can be obtained through the symmetry B 1 0 =B 2 0 ′, B 3 0 =B 4 0 . Therefore, the entire radix-2 3 butterfly unit has 64 branches, but only four branches, i.e., B 1 0 and B 3 0 corresponding to the branches B 1 1 and B 3 1 respectively, are computed. Accordingly, the branch metric computation can be effectively reduced to 1/16 of the original. Likewise, the computation is performed on the other radix-2 3 butterfly unit.
[0042] In view of the foregoing, it is known that the method of the invention for reducing the computational complexity of a Viterbi decoder can effectively reduce the complexity of decoding the convolutional code at the code rate k/n, thereby achieving the purpose of the invention.
[0043] Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.
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A method for reducing the computational complexity of a Viterbi decoder, which is suitable for all code rates of a convolutional code applied by the Viterbi decoder. The method dramatically reduces the branch metric computation to thus reduce the complexity of implementing the Viterbi decoder, without affecting the capability of error correction. Upon the best mode, the Viterbi decoder can reduce the required branch metric computation to ¼ k of the original computation.
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BACKGROUND OF INVENTION
[0001] This invention relates to holiday decorations and, in particular embodiments, to decorative plush articles for interactively counting down the days preceding a holiday.
[0002] Households are often adorned with decorations and ornamentation contemporaneously with the celebration of various holidays and other special events. Various types of decorations and ornamentation have been used to decorate homes, workplaces and retail environments in the months leading up to major holidays such as Christmas, Ramadan, and Hanukah. These decorations include trees, wreaths, ornaments, and other festive holiday trimmings. The decorations create a festive spirit and serve as reminders that a special event is nearing.
[0003] While certain decorations are simply aesthetic and provide basic visual satisfaction for the people that see them, other decorations include various types of interactive functionality. These interactive decorations allow their users to take a more active role in the holiday.
[0004] Another form of holiday decoration is a countdown display. Generally speaking, countdown displays are flat cardstock products which have a plurality of die-cut flap sections having distinct numbers printed on them, each number being associated with the days remaining before a major holiday. On each day leading up to the holiday, a user (often a child) lifts the die-cut flap associated with the number of days remaining before the holiday. Under each flap is a distinct image or message. The countdown display thereby helps build excitement in the days leading up the actual holiday.
SUMMARY OF INVENTION
[0005] A holiday countdown interactive display may include a set of magnetically attachable ornaments that have discrete appearances and functionalities, each ornament being marked with a distinct number associated with the number of days remaining before a holiday. In certain preferred embodiments, the interactive display comprises a plush fabric base generally in the shape of a Christmas tree and containing a plurality of rare earth magnets disposed beneath countdown numbers borne on the exterior of the plush fabric base. The interactive display system may further include a plurality of numbered plush Christmas ornaments each including rare earth magnets, the ornaments adapted to be successively installed on the plush fabric base on the days preceding a holiday event. In various embodiments, the ornaments include power supplies, controllers, vibratory elements, LEDs, speakers, pockets for containing gift items, messages, or the like. In certain embodiments, the fabric base unit may include a power supply, a controller, and one or more electronic element that is activated in response to user stimulus. In some embodiments, the fabric base unit may include a compartment to store unused ornaments or other holiday items.
[0006] The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF DRAWINGS
[0007] FIG. 1 is a perspective view of a fabric interactive display in accordance with one embodiment of the invention.
[0008] FIG. 2 is a rear view of the article shown in FIG. 1 .
[0009] FIG. 3A is a cross-sectional view of the fabric article shown in FIG. 1 .
[0010] FIG. 3B is a front view of an optional, separately attachable storage unit.
[0011] FIGS. 4A-4C illustrate various aspects of an exemplary countdown ornament.
[0012] FIG. 5 is a schematic of an exemplary control circuit for use in connection with the embodiments of FIGS. 4C, 6C , and 8 .
[0013] FIGS. 6A-6C illustrate various aspects of a second exemplary countdown ornament.
[0014] FIGS. 7A-7C illustrate various aspects of a third exemplary countdown ornament.
[0015] FIG. 8 is a schematic of a circuit for use in the fabric article of FIG. 1 .
[0016] FIG. 9 is a partial front view of an additional embodiment of the invention.
[0017] Like reference symbols in the various figures indicate like elements.
DETAILED DESCRIPTION
[0018] FIGS. 1-3 show a fabric article 100 . The fabric article 100 may include a countdown section 105 , an interactive section 110 , and a hanging device 115 . In some embodiments, the countdown section 105 and the interactive section 110 may be combined, and in other embodiments they may be separate. FIG. 1 shows eighteen decorative ornaments 120 attached to the countdown section 105 of the fabric article 100 . FIG. 1 also shows one decorative ornament 120 that is detached from the fabric article 100 . As depicted in FIG. 3A , the fabric article 100 may be constructed of a front panel 305 and a rear panel 310 . These panels are discussed in further detail in association with FIG. 3A .
[0019] The countdown section 105 of the fabric article 100 may include a plurality of countdown labels 125 spaced laterally apart from one another. The countdown labels 125 may be consecutively numbered to indicate the number of days remaining until a holiday. For example, a countdown to Christmas may include countdown labels 125 numbered consecutively from twenty-five to one to represent each of the twenty-five days in December leading up to and including Christmas day. The countdown labels 125 may also reflect the number of days remaining until a holiday using other indicia, such as days of the week or pictures instead of numbers. For example, the countdown labels 125 may include pictures associated with the Twelve Days of Christmas, such that with two days left before Christmas, the countdown label 125 would resemble two turtledoves.
[0020] The countdown labels 125 may be attachments that are separate from the fabric article 100 , thus allowing for compatibility with other fabric articles 100 . An example of this type of detachable countdown label 125 could be removable buttons attached to stems, where the stems are permanently affixed to the fabric article 100 but the buttons could attach to any of the different stems on any given fabric article 100 . These detachable buttons would allow for several different variations and decoration schemes rather than a predictable and fixed numbering scheme for the countdown labels 125 . In a different embodiment, the countdown labels 125 may be permanently affixed to the fabric article 100 or even printed directly on the fabric article 100 . The countdown labels 125 may also be used as mechanical attachment devices that allow affixation of the decorative ornaments 120 via mechanical means, such as where the countdown label buttons receive a loop of string attached to an ornament. Alternately, a decorative ornament 120 having a hook 905 may allow for mechanical attachment to certain embodiments of countdown labels 125 as shown in FIG. 9 and described in more detail below.
[0021] Returning to FIG. 1 , the interactive section 110 of the fabric article 100 includes one or more electrically active devices 130 that may be activated in response to different types of stimuli. These electrically active devices 130 may include speakers, lights, and or vibratory devices, for example. For instance, the interactive section 110 may include a controller, a series of lights and a speaker, the controller being programmed to illuminate the lights in synchronicity with music.
[0022] In some embodiments, the controller disposed in the interactive section 110 may respond to a signal from a pressure sensitive switch so that the reactive section 110 responds to the touch or grasp of a user. In other embodiments, the reactive section 110 may respond to a magnetic stimulus such as the attachment of a magnetic decorative ornament 120 to the fabric article 100 . In such embodiments, a Reed switch may be used in lieu of a pressure sensitive switch to sense the proximity of magnetic materials. The electrically active devices 130 in the interactive section 110 are controlled by a controller 215 , which is further described along with FIG. 8 .
[0023] The hanging device 115 allows the fabric article 100 to be attached to a surface for display. The hanging device 115 may be a loop attached to the fabric article 100 for hanging the fabric article 100 from a surface. The hanging device 115 may also comprise a hook-and-loop fastener system or adhesive tape for attaching the fabric article 100 to a surface. Rather than using a mechanical coupling, the hanging device 115 may have a non-mechanical attachment means such as cooperating magnets. For example, the fabric article 100 may be hung on a refrigerator door using primary magnets 210 that are already contained within the fabric article 100 . These primary magnets 210 are discussed in greater detail in association with FIG. 2 . In other embodiments, the hanging device 115 may be made up of a combination of mechanical devices and/or non-mechanical devices. If outwardly exposed, the hanging device 115 may be festively decorated with designs associated with a holiday.
[0024] FIG. 2 shows a rear view of the fabric article 100 and a rear view of a decorative ornament 120 . The back side of a decorative ornament 120 may include an outwardly exposed ornament label 205 to display the number of days leading up to a given holiday. As with the countdown labels 125 discussed previously, the ornament labels 205 may either numerically or symbolically represent the number of days remaining until a holiday. These outwardly exposed ornament labels 205 also allow the user of the device to match up the decorative ornaments 120 with the corresponding countdown labels 125 disposed on the front of the fabric article 100 . For example, the user may attach a decorative ornament 120 with an ornament label 205 numbered with a nineteen to the fabric article 100 where the countdown label 125 is also numbered with a nineteen, thus indicating that there are nineteen days remaining before the holiday. In some embodiments, the decorative ornaments 120 may not have ornament labels 205 , or the ornament labels 205 may be detachable or otherwise interchangeable. In either of these embodiments, the decorative ornaments 120 may be placed on the fabric article 100 in association with any of the countdown labels 125 . Also, although the previously mentioned embodiments discuss a rearward facing ornament label 205 , the ornament labels 205 may be outwardly exposed on the front side of the decorative ornaments 120 as well.
[0025] As shown from the rear in FIG. 2 , the aforementioned countdown section 105 of the fabric article 100 includes a plurality of primary magnets 210 . The primary magnets 210 may optionally comprise a rare earth magnet, which demonstrates significant magnetic field strength with a relatively small footprint. The primary magnets 210 are disposed within the fabric article 100 and each primary magnet 210 is located proximately rearward of one of the countdown labels 125 displayed on the front of the fabric article 100 . The secondary magnets 410 are discussed in greater detail in association with the different types of decorative ornaments 120 shown in FIGS. 4, 6 , and 7 .
[0026] Also shown in FIG. 2 is the controller 215 that controls the electrically active elements 130 , which may be included as part of the interactive section 110 of the fabric article 100 . As will be discussed in more detail in association with FIG. 8 , the controller 215 may control the electrically active elements 130 by selectively applying voltage and/or generating appropriate timing, sequencing, or other control signals.
[0027] A storage compartment 220 , which may be either coupled to or integrated with the fabric article 100 , may be used to store detached decorative ornaments 120 or other items. The storage compartment may include a partially flexible flap 225 and may allow closure via either mechanical or non-mechanical means. For example, the closure mechanism may include a pair of hook-and-loop fastener strips 230 . In other embodiments, the closure mechanism could be implemented with oppositely polarized magnets instead of the hook-and-loop fastener strips 230 . The use of a storage compartment 220 with the fabric article 100 will be discussed further in association with FIGS. 3A & 3B .
[0028] FIG. 3A shows both the front panel 305 and the rear panel 310 of the fabric article 100 in a cross-sectional view. In some embodiments, fill material 315 may be enclosed between the front panel 305 and the rear panel 310 . As shown in FIG. 3A , the aforementioned primary magnets 210 may be disposed between the front panel 305 and the rear panel 310 of the fabric article 100 , with the primary magnets 210 being situated generally rearward of each countdown label 125 . In other embodiments, the primary magnets 215 may be disposed within a dual-layer front panel 305 . As an example of this particular embodiment, the primary magnets 215 may be sewn into the front panel 305 . The primary magnets 210 may also be disposed in other areas throughout the fabric article 100 .
[0029] Also shown in FIG. 3A is a storage compartment 220 that may be integrated with the rear panel 310 of the fabric article 100 . In such an integrated embodiment, the storage compartment 220 may be defined externally by a separation in the rear panel 310 to allow access to the internal storage compartment 220 . The storage compartment 220 may be defined internally by the inclusion of an internal lining 320 attached above and below the separation to the interior of the rear panel 310 . In other embodiments, the storage compartment 220 may be in the form of an external compartment coupled to the exterior of the fabric article 100 . For example, the storage compartment 220 may be sewn onto the exterior of the rear panel 310 or attached via other means. While each of the previously mentioned embodiments depicts or contemplates rearward facing storage compartments 220 , the storage compartment 220 may also be integrated with or attached to the forward facing side of the fabric article 100 . Such embodiments may include, but are not limited to, either a hidden storage compartment 220 on the front of the fabric article 100 or an externally visible storage compartment 220 .
[0030] The storage compartment 220 shown in FIG. 3B is representative of a non-integrated, external storage compartment 220 that may be coupled to the fabric article 100 as previously discussed. As shown in FIG. 3B , detached decorative ornaments 120 may be stored in the storage compartment 220 for safekeeping while they are not in use. Also depicted is one of the previously mentioned embodiments, namely one where the storage compartment 220 includes a partially flexible flap 225 which may be secured in a “closed” position by way of two hook-and-loop fastener strips 230 .
[0031] FIG. 4 shows an exemplary illuminable decorative ornament 400 . Illuminable decorative ornament 400 have one or more illuminable parts 405 and a main body 406 . The illuminable decorative ornament 400 may also include a secondary magnet 410 for attaching the ornament to the fabric article 100 by magnetic attraction to the primary magnets 210 disposed therein. The pattern and duration of the illumination may be controlled by a ornament controller 415 , which may be included as part of the illuminable decorative ornament 400 . In some embodiments, this ornament controller 415 may also be configured to control other elements such as speakers and vibratory elements.
[0032] FIG. 4C shows an illustrative embodiment of a ornament controller 415 . The ornament controller 415 may control the illumination of one or more LEDs 420 or other illuminable devices. The ornament controller 415 may comprise a power source 425 , a switch 430 , and an ornament control circuit 435 . The power source 425 may, for example, be a battery. The switch 430 may be designed to respond to different types of stimuli. For example, the switch 430 may be a pressure-activated push button switch that activates the ornament control circuit 435 when pressed and deactivates the ornament control circuit 435 when released. In another embodiment, the switch 430 may be a toggle that provides power to the ornament control circuit 435 from the power supply 425 when toggled on and continues providing power to the ornament control circuit 435 until the switch 430 is toggled off.
[0033] The ornament control circuit 435 , which is shown as part of the ornament controller 415 in FIG. 4C and is shown later as part of the sound controller 615 discussed in further detail in association with FIG. 6C , may be implemented in several different ways. In one embodiment, the ornament control circuit 435 may control the decorative ornament's 120 lights, sounds, or vibrations using a timer. For example, an LED 420 in a illuminable decorative ornament 400 may illuminate for a predetermined period of time before turning off. In another embodiment, the ornament control circuit 435 may output signals based upon a pattern generator or based on a pattern saved in memory associated with the control circuit 435 . As an example, the speaker 620 in audio decorative ornament 600 may play the tune “Jingle Bells.” A more specific example of a control circuit 435 is shown in FIG. 5 and is discussed in greater detail in association with that figure.
[0034] FIG. 5 shows an exemplary of a control circuit 500 suitable for use in the circuits of FIGS. 4C, 6C , and 8 . The microcontroller 505 illustrated in this embodiment is a Winbond PowerSpeech™W588B Series voice synthesizer chip. The C capacitor 510 shunted between VDD, which is the microcontroller's 505 operating voltage pin, and ground may have a capacitance of 4.7 μF and is an optional component used to provide power stability to the microcontroller 505 . The C PN capacitor 515 shunted between VDD and ground may have a much smaller capacitance of 0.1 μF and is required for this particular Winbond microcontroller 505 to filter out noise from the power supply. The R LIMIT resistor 520 may be used to limit the amount of current that is supplied to the microcontroller 505 . The R OSC resistor 525 value may vary and depends on the frequency desired for the internal oscillator of the microcontroller 505 . This particular Winbond microcontroller 505 includes memory for storing various speech or other tonal outputs of up to one hundred thirty-three seconds such that a “Ho, ho, ho!” sound effect or a longer holiday tune such as “Jingle Bells” or “Deck the Halls.” Microcontroller 505 includes a built-in driver that provides a signal to the speakers through the pulse wave modulation (PWM) pins 530 on the chip. While this particular embodiment shows a microcontroller configured to activate a speaker, other timing or sequencing microcontrollers may be implemented to control the lights, vibratory elements, or other active devices included in the ornaments or fabric base unit.
[0035] FIG. 6 shows an audio ornament 600 , which is another illustrative embodiment of a decorative ornament 120 . Audio ornaments 600 have one or more audio devices 605 and a main body 406 . Audio ornaments 600 may also include a secondary magnet 410 for attaching the ornament to the fabric article 100 by magnetic attraction to a primary magnet 210 disposed therein. The tune and duration of the sound output by a audio ornament 600 may be controlled by a sound-making ornament controller 615 located within the audio ornament 600 . In some embodiments, this audio ornament controller 615 may also control and trigger other active elements such as LEDs or vibratory elements.
[0036] FIG. 6C shows a embodiment of an audio ornament controller 615 . The ornament controller 615 may control the sound emitted from a speaker 620 or a different type of audio device. For example, in one embodiment, the ornament controller 615 may send signals to the speaker 620 to play a tune associated with the holiday. The ornament controller 615 may comprise a power source 625 , a switch 630 , and an ornament control circuit 435 . The power source 625 may be a battery. Also, the switch 630 may be designed to respond to different types of stimuli. For example, the switch 630 may be a pressure-activated push button switch that activates the ornament control circuit 635 when pressed and deactivates the ornament control circuit 435 when released. In another embodiment, the switch 630 may be a toggle that provides power to the ornament control circuit 435 from the power supply 625 when toggled on and continues providing power to the ornament control circuit 435 until the switch 630 is toggled off.
[0037] FIGS. 7A-7C show a mechanically-operable decorative ornament 700 , which is another illustrative embodiment of a decorative ornament 120 . The main body 406 of the mechanically-operable decorative ornament 700 is similar to the main body 406 of other types of decorative ornaments 120 . However, in addition to the main body 406 , some embodiments of mechanically-operable decorative ornaments 700 may include a flap 710 that allows a user to “open” the ornament to reveal a hidden item 715 inside. For example, a mechanically-operable decorative ornament 700 associated with Christmas may resemble a gift box that opens to reveal a hidden item 715 inside. Different types of hidden items 715 may include printed messages, holiday trinkets, or candy. As with the other types of decorative ornaments 120 , mechanically-operable decorative ornaments 700 may contain a secondary magnet 410 for attaching the ornament to the fabric article 100 via coupling with one of the primary magnets 210 disposed within the fabric article 100 . In yet another embodiment, the mechanically-operable decorative ornament 700 may be constructed as a finger puppet or other shape that may be manually operated by the user.
[0038] Each of the different types of decorative ornaments 120 described in association with FIGS. 4, 6 , and 7 may be labeled with outwardly exposed ornament labels 205 as previously described in association with FIG. 2 . Also, each different type of decorative ornament 120 may be designed to be child-safe such that even young children may participate in decorating the fabric article 100 . In addition to the main body 406 of each different type of decorative ornament 120 , the ornaments may include a holiday message 408 . An illustrative example of a holiday message 408 displayed on a decorative ornament 120 is shown in FIG. 4A . In this particular embodiment, the holiday message 408 displayed reads “Merry Christmas,” but the holiday message 408 may be any other suitable message associated with the holiday.
[0039] FIG. 8 shows one embodiment of a controller 215 for operating the interactive section 110 of the fabric article 100 . The controller 215 may comprise a power source 805 , a switch 810 , and a control circuit 815 . When activated, the control circuit 815 may control one or more lights 820 or speakers 825 or any other type of electrically active elements 130 that are included as part of the fabric article 100 . The power source 805 may be a battery, a DC power supply, an AC power supply, or any other type of source sufficient to power the controller 215 . Similarly, the switch 810 may be one of any number of devices to activate the control circuit 815 in response to certain stimuli. For example, the switch 810 may be a Reed switch that is normally open but that activates the control circuit 815 when a magnet is brought into close proximity with the switch 810 . As another example, the switch 810 may be a pressure-activated switch that is normally open but that activates the control circuit 815 when a user presses on a certain portion of the fabric article 100 . In one embodiment, a plurality of switches 810 may be used, each switch being located proximately to the countdown labels 125 , such that whenever a user places a decorative ornament 120 on the fabric article 100 , the controller 215 is activated and the lights 820 are activated or a song is played through the speakers 825 . In certain embodiments, the control circuit 815 may control the electrically active elements 130 using timing circuitry. In this embodiment, the lights 820 or speakers 825 would be activated for a certain period of time and then be deactivated. The control circuit 815 may also control the electrically active elements 130 using sequencing or pattern generating circuitry. In this particular embodiment, the lights 820 or speakers 825 would be activated and deactivated according to a predefined pattern or sequence defined by the control circuit 815 .
[0040] FIG. 9 shows a rear view of a decorative ornament 120 and a front view of the fabric article 100 . The decorative ornament 120 may have a mechanical attachment device 905 to attach the decorative ornament 120 to the fabric article 100 via non-magnetic means. The mechanical attachment device 905 may be a hook or a loop that mechanically couples to a mechanical fastener 910 attached to the fabric article 100 . As shown in FIG. 9 , these mechanical fasteners 910 may be pegs that are attached to the front of the fabric article 100 , thus allowing the user to hang the decorative ornaments 120 on the fabric article 100 . In another embodiment, the mechanical attachment device 905 and the mechanical fastener 910 may be implemented with hook-and-loop fastener strips that attach to the back side of the decorative ornaments 120 and to the front side of the fabric article 100 .
[0041] As used herein, the term “fabric” means cloth, felt, woven material, or any other material resembling one of the foregoing in appearance or tactile properties.
[0042] A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made and that other embodiments are within the scope of the following claims.
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A holiday countdown interactive display may include a set of magnetically attachable ornaments that have discrete appearances and functionalities, each ornament being marked with a distinct number associated with the number of days remaining before a holiday. In certain preferred embodiments, the interactive display comprises a plush fabric base generally in the shape of a Christmas tree and containing a plurality of rare earth magnets disposed beneath countdown numbers borne on the exterior of the plush fabric base. The interactive display system may further include a plurality of numbered plush Christmas ornaments each including rare earth magnets, the ornaments adapted to be successively installed on the plush fabric base on the days preceding a holiday event. In various embodiments, the ornaments include power supplies, controllers, vibratory elements, LEDs, speakers, pockets for containing gift items, messages, or the like.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to data storage systems that utilize tape or other base storage along with high speed cache. More particularly, the invention concerns a data storage system that stores data objects with encapsulated metadata tokens in cache and/or base storage to protect against recalling stale data from base storage in the event of a cache failure.
2. Description of the Related Art
Many data processing systems require a large amount of data storage, for use in efficiently accessing, modifying, and re-storing data. Data storage is typically separated into several different levels, each level exhibiting a different data access time or data storage cost. A first, or highest level of data storage involves electronic memory, usually dynamic or static random access memory (DRAM or SRAM). Electronic memories take the form of semiconductor integrated circuits where millions of bytes of data can be stored on each circuit, with access to such bytes of data measured in nanoseconds. The electronic memory provides the fastest access to data since access is entirely electronic.
A second level of data storage usually involves direct access storage devices (DASD). DASD storage, for example, includes magnetic and/or optical disks. Data bits are stored as micrometer-sized magnetically or optically altered spots on a disk surface, representing the “ones” and “zeros” that comprise the binary value of the data bits. Magnetic DASD includes one or more disks that are coated with remnant magnetic material. The disks are rotatably mounted within a protected environment. Each disk is divided into many concentric tracks, or closely spaced circles. The data is stored serially, bit by bit, along each track. An access mechanism, known as a head disk assembly (HDA) typically includes one or more read/write heads, and is provided in each DASD for moving across the tracks to transfer the data to and from the surface of the disks as the disks are rotated past the read/write heads. DASDs can store gigabytes of data, and the access to such data is typically measured in milliseconds (orders of magnitudes slower than electronic memory). Access to data stored on DASD is slower than electronic memory due to the need to physically position the disk and HDA to the desired data storage location.
A third or lower level of data storage includes tapes, tape libraries, and optical disk libraries. Access to library data is much slower than electronic or DASD storage because a robot or human is necessary to select and load the needed data storage medium. An advantage of these storage systems is the reduced cost for very large data storage capabilities, on the order of Terabytes of data. Tape storage is often used for backup purposes. That is, data stored at the higher levels of data storage hierarchy is reproduced for safe keeping on magnetic tape. Access to data stored on tape and/or in a library is presently on the order of seconds.
Data storage, then, can be conducted using different types of storage, where each type exhibits a different data access time or data storage cost. Rather than using one storage type to the exclusion of others, many data storage systems include several different types of storage together, and enjoy the diverse benefits of the various storage types. For example, one popular arrangement employs an inexpensive medium such as tape to store the bulk of data, while using a fast-access storage such as DASD to cache the most frequently or recently used data.
During normal operations, synchronization between cache and tape is not all that important. If a data object is used frequently, it is stored in cache and that copy is used exclusively to satisfy host read requests, regardless of whether the data also resides in tape. Synchronization can be problematic, however, if the cache and tape copies of a data object diverge over time and the data storage system suffers a disaster. In this case, the cache and tape contain different versions of the data object, with one version being current and the other being outdated. But, which is which? In some cases, there may be some confusion as to which version of the data object is current. At worst, a stale or “down-level” version of a data object may be mistaken (and subsequently used) as the current version. Thus, in the event of cache failure, data integrity may be questionable and there is some risk of the data storage system incorrectly executing future host read requests by recalling a stale version of the data.
SUMMARY OF THE INVENTION
Broadly, the present invention concerns a cache-equipped data storage system that stores data objects with encapsulated metadata tokens to protect against recalling stale data from base storage in the event of a cache failure. The storage system includes a controller coupled to a cache, base storage, and token database. The controller may be coupled to a hierarchically superior director or host.
When a data object is received for storage, the controller assigns a version code for the data object if the data object is new to the system; if the data object already exists, the controller advances the data object's version code. A “token,” made up of various items of metadata including the version code, is encapsulated for storage with its corresponding data object. The controller then stores the encapsulated token along with its data object and updates the token database to cross-reference the data object with its token. Thus, the token database always lists the most recent version code for each data object in the system.
The data object may be copied from cache to base storage automatically, de-staged from cache to base storage based on lack of frequent or recent use, or according to another desired schedule. Whenever the controller experiences a cache miss, there is danger in blindly retrieving the data object from base storage. In particular, the cache miss may have occurred due to failure of part or all of the cache, and at the time of cache failure the base storage might have contained a down-level version of the data object. The present invention solves this problem by comparing the version code of the data object from base storage to the version code of the data object in the token database. Only if the compared version codes match is the data object read from storage and provided as output. Otherwise, an error message is generated since the data object is stale.
As a further enhancement, the invention may utilize a “split” version code, where the version code has a data subpart and properties subpart. The data subpart is advanced solely to track changes to the data, while the properties subpart is advanced according to changes in attributes of the data object other than the data itself. In this embodiment, when the data object's version code from base storage is examined after a cache miss, the data subpart is reviewed without regard to the properties subpart. This avoids the situation where, although the base storage contains a current version of data, this data object would be regarded as stale because a non-split version code that does not make any data/properties differentiation has been advanced due to a change in the data object's properties not affecting the data itself. Accordingly, with this feature, data objects from base storage are more frequently available to satisfy cache misses.
Accordingly, as discussed above, one embodiment of the invention involves a method of operating a cache-equipped data storage system. In another embodiment, the invention may be implemented to provide an apparatus, such as a data storage system configured as discussed herein. In still another embodiment, the invention may be implemented to provide a signal-bearing medium tangibly embodying a program of machine-readable instructions executable by a digital data processing apparatus to perform operations for operating a data storage system. Another embodiment concerns logic circuitry having multiple interconnected electrically conductive elements configured to perform operations as discussed above.
The invention affords its users with a number of distinct advantages. For example, in the event of a cache miss resulting from unintentional loss of the cached data, the invention avoids unknowingly recalling a down-level data object from base storage. Thus, the invention helps ensure data integrity. Furthermore, in the event of a cache miss, the invention increases data availability by using “split” version codes. Despite any changes to the data's properties that still leave the data intact, the data object is still available for retrieval if the data subpart of its version code is still current according to the token database. The invention also provides a number of other advantages and benefits, which should be apparent from the following description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the hardware components and interconnections of a data storage system according to the invention.
FIG. 2 is a block diagram of a digital data processing machine according to the invention.
FIG. 3 shows an exemplary signal-bearing medium according to the invention.
FIG. 4 is a flowchart of an operational sequence for storing and retrieving data that utilize encapsulated tokens according to the invention.
DETAILED DESCRIPTION
The nature, objectives, and advantages of the invention will become more apparent to those skilled in the art after considering the following detailed description in connection with the accompanying drawings.
Hardware Components & Interconnections
Introduction
One aspect of the invention concerns a data storage system, which may be embodied by various hardware components and interconnections. One example is described by the data storage system 100 of FIG. 1 . As explained in greater detail below, the data storage system 100 stores data in base storage, and also utilizes a cache to more quickly access the more frequently or recently used data objects. In this particular example, the system 100 uses redundant storage, where one copy of data is used for read/write access and the other copy is used as a backup for disaster recovery. The data storage system 100 includes a director 104 , which is coupled to two storage sites, including a primary site 150 and a backup site 151 . Although two storage sites are shown in this example, a greater or lesser number may be used if desired.
Host
The data storage system 100 is coupled to a host 102 . Among other possible functions, the host 102 supplies data to the system 100 for storage therein and sends requests to the system 100 to retrieve data therefrom. The host role may be satisfied by various types of hardware, such as a digital data processing computer, logic circuit, construction of discrete circuit components, interface to a human operator, etc. As an example, the host 102 may comprise an IBM ES/9000 machine employing an operating system such as MVS.
Director
The storage director 104 relays host data storage/retrieval requests to hierarchically inferior components that carry out the requests. In the illustrated example, the director 104 also synchronizes data exchanges between redundant primary and backup storage sites 150 - 151 .
The director 104 communicates with the host 102 by an interface 103 such as wires/cables, one or more busses, fiber optic lines, wireless transmission, intelligent communications channel, etc. As an example, the interface 103 may comprise an ESCON connection. The director 104 comprises a digital data processing machine, logic circuit, construction of discrete circuit components, or other automated mechanism for managing storage operations in the system 100 . The director 104 operates according to programming or other configuration, as discussed in greater detail below. To provide a specific example, the director 104 may comprise an external RS/6000 component attached to a commercially available IBM Virtual Tape Server (“VTS”) product.
If one of the storage sites 150 - 151 is omitted to save costs and provide non-redundant storage, the director 104 may also be omitted, and its function performed by one or both of the remaining controllers 106 - 107 .
Controller
The data storage system 100 also includes primary and backup controllers 106 - 107 , which are coupled to the director 104 . According to instructions from the director 104 , the controllers 106 - 107 manage local storage operations conducted on respective cache 110 - 111 111 and base 112 - 113 storage units. The controllers 106 - 107 communicate with the director 104 by interfaces such as wires/cables, one or more busses, fiber optic lines, wireless transmission, intelligent communications channel, etc.
Each controller 106 - 107 comprises a digital data processing machine, logic circuit, construction of discrete circuit components, or other automated mechanism for managing storage operations in the system 100 , and operates according to suitable programming, physical configuration, etc. To provide a specific example, each controller 106 - 107 may comprise an RS/6000 component of a commercially available IBM VTS product.
The controllers 106 - 107 also include respective cache directories 106 a - 107 a . Each controller's cache directory lists the data objects residing in that controller's cache 110 - 111 . The cache directories may list data objects by various means, such as name, volser, and/or certain metadata such as the data object's anywhere token, certain file attributes, etc. The controllers 106 - 107 may also include base directories 106 b - 107 b listing contents of their respective base storage 112 - 113 , or such directories may be stored on base storage instead.
Other Components of the Storage Sites
In addition to the controllers 106 - 107 , each storage site includes a cache 110 - 111 , base storage 112 - 113 , and token database 108 - 109 . The cache units 110 - 111 comprise high-speed storage devices to efficiently store and retrieve the most likely, most frequently, or most recently used data objects in the system 100 . Although the cache units 110 - 111 may be implemented with nearly any type of digital data storage, cache preferably utilizes faster storage than would be practical or cost-effective for use as the base storage 112 - 113 . Thus, the cache units 110 - 111 are best implemented by DASD, electronic memory, or other suitable fast-access storage appropriate to the applicable requirements of cost, access speed, reliability, etc.
In contrast to the cache, each base storage unit 112 - 113 preferably embodies one or more storage devices including read/write drives that access magnetic, optical, or other removable, serially accessible storage media. The base storage units 112 - 113 may comprise, for example, one or more IBM model 3590 tape drives with tape media constituting one or more removable magnetic tape cartridges.
Also coupled to the controllers 106 - 107 are respective token databases 108 - 109 . Each database 108 - 109 stores machine-readable “tokens.” As explained below, each token contains various metadata relating to a data object stored in the cache 110 - 111 and/or base storage 112 - 113 . As explained below, the data objects are stored with their respective data objects in the cache 110 - 111 or base storage 112 - 113 . The token databases 108 - 109 may be stored upon disk, tape, electronic memory, or any desired media, whether physically distinct from the controllers 106 - 107 (as shown) or not.
Without any intended limitation, TABLE 1 (below) provides an exemplary list of metadata that may be included in each token.
TABLE 1
TOKEN CONTENTS
volume serial number (“volser”)
split version code, including data subpart and properties subpart
data inconsistent
data in state change
category (“scratch” or “private” tape mount)
director ID
properties in state change
category inconsistent
volume damaged
export pending
import pending
MES flag
properties level
As shown in TABLE 1, each token includes a “split version code.” Each version code including a “data” subpart and a “properties” subpart, each comprising one level from a predetermined sequence of distinct levels, such as alphabetic, alphanumeric, numeric, or other codes capable of indicating a data object's version. As explained below, the data subpart tracks changes to a data object's underlying data, while the properties subpart tracks changes to non-data properties of the data object. The version code is useful to avoid recalling a stale version of a data subpart from base storage in the event of a cache failure, as explained in greater detail below.
TABLE 2, below, shows several exemplary entries in the token database 108 . In this example, each row corresponds to one data object, and each data object is a logical volume. For each data object, TABLE 2 lists the data object's version code data subpart. Although not shown, the version code properties subpart may also be listed if desired.
TABLE 2
TOKEN DATABASE
DATA OBJECT
VERSION CODE DATA SUBPART
Volume 1
. . . version code 10 . . .
Volume 2
. . . version code 90 . . .
Volume 3
. . . version code 51 . . .
Redundant Storage
As described above, the present invention may optionally include redundant storage components, such as the backup controller 107 , token database 109 , cache 111 , base storage 113 , cache directory 107 a , and base directory 107 b . In the illustrated example, the controller 106 and its associated storage components may be permanently designated “primary” with the other controller 107 and its storage components being “backup.” Alternatively, under a more flexible arrangement, the sites 150 - 151 may operate in parallel with each other, on equal stature, with the sites temporarily assuming primary/backup roles for specific data storage and retrieval operations. In any event, the director 104 operates the backup storage site to replicate storage operations performed on the primary storage site. If one storage site experiences a failure, data storage/retrieval requests from the host 102 may still be carried out using the other storage site.
Exemplary Digital Data Processing Apparatus
As mentioned above, the director 104 and controllers 106 - 107 may be implemented using many different types of hardware. One example is a digital data processing apparatus, which may itself be implemented in various ways, such as the exemplary digital data processing apparatus 200 of FIG. 2 . The apparatus 200 includes a processor 202 , such as a microprocessor or other processing machine, coupled to a storage 204 . In the present example, the storage 204 includes a fast-access storage 206 , as well as nonvolatile storage 208 . The fast-access storage 206 may comprise RAM and may be used to store the programming instructions executed by the processor 202 . The nonvolatile storage 208 may comprise, for example, one or more magnetic data storage disks such as a “hard drive”, a tape drive, or any other suitable storage device. The apparatus 200 also includes an input/output 210 , such as a line, bus, cable, electromagnetic link, or other means for the processor 202 to exchange data with other hardware external to the apparatus 200 .
Despite the specific foregoing description, ordinarily skilled artisans (having the benefit of this disclosure) will recognize that the apparatus discussed above may be implemented in a machine of different construction, without departing from the scope of the invention. As a specific example, one of the components 206 , 208 may be eliminated; furthermore, the storage 204 may be provided on-board the processor 202 , or even provided externally to the apparatus 200 .
Logic Circuitry
In contrast to the foregoing digital data storage apparatus, a different embodiment of the invention uses logic circuitry to implement the director 104 and/or controllers 106 - 107 instead of computer-executed instructions. Depending upon the particular requirements of the application in the areas of speed, expense, tooling costs, and the like, this logic may be implemented by constructing an application-specific integrated circuit (ASIC) having thousands of tiny integrated transistors. Such an ASIC may be implemented with CMOS, TTL, VLSI, or another suitable construction. Other alternatives include a digital signal processing chip (DSP), discrete circuitry (such as resistors, capacitors, diodes, inductors, and transistors), field programmable gate array (FPGA), programmable logic array (PLA), and the like.
Operation
In addition to the various hardware embodiments described above, a different aspect of the invention concerns a method for operating a data storage system to store data with an encapsulated metadata token, and to use this information to protect against recalling stale data from base storage in the event of a cache failure.
Signal-Bearing Media
In the context of FIGS. 1-2, such a method may be implemented, for example, by operating components such as the director 104 and/or controller(s) 106 - 107 (each embodying a digital data processing apparatus 200 ) to execute a sequence of machine-readable instructions. In the absence of a storage failure, the backup controller 107 operates according to a different sequence of instructions (not shown), which primarily serve to copy data objects from the primary storage site 150 to the backup site 151 for backup purposes. The instructions may reside in various types of signal-bearing media. In this respect, one aspect of the present invention concerns a programmed product, comprising signal-bearing media tangibly embodying a program of machine-readable instructions executable by a digital data processor to operate a data storage system to store data with an encapsulated metadata token in base storage, and to use this information to protect against recalling stale data from base storage in the event of a cache failure.
This signal-bearing media may comprise, for example, RAM (not shown) contained within the controller 106 , as represented by the fast-access storage 206 for example. Alternatively, the instructions may be contained in another signal-bearing media, such as a magnetic data storage diskette 300 (FIG. 3 ), directly or indirectly accessible by the processor 200 . Whether contained in the storage 206 , diskette 300 , or elsewhere, the instructions may be stored on a variety of machine-readable data storage media, such as direct access storage (e.g., a conventional “hard drive,” redundant array of inexpensive disks (RAID), or another direct access storage device (DASD)), magnetic tape, electronic read-only memory (e.g., ROM, EPROM, or EEPROM), optical storage (e.g., CD-ROM, WORM, DVD, digital optical tape), paper “punch” cards, or other suitable signal-bearing media including transmission media such as digital and analog and communication links and wireless. In an illustrative embodiment of the invention, the machine-readable instructions may comprise software object code, compiled from a language such as “C,” etc.
Logic Circuitry
In contrast to the signal-bearing medium discussed above, the method aspect of the invention may be implemented using logic circuitry, instead of executing instructions with a processor. In this embodiment, the logic circuitry is implemented in the controller 106 , and is configured to perform operations to implement the method of the invention. The logic circuitry may be implemented using many different types of circuitry, as discussed above.
Operational Sequence
FIG. 4 shows an overall process for operating the data storage system 100 , to illustrate one example of the method aspect of the present invention. For ease of explanation, but without any intended limitation, the example of FIG. 4 is described in the context of the structure of FIGS. 1-2, described above.
After the routine 400 begins in step 402 , a number of concurrent operations begin. In particular, there is a write sequence 407 - 412 , properties subpart sequence 415 - 416 , data subpart sequence 419 - 420 , and read sequence 423 - 430 . Generally, the write sequence serves to write data objects to the cache 110 and base storage 112 . The properties subpart sequence updates data objects' version codes (properties subpart only) when the data objects' non-data properties change. Likewise, the data subpart sequence updates data objects' version codes (data subpart only) when the data objects' underlying data changes. Finally, in the read sequence, the controller 106 reads data from the cache 110 and/or base storage 112 .
Write
Considering FIG. 4 in greater detail, the write sequence 406 begins in step 407 where the director 104 receives a data object. Namely, in step 407 the host 102 sends the director 104 a data object and a storage request. The data object may comprise a logical volume, record, file, physical volume, cylinder, logical or physical device, surface, sector, page, byte, bit, or any other appropriate unit of data. Also in step 407 , the director 104 forwards the data to the “primary” one of the controllers 106 - 107 . For purposes of illustration, the controller 106 constitutes the primary controller in this example. In step 408 , the primary controller 106 writes the data object to its cache 110 and/or base storage 112 . Whether data is written to cache, base storage, or both is determined by the controller's pre-programmed data management strategy, which may include various alternatives such as (1) always storing received data objects on cache and occasionally copying or removing cached data objects to base storage, (2) storing received data objects in base storage and only caching the data objects that are most frequently used or likely to be used, (3) another known or novel approach. The controller 106 also makes an entry in the token database 108 in step 408 . This entry cross-references the data object with its token, which is discussed in greater detail below. At the very least, the token database lists each data object with its version code data subpart. Copying of the data object between primary and backup storage sites may also occur in step 408 , or at another suitable time.
Until step 409 determines that the write operation is complete, step 409 repeats steps 407 - 408 as necessary. When the write operation finishes, step 409 advances to step 410 . In step 410 , the controller 106 encapsulates the current data object's token (as updated by steps 415 , 419 described below). Encapsulation of the token involves collecting some or all of the various token subcomponents listed in TABLE 1 and combining them into a suitable form for storage. Such encapsulation may entail concatenation, aggregation, encoding the parts together into a unified form, encrypting, etc. Step 411 writes the encapsulated token to the cache 110 and/or base storage 112 , along with the data object written in step 408 , depending upon the type of data management strategy in place. After step 411 , the write sequence 406 ends in step 412 .
As an alternative, step 410 may encapsulate the token with its corresponding data object, and write the encapsulated result in step 411 . In this case, step 408 buffers received data for subsequent writing to storage in step 411 . The data object and token may be encapsulated, for example, by concatenation, aggregation, encoding the parts together into a unified form, encrypting, etc.
Version Code Properties Subpart
The version code properties subpart routine 415 - 416 is initiated whenever a data object experiences a change to attributes of the data object other than the underlying data. These attributes include statistics about the data, such as the information shown in TABLE 1. This metadata may change when the controller 106 receives a new or modified data object, or when a data object's characteristics change.
In step 415 , the controller 106 first determines whether the current data object is new to the storage site 150 . If so, the controller 106 generates a new version code properties subpart for the data object and stores it in the token in the database 108 . Otherwise, if the data object is already represented in the cache 110 and/or base storage 112 , the controller 106 advances the data object's existing version code properties subpart in its token database 108 . As an example, version code advancement may be achieved by alphabetically, numerically, or alphanumerically incrementing the version code properties subpart. Only the properties subpart is advanced in step 415 because this advancement is being performed due to a change in properties rather than a write operation, which would affect the data object's underlying data.
Version Code Data Subpart
The version code data subpart routine 419 - 420 is initiated whenever the controller 106 receives a data object for storage at the site 150 . This data object may be new to the site 150 , or it may represent modification to a data object already stored in the cache 110 or base storage 112 . The routine 419 - 420 may be triggered, for example, by the step 407 .
In step 419 , the controller 106 first determines whether the current data object is new to the storage site 150 . If so, the controller 106 generates a new version code data subpart for the data object and stores the new code in the token database 108 , cross-referenced against the data object by name or other identity. Otherwise, if the data object is already represented in the cache 110 and/or base storage 112 , the controller 106 advances the data object's existing version code data subpart in its token database 108 . The data subpart in the token database 108 is advanced in anticipation of the data object's update, to be performed by way of writing to the storage site 150 . As an example, this advancement may be achieved by alphabetically, numerically, or alphanumerically incrementing the version code data subpart. Only the data subpart is advanced in step 419 because the present token advancement is being performed due to a write operation, which affects the data object's underlying data rather than properties. The properties subpart is not changed.
Read
The read sequence 423 - 430 is started when the director 104 receives a read request from the host 102 . In response, the director 104 forwards the read request to the primary controller 106 , which determines whether the requested data object is stored in cache 110 (step 423 ). If not, this represents a cache miss, and step 423 advances to step 424 . In step 424 , the controller 106 reads the data object's version code data subpart from the token database 108 . In step 425 , the controller 106 reads the data object's encapsulated token from base storage 112 to obtain the data object's version code data subpart. The controller 106 then proceeds to step 426 , where it determines whether these data subparts match. Step 426 does not need to consider the version code properties subpart. If the data subparts match, then the data object contained in the base storage 112 is current. This prevents the data object from being deemed “stale” if the data object has experienced various updates that have not affected its data content.
One exemplary situation where non-matching version codes may arise follows. At some early time, the cache 110 and base storage 112 contain the same version of data object. However, the cache 110 may experience several relatively rapid updates before the data object is copied to base storage 112 . In this situation, the cache 110 contains a current version of a data object, whereas the base storage 112 contains an older version. Accordingly, the token database 108 contains a token corresponding to the newest version of the data object, i.e., the data object contained in cache 110 . In this example, the cache 110 experiences a failure causing the loss of the data object from cache 110 . The cache 110 is subsequently repaired, but the lost data object is gone. At this point, the data object on base storage 112 contains an old version code and the token database contains a newer, non-matching version code. The data object in base storage 112 is therefore a “down-level” version.
Referring back to the sequence of FIG. 4, step 426 branches to step 427 if the version code data subparts match. In step 427 , the controller 106 reads the data object from base storage 112 and provides the data object as output. After step 427 , the program ends (step 430 ). Otherwise, if step 426 finds that the version code data subparts do not match, then the data object from base storage 112 contains down-level data with respect to the version code data subpart stored in the token database 108 . In this event, the data object from base storage 112 is considered stale, and the controller 106 issues an error message (step 428 ), and the program ends (step 429 ).
Other Embodiments
While the foregoing disclosure shows a number of illustrative embodiments of the invention, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the scope of the invention as defined by the appended claims. Furthermore, although elements of the invention may be described or claimed in the singular, the plural is contemplated unless limitation to the singular is explicitly stated.
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A data storage system stores data with a corresponding encapsulated metadata token in cache and/or base storage to protect against recalling stale data from base storage in the event of a cache failure and subsequent cache miss. A controller is coupled to a cache, base storage, and token database. After receiving a data object and associated write request, the controller assigns a version code to the data object. If the data object already exists, the controller advances the data object's version code. A token, including the version code along with other items of metadata, is encapsulated for storage. Then, the controller stores the data object and encapsulated token in cache and/or base storage and updates the token database to cross-reference the data object with its version code. When the controller experiences a cache miss, there is danger in blindly retrieving the data object from base storage since the cache miss may have occurred due to cache failure before the data was de-staged, leaving a down-level version of the data object on base storage. This problem is avoided by comparing the data object's version code contained in base storage to the version code listed for the data object in the token database. Only if the compared version codes match, the data object is read from base storage and provided as output.
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BACKGROUND OF THE INVENTION
A number of barbecued food cooking grills have been proposed, including those in which a pan for burning a fuel such as charcoal have been proposed with a supporting grill for the food, wherein the grill may be rotated by a motor. This construction is shown in a number of patents, e.g.. U.S. Pat. Nos. 3,134,320; 3,298,301; 3,131,685; 3,085,497; 3,012,496; 3,033,190; and 3,033,189. The latter patent is exemplary of the type of rotary grill for food which would have a high mass and inertia, and hence require a motor with enough power to overcome such high mass and inertia, especially with an unbalanced load on the grill.
U.S. Pat. No. 3,511,167 discloses a rotisserie spit for meat which may be oscillated over a small arc so as not to break a conductor wire to a thermal sensing probe in the meat. The means for effecting the reversal of rotation is not disclosed.
In the charcoal-fired cooking grills as shown in most of the first-mentioned group of patents, it is easy and practical for the cooking chef to prepare a charcoal fire of only the necessary size for the quantity of food to be cooked. Such charcoal fire can be placed in a large grill at one smaller location and the food on the grill is placed at that same smaller location. In recent years, gas-fired cooking grills have become more popular, either fired from a gas pipe or fired from a portable storage tank such as for propane. In the typical prior art gas cooking grill, the gas flame is from a large burner which covers substantially all of the grill area. When one wants to cook only a small amount of food on a large grill, this is quite wasteful of the heat source, which in this case is a gas flame.
SUMMARY OF THE INVENTION
The problem to be solved, therefore, is how to conserve the heat source when the amount of food to be cooked covers less than all of the surface of the grill.
This problem is solved by a cooking grill assembly comprising, in combination, a support having an axis, a grill carried relative to said support, a heat source carried relative to said support adjacent said grill and extending substantially perpendicularly to said axis to cooperate with any food on said grill, a bearing on said support substantially coaxial at said axis, the food to be cooked on the grill adapted to be disposed on a given area less than 100% of the area of the grill, means to limit the heat source to substantially said given area of said grill, said limiting means including a motor, drive linkage and variable means, said drive linkage connecting said motor to rotate one of said heat source and said grill in said bearing, and said variable means varying the effective area of cooperation of said heat source to said given area of said grill.
Accordingly, an object of the invention is to provide a food cooking grill with variable means varying the effective cooking area on the grill.
Other objects and a fuller understanding of the invention may be had by referring to the following description and claims, taken in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a plan view of a cooking grill embodying the invention;
FIG. 2 is a sectional view on line 2--2 of FIG. 1;
FIG. 3 is an enlarged sectional view similar to FIG. 2;
FIG. 4 is an end view of the burner tube;
FIG. 5 is an enlarged plan view of a variable stop for the burner tube;
FIG. 6 is an elevational view of the stop of FIG. 5;
FIG. 7 is an enlarged plan view of the variable stop in a stop position;
FIG. 8 is an elevational view of the stop of FIG. 7;
FIG. 9 is a partial cross-sectional view of a second embodiment; and
FIG. 10 is a partial sectional elevational view of a third embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 to 8 illustrate a cooking grill 10 which includes a support 11. This support may be partially louvered or with baffles, or with air apertures 12, and is shown in the form of a closed bottom pan with legs 13. This support pan is shown as being circular and has an axis 14 which in this preferred embodiment is vertical. The upper rim 15 of the pan 11 supports a food cooking grill 16 and in this embodiment the grill 16 is also circular to conform to the circular shape of the pan 11. A heat source is provided to do the cooking of the food on the grill, and in this embodiment the heat source is carried relative to the support pan 11 and adjacent to the grill 16. The heat source in this embodiment is shown as a burner tube 19 which extends substantially perpendicularly to the axis 14. The burner tube extends to the axis 14 and in this embodiment is L-shaped with a long arm 20 and a short arm 21 on the axis 14. A bearing 22 is provided on the support pan 11 on the axis 14. This bearing establishes rotation of either the grill 16 or the burner tube 19, and in this embodiment it is the burner tube 19 which is journaled in the bearing 22 for rotation. The long arm 20 of the burner tube has burner ports 24 to emit gas for a flame for cooking the food on the grill. These burner ports are one vertical side of the tube, and in the preferred embodiment those ports closest to the axis 14 may be smaller than those ports more distant from the axis. A drip shield 25 is secured to the long arm 20 and extends slightly outwardly over the burner ports 24 so as to prevent the ports from being fouled by any drippings from the food being cooked.
The grill might be 24 inches in diameter, for example, and in many cases the food to be cooked does not cover the entire grill 16 but only a given area less than 100% of the surface area of the grill 16. The present invention includes a means to limit the heat source to substantially that given area of the grill. This limiting means includes generally a motor 28, drive linkage 29, and variable means 30. The central portion of the pan support 11 is raised to form a housing 32 on which the bearing 22 is mounted. An enclosure plate 33 is secured with fasteners 34 to this pan support 11 and the motor 28 is mounted on this enclosure plate 33. The enclosure plate 33 may have openings 35 for admitting air inside the housing 32.
The motor is preferably an electric motor, and the drive linkage 29 is connected between this motor and the burner tube. The drive linkage 29 is preferably a gear reduction unit to reduce the speed of the motor 28 relative to that of the burner arm 19. The drive linkage 29 includes a driven gear 36 fixed on the short arm 21 of the burner tube 19. This driven gear is hollow and is centered on an orifice spud 37 which emits gas into the burner tube through the bearing 22. The hollow driven gear 36, therefore, also acts as a radial bearing for support of the burner tube 19. The burner tube 19 may be lifted out of the bearing 22 for cleaning purposes, if necessary. The burner tube short arm 21 has an aperture 38 for primary air, and the air openings 12 provide secondary air for the gas flame emitting from the burner ports 24.
The orifice spud 37 is connected to a gas fitting 39 mounted on the enclosure plate 33. A gas valve 41 controls flow of gas to the fitting 39 from a gas source 42, which may be a gas line or a portable container, such as for propane. Preferably, the valve 41 is a multiple-position valve controlled by a knob 43 with full ON, half, quarter, and OFF positions.
The variable means 30 which varies the effective cooking area includes generally stop means 46 which are at different locations around the periphery of the support pan 11 and have variable conditions. One of these stop means is shown enlarged in FIGS. 5-8. In FIGS. 7 and 8, the stop 46 is shown in the active condition, and in FIGS. 5 and 6 is shown in the inactive condition. This stop 46 is a means to stop rotation of the burner tube 19 and to effect rotation in the opposite direction. By this means, by establishing the active or inactive condition of the stops at the nine o'clock, twelve o'clock, and three o'clock positions of FIG. 1, one may select either one-fourth, one-half, three-quarter, or 358-degree oscillating arcuate movement or continuous rotation in one direction. In more detail, the variable means 30 shown in FIGS. 5-8 includes a sheet metal plate 48 which is secured to the side wall of the pan support 11 by any suitable means, such as rivets 49. The upper portion 50 and the lower portion 51 extend inwardly toward the axis 14. A midportion 52 of the plate 48 forms a U-shaped channel for a guide and bearing of the midportion 54 of the rodlike stop 46. This stop 46 has an upper arm 55 and a depending arm 56, and it is this depending arm 56 which extends into the path of the burner tube 19 in the active position shown in FIGS. 7 and 8. A small foot or handle 57 is on the lower end of the midportion 54 and extends outwardly through an aperture 58 in the side wall of the pan support 11. This handle may be grasped and the stop means 46 lifted until the upper arm 55 is above a projection 59 on the upper portion 50 of the plate 48 Then the handle 57 may be turned through a 90-degree arc to change between the conditions of FIGS. 5 and 7, and then gravity will lower the stop means 46 into the selected position of either FIG. 5 or FIG. 7. In the active condition of FIG. 7, the upper arm 55 rests in a notch 60 in the plate upper portion 50, and this combined with the guide and bearing portion 52 holds the stop 46 in the active condition as the burner tube 19 strikes it from either direction.
In the operation of the cooking grill assembly 10, if one has only a small amount of food to be cooked, it can then be placed in the sector between twelve o'clock and three o'clock and the stop means 46 at these two locations moved into the active condition by lifting the stop handle 57 in the position of FIG. 5 and rotating the handle to the position shown in FIG. 7 and then allowing the stop means to drop into the notch 60. This will place the stop arm 56 in the path of movement of the end of the burner tube 19 so that it will oscillate between these two positions through about a 90-degree arc. The motor 28 is preferably an electric motor, and preferably is an alternating voltage permanent magnet and bidirectional motor. Such motor need only have a very small power output, e.g., a 10-watt output, and then the speed reduction of the drive linkage 29 may have a large speed reduction, e.g., 300:1 or 1000:1, to provide relative oscillation between the burner tube 19 and the grill 16. In this embodiment, it is the burner tube 19 which moves. This may be made from light-weight aluminum so that the mass and inertia are quite low and easy for the small power output motor 28 to move. If this is a 3600 rpm motor, on 60 Hertz power, this will be a two-pole motor, and typically the two poles are diametrically opposite on the rotor. When the burner tube 19 hits one of the stop means 46, this will stall the motor 28 as soon as all of the lost motion is taken out of the drive train. When the motor stalls, this absorption of the lost motion is somewhat elastic, which tends to give an acceleration of the motor in the opposite rotational direction. The end result is that the motor does accelerate and run in the opposite direction to drive the burner tube back to the other active stop. By this means, the burner tube 19 oscillates back and forth between the selected active stops so as to vary the effective area of the heat source relative to the food being cooked, and hence the heat source is limited to substantially the given area of the grill on which the food is placed.
If the active stops are selected at the nine o'clock and three o'clock positions, for example, then the burner tube 19 will oscillate to about a 180-degree arc. If the active stops are selected at the twelve o'clock and three o'clock positions when the burner tube is outside of this arc, the burner tube will be limited to about a 270-degree rotation. If only one of the stops is placed in the active condition, the burner tube will have about a 358-degree rotation before it is reversed. As an alternative, all of the stops may be placed in the inactive position and the motor will then drive the burner tube in a single direction of rotation continuously.
The multiposition gas valve 41 may have positions such as full ON, one-half, one-fourth, and OFF, in order to cooperate with the selected percentage of area of the grill on which food is being cooked. The remainder of the grill may be used for other items of food which are to be kept warm but not really cooked.
Although the burner tube 19 is always in motion, the proximity of the orifice spud 37 to the burner tube opening on the axis 14 remains constant for a uniform gas flow and uniform flame. The gas consumption of this grill is at least 50% less than grills with comparable grid area. This is accomplished by the close proximity of the burner flame to the food being cooked and the elimination of the secondary heating masses, sometimes called "lava rocks," which must be heated to temperature before the food can be cooked.
If the secondary heating masses are desired, then FIG. 9 illustrates an extension rim 65 which may be secured by fasteners 66 to the support pan 11. The upper edge of the extension rim 65 supports the cooking grill 16 and a shelf 67 supports a supplementary grill 68 to carry the secondary heating masses 69. Therefore, if a person desires the use of these so-called lava rocks, they may easily be used with this cooking grill assembly.
FIG. 10 illustrates a further modification wherein the support, such as the shelf 67, may support a grease baffle 72 with louvers 73. This can prevent drippings from the food being cooked from dropping onto the burner tube 19 or into the support pan 11.
The cooking grill assembly 10 provides a low cost and energy-efficient gas grill compared with many of the prior art which had a gas burner commensurate in size with the size of the cooking grill. The burner ports 24 may be in close proximity to the food being cooked, but since the burner tube 19 is in constant motion, there is no burning of the food and the gas consumption is much less than with prior art assemblies. The heat source is limited to that area of the grill on which the food is to be cooked, and this results in the highly energy-efficient cooking grill assembly of the present invention.
The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention as hereinafter claimed.
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A cooking grill assembly of high energy efficiency is disclosed. A gas burner arm heat source is oscillated through an arc of a variable amount in order to limit the heat source cooperation with the cooking grill to that area of the grill on which the food is to be cooked. A means to limit the heat source to this given area of the grill is provided and includes a motor, drive linkage, and variable stop means so that the arc of the burner tube oscillation is limited to the selected area. The foregoing abstract is merely a resume of one general application, is not a complete discussion of all principles of operation or applications, and is not to be construed as a limitation on the scope of the claimed subject matter.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. National Stage application Ser. No. 13/128,416, filed Jun. 9, 2011, which is based upon and claims benefit of PCT Application No. PCT/U.S. Ser. No. 09/066,796, filed Dec. 4, 2009, which is based upon and claims benefit of U.S. Provisional Patent Application Ser. No. 61/119,908 filed Dec. 4, 2008, which is hereby incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable.
REFERENCE TO A SEQUENCE LISTING
[0004] Not Applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The invention relates to a link belt for use in a continuous furnace and, more particularly, link belts having roller configurations.
[0007] 2. Background Art
[0008] It is known to advantageously treat various articles by subjecting the articles to high temperatures for preselected periods of time. Such treatment may, for example, effect sintering of articles which are made by compacting powdered refractory metals or ceramics. In this regard, some of these processes include method steps where the articles are transported through a heat treating zone in a furnace, rather than being loaded and unloaded in batches.
[0009] For example, it is known to transport articles through heating zones on link belts made of wire which are formed by conventional belt links. Somewhat similar to a wire belt is a transport belt disclosed in Miller, Jr. et al., U.S. Pat. No. 3,535,946 issued Nov. 15, 1995. The Miller, Jr. et al. patent discloses a belt made up of a succession of interwoven links, with each of the links formed of a length of tungsten wire which has been treated to a temperature of at least 400° C. The links are wound around an elliptical mandrel so as to provide, when cooled, a link which is in the form of a slightly flattened helix. Miller, Jr. et al. further disclose that they believe that by the avoidance of sharp bends in the link form and by the provision of a large number of interlocking contact points between links, strength and failure resistance are improved.
[0010] Autenrieth, et al. U.S. Pat. No. 5,199,868 issued Apr. 6, 1993 discloses a continuous furnace which serves for the simultaneous two-sided sintering of sintered sheets upon substrates. The furnace of Autenrieth, et al. includes a muffle and a conveyor belt longitudinally traversing the muffle and carrying the substrates. The belt consists of a pair of individual belts which are guided in parallel next to each other in a synchronous manner. The belt surfaces are mutually inclined at a small angle to the horizontal in the muffle. The substrates are self supporting between two parallel lateral edges. The substrates lie with one lateral edge on the belt surface of one belt and with the second lateral edge on the belt surface of the other belt. In this manner, the bottom side of each substrate does not touch the individual belts.
[0011] Fritsch, U.S. Pat. No. 2,994,917 issued Jul. 28, 1954 discloses an apparatus for converting metal powder into wrought metal shapes comprising at least one pair of oppositely disposed and laterally spaced vertical compactor elements. Each of the compactor elements includes an endless link belt mounted to travel about a pair of support wheels. The adjacent outer surfaces of the link belt form substantially continuous pressure surfaces inclined at an acute angle to the common axis of the pair of compactor elements. The adjacent pressure surfaces define a truncated V-shaped passageway. Means are provided for moving the link belt at the same rate of speed and in opposite directions so that the adjacent pressure surfaces travel uniformly toward the narrow end of the passageway defined by the compactor elements. In this manner, loose metal powder is compacted into a precompressed strip having sufficient mechanical strength to retain its form. This strip is introduced into a pair of pressure rolls. A power feed hopper is adapted to introduce loose metal powder into the wide end of the passageway. A pair of oppositely disposed pressure rolls having the axis of the rolls disposed in a horizontal plane define a roll gap with a width which is less than the width of the narrow end of the passageway.
[0012] Daringer, U.S. Pat. No. 5,558,204 issued Sep. 24, 1996 describes a weld-free belt assembly in which elongated length modules are coupled in widthwise and side-by-side relationships by transversely-oriented coupling modules. An internal cavity is defined within each link along with a surface configuration on each side of the link. This configuration defines an entry access portion for a coupler and slot portions for enabling relative longitudinal movement of the coupler, while retaining the coupler within the internal cavity. The interfitting coactions of the links and couplers enable an assembled belt to move from linear planar travel into a curved path so as to establish an endless belt configuration. Relative movement of the couplers within a link cavity enables longitudinal collection of links along the inner circumference when the belt enters a curvilinear travel path in approximately the same plane, and enables re-extension for return to linear travel. An assembled belt can be driven longitudinally by sprockets. Also, the belt can be driven along a serpentine path by lateral-edge dynamic frictional drive. Alternatively, a similarly driven and layered helical-path “carousel” arrangement can be used. Special configuration lateral-edge links provide protrusion-free lateral edge surfaces enabling smooth dynamic frictional drive along inner circumference surfaces during curvilinear travel.
SUMMARY OF THE INVENTION
[0013] In accordance with certain concepts of the invention, a continuous conveyor belt is provided, which primarily consists of five separate parts. These parts are center links, side links, rollers, pins and washers. Pins are utilized to hold the parts together, and the washers are utilized at the ends of the pins to keep the assembly from accidentally falling apart.
[0014] A principal purpose of the invention is to convey “green” parts stacked on ceramic plates through a furnace. Most applications are between 2000° F. and 2250° F. The heat of the furnace allows the green parts to be sintered.
[0015] Several challenges exist with respect to the applications for which the current invention has been designed. First, the market to which the continuous conveyor belt would be applied would greatly increase if the invention could be retrofitted into current furnace designs. Current furnaces utilize a drive mechanism called a pinch roll. This style of drive uses a roll to pinch the topside of the belt onto the larger drive roll, assuring that it has enough grip to convey the belt through the furnace. The second challenge was the amount of friction between the conveyor belt and hearth at application temperatures. In this case, friction could be as high as u=3.
[0016] To overcome these challenges, a conveyor is provided which will have a grip on the pinch roller, with reduced friction. This configuration is provided by a conveyor belt produced from asymmetric links that utilize an offset roller, so that it can roll across the hearth but still track across the drive roll. Ceramic plates with parts, could still be set directly on top of the belt.
[0017] One problem which was needed to be overcome in accordance with the invention relates to the concept that asymmetry produces what is simply called “bending stress.” To avoid this issue, finite element analysis was used to minimize parts bend moment. The result is a part which is an “interesting” I-beam configuration on its top surface. Because the green parts sit right on plates, a solid upper surface is not required.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0018] The invention will now be described with respect to the drawings, in which:
[0019] FIG. 1 is a partially schematic and partially diagrammatic view of a sintering furnace with which a link belt may be used in accordance with the invention;
[0020] FIG. 2 is an underside, perspective view of a belt section in accordance with the invention;
[0021] FIG. 3 is an upper, perspective view of the belt section shown in FIG. 2 ;
[0022] FIG. 4 is a perspective and exploded view of the belt section shown in FIGS. 2 and 3 ;
[0023] FIG. 5 is a side, elevation view of the belt section, showing the roller configuration;
[0024] FIG. 6 is an underside, perspective view of a center link of the belt section shown in FIG. 2 ;
[0025] FIG. 7 is an upper, perspective view of a center link of the belt section shown in FIG. 2 ;
[0026] FIG. 8 is a plan view of the center link shown in FIG. 6 ;
[0027] FIG. 9 is a front, elevation view of the center link shown in FIG. 6 ;
[0028] FIG. 10 is a left-side elevation view of the center link shown in FIG. 6 ;
[0029] FIG. 11 is a right-side elevation view of the center link shown in FIG. 6 ;
[0030] FIG. 12 is an upper side view of the center link shown in FIG. 6 ;
[0031] FIG. 13 is an elevation view of the center link shown in FIG. 6 ;
[0032] FIG. 14 is a rear, elevation view of a side link of the belt section shown in FIG. 2 ;
[0033] FIG. 15 is a plan view of the side link shown in FIG. 14 ;
[0034] FIG. 16 is a front, elevation view of the side link shown in FIG. 14 ;
[0035] FIG. 17 is a left-side elevation view of the side link shown in FIG. 14 ;
[0036] FIG. 18 is a right-side elevation view of the side link shown in FIG. 14 ;
[0037] FIG. 19 is a bottom view of the side link shown in FIG. 14 ; and
[0038] FIG. 20 is a perspective view of the side link shown in FIG. 14 .
DETAILED DESCRIPTION OF THE INVENTION
[0039] The principles of the invention will now be described, with respect to a sintering furnace 10 and a link belt 14 as illustrated in FIGS. 1-20 . Advantageously and in accordance with various aspects of the invention, the link belt overcomes relatively high friction due to its roller configuration. In addition, as a result of the link belt in accordance with the invention having a relatively flat upper surface 142 (comprising lateral surface 144 and longitudinal surfaces 146 ) and offset rollers 128 , larger parts are allowed to be placed on the belt. Still further, the offset rollers allow for use in current furnaces which use friction drives. The belt uses rollers 128 which can be formed of ceramic material. The use of the ceramic precludes spot welding of the rollers 128 to the pins 132 . Still further, the use of ceramic material for the rollers avoids the potential for “stiction” if the belt is stopped while under relatively high temperatures. The belt links can be constructed of iron-nickel super alloys or other suitable metal. This type of construction will maintain relatively high strength, while also maintaining relatively better ductility than a fully ceramic belt. The belt has a relatively lower initial cost of ownership than belts which consist of wire mesh systems, or which otherwise consist of fully ceramic systems.
[0040] Turning to FIG. 1 , the drawing illustrates a sintering furnace system 10 . The furnace system 10 includes a sintering furnace 12 . It should be emphasized that link belts in accordance with the invention may be utilized with apparatus other than sintering furnaces. For background information, sintering consists of a method for making objects from powder, by heating the material (heating below its melting point for solid state sintering) until the particles adhere to each other. Sintering is traditionally used for manufacture of ceramic objects, and also has uses in fields such as metallurgy.
[0041] For providing the sintering functions associated with the furnace 12 , a link belt 14 is utilized to transport the items to be sintered through the relatively high temperature furnace 12 . The link belt 14 can take on any of a number of different configurations, and will move through the furnace 12 in the direction shown by the arrows 16 . The link belt 14 itself moves along a path determined by a series of system rollers 18 . The drive mechanism for the link belt 14 is provided by a conventional motor drive 20 which exerts forces on the link belt 14 between the motor drive 20 itself and the drive system roller 22 . As further shown in FIG. 1 , items (not shown) which are to be subjected to the sintering process through the furnace 12 can be placed on the link belt 14 at the charge end 24 . Once the sintering process is completed through the furnace 12 , the items which have been sintered can be removed at the discharge end 26 of the link belt 14 .
[0042] The link belt 14 will now be described with respect to FIGS. 2-20 . As shown in FIG. 2 , the link belt 14 can include a series of belt sections 102 . The belt sections 102 can be linked together in a manner which will be apparent from the subsequent description herein. With reference to FIGS. 2 , 3 , 4 and 6 - 13 , each of the belt sections 102 can include a series of alloy center links 104 , such as shown in the drawings. In the particular belt section 102 shown in FIG. 2 , there are 8 center links 104 illustrated. With reference to FIG. 6 , each of the center links 104 can include a horizontally disposed bottom section 106 . Integral with the horizontal section 106 are a pair of opposing end sections or noses 108 . As shown in FIGS. 8-13 , the noses 108 include a first end section 110 and a second end section 112 . Each of the noses 108 can include a downwardly directed arcuate section 114 . In FIG. 6 , the first end section 110 includes an arcuate section 114 which curves inwardly toward the horizontal section 106 . Correspondingly, the second end section 112 also includes a downwardly directed arcuate section 114 which curves inwardly toward the horizontal section 106 . In this manner, the end sections 108 oppose each other.
[0043] As each of the arcuate sections depend downwardly, the sections form straight sections 140 . The straight sections 140 terminate in what can be characterized as working surfaces 142 . The working surfaces 142 act as the actual contact surfaces. These working surfaces 142 are particularly shown in FIGS. 3 , 4 and 7 . As particularly shown in FIG. 7 , the working surfaces 142 include a pair of laterally extending surfaces 144 . Integral with the lateral working surfaces 144 is a longitudinally extending working surface 146 .
[0044] In addition to the foregoing, and as particularly shown in FIGS. 9 and 13 , the arcuate sections 114 and straight sections 140 , along with the bottom section 106 , form a pair of pin holes 148 . The pin holes 148 comprise apertures 116 which are utilized to receive pins as described in subsequent paragraphs herein. In addition to the pin holes 148 , each of the center links 144 also include a center post 150 . The center post 150 is utilized to provide rigidity and strength to the entirety of the center link 104 . With this particular configuration of the center link 104 in accordance with the invention, the link 104 is made relatively light weight by the structure of the link and portions of the structure which essentially comprise hollow interior. Advantageously, and in accordance with certain aspects of the invention, the links 104 may be constructed of iron-nickel super alloys. Such construction will maintain relatively high strength, while also maintaining and facilitating better ductility then may be obtained from a fully ceramic belt. Also, it should be noted that a crown may now exist on the top plates. This avoids any requirement of a corrugated plate, while still using a friction drive.
[0045] In addition to the alloy center links 104 , the belt section 102 also includes a series of alloy side links 120 . In the particular illustration of the belt section 102 shown in FIG. 2 , there are two alloy side links 120 . However, it should be emphasized that additional side links 120 would exist on the side of the belt section 102 opposing the side on which the side links 120 are shown. The side links 120 will now be described with respect to FIGS. 14-20 . With reference thereto, each of the alloy side links 120 includes a vertically disposed central section 122 . At opposing ends of the central section 122 are a pair of end sections 124 . Each of the end sections 124 has a arcuate-shaped end surface. Formed horizontally through each of the end sections 124 is an aperture 126 . The alloy side links 120 are utilized to secure together the alloy center links 104 , and the apertures are utilized with alloy pins as described in subsequent paragraphs herein to secure the alloy center links and rollers together on a “widthwise” basis. Each of the alloy side links 120 can also be constructed of iron-nickel super alloys, for maintaining strength and ductility.
[0046] Turning again to FIGS. 2-4 , each belt section 102 also includes a series of rollers 128 . Advantageously, and in accordance with certain aspects of the invention, the belt section 102 essentially is formed of a flat upper surface (through the surfaces 142 , 144 , 146 of the alloy center links 104 ) and the rollers 128 are “offset” relative to the belt center links of the section. Such offset rollers 128 can be utilized with current furnaces having friction drives. As shown primarily in FIG. 4 , each of the rollers 128 is of a cylindrical configuration and includes an aperture 130 ( FIG. 2 ) extending horizontally therethrough.
[0047] Again, as earlier mentioned, development of the invention involved the conception of a conveyor that would have grip on the pinch roller and reduced friction. In accordance with the invention, a conveyor belt was produced from asymmetric links that utilize rollers 128 which are offset so that they can roll across the hearth, but still track across the drive roll. Ceramic plates, full of parts, can still be set directly on top of the belt.
[0048] The rollers 128 may be formed of various materials. However, advantageously and in accordance with certain aspects of the invention, the rollers 128 maybe formed of ceramic materials. Ceramic material has a relatively high thermal conductivity. These materials are used in a number of different types of applications where it is necessary to withstand relatively extreme temperatures. For example, ceramic is often used in disc brakes. In this regard, the use of ceramic for the rollers 128 will tend to avoid spot welding of the rollers 128 to the alloy pins. Further, the rollers 128 will also avoid the potential for “stiction,” if the belt 14 for some reason has stopped while under temperature.
[0049] In addition to the aforedescribed elements, the belt section 102 also includes a series of alloy pins 132 . The alloy pins 132 are particularly shown in FIG. 4 and are of a cylindrical configuration. As shown primarily in FIGS. 2 , 3 and 4 , the pins 132 are utilized to secure together the rollers 128 , alloy side links 120 and alloy center links 104 . Where the pins extend through to the side links 120 , pin connectors 134 can be utilized to secure the pins in an appropriate manner. As also shown in FIGS. 2 , 3 and 4 , the alloy pins 132 will extend through the apertures 130 , 126 and 116 .
[0050] In accordance with the foregoing, the belt section 102 can be formed. It should be emphasized that the width of the belt section 102 can be adjusted as desired by adding or subtracting the individual elements of the belt sections 102 .
[0051] In accordance with the foregoing, a continuous conveyor belt has been described, primarily consisting of five separate parts. These parts included center links, side links, rollers, pins and washers. As earlier stated, a primary purpose of the invention is to convey “green” parts stacked on ceramic plates through a furnace. With most applications operating between 2000° F. and 2250° F., the heat of the furnace allows the green parts to be sintered.
[0052] Conveyor belts in accordance with certain concepts of the invention can be retrofitted into current furnace designs. Such current furnaces utilize a drive mechanism identified as a pinch roll. This style of drive utilizes a roll to pinch the top side of the belt onto the larger drive roll, assuring that it has enough grip to convey the belt through the furnaces. A second challenge is the amount of friction between the conveyor belt and hearth at application temperatures. Friction in these cases can be relatively high.
[0053] As described in detail herein, these challenges are overcome by the concept of a conveyor that would have grip on the pinch roller and reduced friction. A conveyor belt was produced from asymmetric links which utilize an offset roller, so that they can roll across the hearth, but still track across the drive roll.
[0054] Of primary importance, asymmetry produces another challenge, commonly referred to as bending stress. To avoid this issue, finite element analysis was used to minimize the parts bend moment. The result is a part which has a somewhat “interesting” I-beam shape on its top surface. Since the green parts ride on plates, a solid upper surface is not required.
[0055] To insure adequate disclosure and clarification of the embodiments of the invention described herein, concepts associated with bending stress relate to the general concept of bending moments for structural elements. A bending moment is a reaction induced in a structural element when external force or moment is applied to the element, causing the element to bend. Correspondingly, finite element analysis relates to techniques originally developed for numerical solution of complex problems and structural mechanics. Utilizing the finite element method, a structural system can be modeled by a set of appropriate finite elements interconnected at points called nodes. Elements may have physical properties, such as thickness, coefficient of thermal expansion, density, Young's modules, shear modules, and Poisson's ratio. Elements are typically interconnected only at exterior nodes, although they are meant to cover an entire domain as accurately as possible. Nodes will have nodal displacements or degrees in freedom which may include translations, rotations and the like. Displacements of any points in the element will be interpolated from the nodal displacement, with this being the main reason for the approximate nature of a solution.
[0056] It will be apparent to those skilled in the pertinent arts that other embodiments of link belts in accordance with the invention may be designed. That is, the principles of the invention are not limited to the specific embodiments described herein. Accordingly, it will be apparent to those skilled in the art that modifications and other variations of the above-described illustrative embodiments of the invention may be effected without departing from the spirit and scope of the novel concepts of the invention.
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A link belt for use in a sintering furnace, which is made of a plurality of first links, each of said links having working surfaces for supporting objects to be carried on the belt. A plurality of rollers are positioned intermediate certain of said first links, and a plurality of pins pass through apertures within said first links and within said rollers.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims benefit of U.S. Provisional Application No. 60/666,940 filed on Mar. 31, 2005, the contents of which are incorporated by reference herein. This application is a continuation-in-part of U.S. application Ser. No. 10/601,820 entitled Spray Dyeing of Garments and filed on Jun. 23, 2003, now U.S. Pat. No. 7,033,403 the contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to fabric dyeing. More particularly, the present invention is related to processes of spray dyeing fabrics.
2. Description of Related Art
Today, fabrics are made from a wide-variety of natural fibers, synthetic fibers, and any combination thereof. Many processes have been proposed for dyeing fabrics.
One process, commonly referred to as yarn dyeing, involves dyeing individual fibers or yarns before the fibers are sewn or knitted into a fabric. One problem associated with such yarn dyeing process relates to inventory control of the yarns and associated garments. For example, yarn dyeing requires the garment manufacturer to maintain a supply of the various colored yarns used in its products. This can lead to an increased cost of goods.
Another dyeing process is commonly referred to as bulk dyeing. In bulk dyeing, un-dyed fibers or yarns are knitted or woven into a raw or un-dyed fabric. The raw fabric is subsequently dyed. The dyed fabric is then used to make the desired product, such as a garment.
Some common bulk dyeing processes include vat dyeing, beam dyeing, jet dyeing, and bath dyeing. Vat dyeing typically consists of immersing a piece of fabric in a vat of liquid dye. Beam dyeing involves winding a length of fabric about a perforated beam. The beam is then placed in a vessel where liquid dye is pumped into the center of the beam, out of the perforations, and through the fabric. Jet dyeing involves placing the fabric in a high-pressure, high-temperature kettle of liquid dye. Bath dyeing involves immersing the fabric in a bath of dye, which is contained in a rotating drum.
One problem associated with bulk dyeing processes relates to the large amounts of water required during processing, which can increase cost of goods for such bulk dyed fabrics.
Yet another problem with bulk dyed fabrics in the manufacture of garments is related to the unpredictability of consumer color preferences. In the garment industry, change in the consumer's preference for one color over another color can lead to an overstock of the undesired colored garments and a back order situation of the desired colored garments. Thus, garments made from bulk dyed fabrics have not proven flexible enough to meet increasing and changing consumer demands.
Further processes of dyeing fabrics involve printing a dye onto a surface of a fabric. This process is commonly used to apply a decorative pattern on the surface of the fabric. Such printing processes include screen-printing and inkjet printing. While these processes have proven useful in quickly changing from one decorative pattern to another, they have not proven useful in bulk dyeing of fabrics.
Accordingly, there is a continuing need for flexible, low cost, low waste processes of dyeing fabrics.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide processes for continuously dyeing fabric to a substantially uniform color.
The process can include continuously moving the fabric in a machine direction; removing folds or creases from the fabric; spraying a first surface of the fabric with a dye; and exposing the fabric to atmospheric steam after spraying the dye on the first surface but prior to the dye drying on the first surface so that the dye migrates from the first surface to a second surface of the fabric and reacts with and affixes to a component of the fabric.
The process can include continuously moving the fabric in a machine direction; opening the fabric and ensuring that the fabric is taut so that any folds or creases in the fabric are substantially removed; spraying a first surface of the fabric with a dye while the fabric is open; and exposing the fabric to atmospheric steam after spraying the dye on the first surface but prior to the dye drying on the first surface so that the dye migrates from the first surface to a second surface of the fabric and reacts with and affixes to a component of the fabric.
A process for continuously dyeing a tubular fabric is also provided. The process includes opening the tubular fabric; spraying a first surface of the open tubular fabric with a dye; closing the tubular fabric; and exposing the closed tubular fabric to atmospheric steam after spraying the dye on the first surface but prior to the dye drying on the first surface so that the dye migrates from the first surface to a second surface of the tubular fabric and reacts with and affixes to a component of the tubular fabric.
The above-described and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description, and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an exemplary embodiment of an automated process for dyeing fabric according to the present invention;
FIG. 2 is a schematic view of another alternate exemplary embodiment of an automated process for dyeing fabric according to the present invention;
FIG. 3 is a top schematic view of another alternate exemplary embodiment of an automated process for dyeing fabric according to the present invention;
FIG. 4 is a side view of the second station of FIG. 3 ; and
FIG. 5 is a schematic view of an exemplary embodiment of a collection unit for collecting finished fabric from the automated process of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings and in particular to FIG. 1 , an exemplary embodiment of a process 10 according to the present disclosure is shown. Process 10 is effective at continuously dyeing a wide fabric 12 with a dye 14 . Fabric 12 can be a warp knit fabric in its un-dyed or raw state.
Process 10 has a first station 16 , a second station 18 , and a third station 20 . Fabric 12 is, preferably, moved among the first, second, and third stations 16 , 18 , 20 in a machine direction 22 . Alternately, it is contemplated for stations 16 , 18 , 20 to move with respect to fabric 12 in a direction opposite to the machine direction 22 . Further, it is contemplated for stations 16 , 18 , 20 and fabric 12 to move with respect to one another.
At first station 16 , folds are removed from fabric 12 . For example, first station 16 can draw fabric 12 over a former 24 so that the former ensures that the fabric is taut and, thus, any folds or creases in the fabric are substantially removed. Former 24 can be a substantially planar frame as shown in FIG. 1 .
In an alternate exemplary embodiment, process 10 draws fabric 12 from a supply of fabric, such as a knitting machine or a fabric roll 26 so that the fabric is taut and, thus, any folds or creases in the fabric are substantially removed.
Next, process 10 exposes fabric 12 to second station 18 where at least one surface (e.g., technical face or technical back) of the fabric are sprayed with the dye. This is preferably achieved by controlling a spray nozzle 28 to spray fabric 12 with dye 14 . In the illustrated embodiment, nozzle 28 is a stationary or fixed nozzle that sprays fabric 12 with dye as the fabric is moved in machine direction 22 . Nozzle 28 can be a linear spray bar as shown. Of course, it is contemplated by the present disclosure for nozzle 28 to move with respect to fabric 12 .
For purposes of clarity, former 24 is shown in FIG. 1 ending before second station 18 . Preferably, first and second stations 16 , 18 are at the same point along process 10 so that former 24 removes folds and creases from fabric 12 in the area of spray nozzle 28 . Thus, process 10 provides former 24 at least in the area of second station 18 .
Process 10 then exposes fabric 12 to third station 20 before dye 14 dries on the fabric. Third station 20 spreads dye 14 throughout fabric 12 and affixes the dye to the fabric so that the dye reacts with and affixes to a component of the fabric 12 . The term “reactive” or “reacts” as used herein shall mean the action of the dye with the fabric that results in the formation of an attachment to the one or more components of the fabric, wherein the attachment can be a covalent bond, an ionic bond, a disbursement into the fiber molecule, or any combination of the foregoing.
For example, the fabric 12 can be a polyamide fabric with or without an elastic yarn, including elastane, lycra, nylon, spandex, or any combinations thereof. Dye 14 can be a dye as in U.S. Pat. No. 4,786,721, U.S. Patent Application 2002/0138922A1, European Patent Application No. EP 1 275 700, and other dyes.
In one embodiment, fabric 12 is a synthetic polyamide fabric and dye 14 is a water-soluble dye that reacts with and affixes to an amine site of the fabric so that the dye can bind with the fabric. The reaction of dye 14 with the amine sites of fabric 12 affixes the dye to the fabric through the formation of a covalent bond. It has been found that dye 14 provides a degree of fixation to and penetration into the individual fibers of fabric 12 . This fixation of dye 14 to fabric 12 is sufficient to allow the dye to be sprayed on only on one surface of the fabric (e.g., technical face), while providing substantially uniform color at the second surface (e.g., technical back).
Fabric 12 is described above by way of example as a synthetic polyamide fabric. Additionally, dye 14 is described above by way of example reacting with an amine site of the synthetic fabric. However, it is contemplated by the present invention for fabric 12 to be made of any natural fiber, synthetic fiber, or any combination thereof. Similarly, it is contemplated by the present invention for dye 14 to be any fiber-reactive compound. For example, dye 14 can be a dye capable of reacting with and/or chemically bonding to the hydroxyl groups of cellulose fibers (e.g., cotton), the amino, carboxy, hydroxy and/or thiol groups of wool or silk fibers, and/or the amino groups and/or carboxy groups of synthetic polyamides.
Third station 20 exposes fabric 12 to steam and heat in a manner and amount sufficient to spread dye 14 throughout fabric 12 and affix the dye to the fabric. For example, third station 20 can have a steam hood that exposes fabric 12 to steam and heat in a manner and amount sufficient to spread dye 14 throughout fabric 12 and affix the dye to the fabric as the fabric is continuously moved through the third station 20 . When affixing dye 14 to fabric 12 made of natural fibers, third station 20 can apply saturated steam, such as atmospheric steam (i.e., steam at atmospheric pressure) at a temperature of about 102 degrees Celsius and a relative humidity of about 100 percent. Third station 20 can apply steam to fabric 12 for about 1 to 7 minutes, preferably about 3 to 5 minutes. When affixing dye 14 to fabric 12 made of synthetic fibers and/or combinations of natural and synthetic fibers, third station 20 can apply saturated steam, such as superheated steam (i.e., steam at atmospheric pressure) at a temperature of up to about 130 degrees Celsius and a relative humidity of upto about 100 percent.
After dye 14 has been spread through and affixed to fabric 12 at third station 20 , fabric 12 can be exposed to a fourth station 30 . Fourth station 30 can wash off or remove any unfixed dye 14 from fabric 12 .
Advantageously, process 10 , with or without the use of former 24 , minimizes contact with fabric 12 to reduce the surface area for condensation to gather and reduce dye bounce off, allows sprayed dye to pass through the garment, minimizes the formation of condensation by on the former. Thus, process 10 also eliminates or mitigates many of the deleterious effects that can occur during spray dyeing.
In some embodiments, process 10 can include a fifth station 32 positioned between second station 18 and third station 20 as shown in phantom. Fifth station 32 can include a heating device 34 for adjusting the moisture content of fabric 12 after application of dye 14 at second station 18 , but before exposure to the steam of third station 20 . For example, heating device 34 can include a radiant heating device, a convection device, or any combinations thereof.
Importantly, fifth station 32 does not dry dye 14 or fabric 12 . Rather, fifth station 32 adjusts the moisture content of fabric 12 . After exposure to second station 18 , fabric 12 has a moisture content of between about 30% to about 100%, and all subranges therebetween. Preferably, fifth station 32 adjusts the moisture content of fabric 12 to between about 20% to about 80% prior to exposure to third station 20 .
Without being limited to any particular theory, it is believed that the heat from fifth station 32 is sufficient to act as a catalyst to start the reaction of dye 14 with fabric 12 , which assists process 10 in yielding a fixation rate of the dye to the fabric 12 of between about 80% to about 90%. In addition, fifth station 32 may assist in preventing dye 14 from dripping from fabric 12 prior to exposure to third station 20 .
Alternate exemplary embodiments of the process according to the present disclosure are shown in FIGS. 2 and 3 , where component parts performing similar and/or analogous functions are labeled in multiples of one hundred.
In the embodiment illustrated in FIG. 2 , process 110 is shown continuously dyeing a tubular fabric 112 with dye 114 . Fabric 112 can be a circular or weft knit fabric in its un-dyed or raw state.
Process 110 has a first station 116 , a second station 118 , and a third station 120 . Fabric 112 is, preferably, moved among the first, second, and third stations 116 , 118 , 120 in a machine direction 122 . Alternately, it is contemplated for stations 116 , 118 , 120 to move with respect to fabric 112 in a direction opposite to the machine direction 122 . Further, it is contemplated for stations 116 , 118 , 120 and fabric 112 to move with respect to one another.
At first station 116 , folds are removed from fabric 112 . For example, first station 116 can draw fabric 112 over a former 124 so that the former opens the tubular fabric to knitted size width and ensures that the fabric is taut and, thus, any folds or creases in the fabric are substantially removed. Former 124 can be one or more substantially tubular frames as shown in FIG. 2 . As used herein, the term “open” when used with respect to tubular fabric shall mean that the interior surface (e.g., the technical back) of the fabric does not contact itself.
In an alternate exemplary embodiment, process 110 can draw fabric 112 from a supply of fabric, such as a roll of circular-knit fabric or a circular-knitting machine 126 so that the fabric is taut and, thus, any folds or creases in the fabric are substantially removed.
Next, process 110 exposes fabric 112 to second station 118 where an exterior surface (e.g., technical face) of the fabric is sprayed with the dye. This is preferably achieved by controlling a spray nozzle 128 to spray fabric 112 with dye 114 . In the illustrated embodiment, nozzle 128 is a stationary or fixed nozzle that sprays fabric 112 with dye as the fabric is moved in machine direction 122 . Nozzle 128 can be a circular spray bar as shown. Of course, it is contemplated by the present disclosure for nozzle 128 to move with respect to fabric 112 .
For purposes of clarity, former 124 is shown ending before second station 118 . Preferably, first and second stations 116 , 118 are at the same point along process 110 so that former 124 removes folds and creases from fabric 112 in the area of spray nozzle 128 . Thus, process 110 provides former 124 at least in the area of second station 118 .
Process 110 then exposes fabric 112 to third station 120 before dye 114 dries on the fabric. Third station 120 spreads dye 114 throughout fabric 112 and affixes the dye to the fabric. As discussed above, third station 120 can have a steam hood that exposes fabric 112 to steam and heat in a manner and amount sufficient to spread dye 114 throughout fabric 112 and affix the dye to the fabric as the fabric is continuously moved through the third station. When affixing dye 114 to fabric 112 made of natural fibers, third station 120 can apply saturated steam, such as atmospheric steam (i.e., steam at atmospheric pressure) at a temperature of between about 60 to about 102 degrees Celsius and a relative humidity of about 100 percent. Third station 120 can apply steam to fabric 112 for about 1 to 7 minutes, preferably about 3 to 5 minutes. When affixing dye 114 to fabric 112 made of synthetic fibers and/or combinations of natural and synthetic fibers, third station 120 can apply saturated steam, such as superheated steam at a temperature of up to about 130 degrees Celsius and a relative humidity of upto about 100 percent.
After dye 114 has been spread through and affixed to fabric 112 at third station 120 , fabric 112 can be exposed to a fourth station 130 . Fourth station 130 can wash off or remove any unfixed dye 114 from fabric 112 .
Advantageously, process 110 , with or without the use of former 124 , minimizes contact with fabric 112 to reduce the surface area for condensation to gather and reduce dye bounce off, allows sprayed dye to pass through the garment, minimizes the formation of condensation by on the former. Thus, process 110 also eliminates or mitigates many of the deleterious effects that can occur during spray dyeing.
Process 110 can also include a fifth station 132 positioned between second station 118 and third station 120 as shown in phantom. Fifth station 132 can include one or more heating devices 134 (only one shown) for adjusting the moisture content of fabric 112 after application of dye 114 at second station 118 , but before exposure to the steam of third station 120 . For example, heating device 134 can include a radiant heating device, a convection device, or any combinations thereof. Preferably, process 110 includes both a plurality of heating devices 134 configured to generate a curtain of hot air (not shown) through which fabric 112 moves. In some embodiments, the curtain of hot air can assist in transporting fabric 112 into third station 120 .
Importantly, fifth station 132 does not dry dye 114 or fabric 112 . Rather, fifth station 132 adjusts the moisture content of fabric 112 . After exposure to second station 118 , fabric 112 has a moisture content of between about 30% to about 100%. Preferably, fifth station 132 adjusts the moisture content of fabric 112 to between about 20% to about 80% prior to exposure to third station 120 .
In the embodiment illustrated in FIG. 3 , process 210 is shown continuously dyeing a tubular fabric 212 with dye 214 . Fabric 212 can be a circular or weft knit fabric in its un-dyed or raw state.
Process 210 has a first station 216 , a second station 218 , a third station 220 , a fourth station 230 , and, if needed, a fifth station 232 . Fabric 212 is, preferably, moved among the stations in a machine direction 222 . Alternately, it is contemplated for the stations to move with respect to fabric 212 in a direction opposite to the machine direction 222 . Further, it is contemplated for the stations and the fabric 212 to move with respect to one another.
At first station 216 , fabric 212 is opened and folds or creases are removed from the fabric. For example, first station 216 can draw fabric 112 from a supply of fabric 226 through an air bearing opening unit 224 , known in the art, the former opens the tubular fabric and ensures that the fabric is taut and, thus, any folds or creases in the fabric are substantially removed. Advantageously, air bearing unit 224 maintains fabric 212 in the open state as the fabric moves through second station 218 and, when present, fifth station 232 .
Second station 218 sprays one or more exterior surfaces 236 (e.g., technical face) of the open fabric with dye 214 as shown in FIG. 4 . This is preferably achieved by controlling one or more spray nozzles 228 (only two shown) to spray the fabric 212 with dye 214 . Preferably, nozzle 228 moves in a direction 238 that is perpendicular to machine direction 222 .
In some embodiments, process 210 includes fifth station 232 positioned between second station 218 and third station 220 . Fifth station 232 can include a heating device 234 for adjusting the moisture content of fabric 212 after application of dye 214 at second station 118 , but before exposure to the steam of third station 220 . Importantly, fifth station 212 does not dry dye 214 or fabric 212 . Rather, fifth station 232 adjusts the moisture content of fabric 212 to a desired range. Preferably, fifth station 232 adjusts the moisture content of fabric 212 to between about 20% to about 80% prior to exposure to third station 220 .
Third station 220 exposes fabric 212 to atmospheric steam (i.e., steam at atmospheric pressure) before dye 214 dries on the fabric. As discussed above, third station 220 exposes fabric 212 to steam and heat in a manner and amount sufficient to spread dye 214 throughout fabric 212 (e.g., from the technical face to the technical back) and affix the dye to the fabric as the fabric is continuously moved through the third station.
Preferably, process 210 closes fabric tube 212 while maintaining the fabric taut before entry into third station 220 by, for example, running the fabric through a set of nip rollers 240 .
In some embodiments, third station 220 can increase the dwell time of fabric 212 within the third station, while decreasing the size of the third station by routing the fabric through a series of vertically arranged rollers 242 . Of course, it is contemplated by the present disclosure for rollers 242 to be horizontally arranged, angled with respect to the horizontal or vertical, or any combinations thereof. It is also contemplated to adjust the speed of rollers 242 with respect to one another so that fabric 212 relaxes as it moved through third station 220 . Advantageously, the rollers 242 are configured to minimize the contact between fabric 212 and third station 220 during the fixation process.
After dye 214 has been spread through and affixed to fabric 212 at third station 220 , process 210 exposes fabric 212 to a fourth station 230 to wash off or remove any unfixed dye from the fabric. Fourth station 230 returns fabric 212 to the open state using a second air bearing opening unit 224 and exposes fabric 212 to a first rinse unit 244 .
First rinse unit 244 rinses the open fabric tube 212 with pressurized hot water having a temperature of between about 40 to about 80 degrees Celsius, with about 70 degrees Celsius being preferred. The use of pressurized hot water ensures the minimal use of water. In addition, it is believed that the pressure of the hot water can assist in reducing shrinkage of fabric 212 by bulking the fabric during the rinse.
Next, fourth station 230 closes the fabric tube 212 by running the fabric through a second set of nip rollers 240 to extract the rinse water and unattached dye from the fabric. In some embodiments, fourth station 230 can expose fabric 212 to a second rinse unit 246 that rinses fabric 212 with pressurized hot rinse water having a temperature of between about 40 to about 80 degrees Celsius, with about 70 degrees Celsius being preferred.
In some embodiments, fourth station 230 can also include a pH adjustment device. For example, first rinse unit 244 and/or second rinse unit 246 can spray rinse water having a predetermined pH level so that the rinse water adjusts the pH of the dyed fabric to a pH that is neutral and/or slightly acidic.
In other embodiments, fourth station 230 can also be used to apply finishing components to fabric 212 . For example, first rinse unit 244 and/or second rinse unit 246 can spray rinse water having a finishing component, such as the aforementioned pH adjusting component, a fabric softener, a fragrance, a stain repellant component, a water repellant component, any other fabric finishing component, and any combinations thereof.
Finally, fourth station 230 extracts the rinse water and unattached dye from the fabric by running the fabric through a third set of nip rollers 240 .
Process 210 can then collect the finished fabric 212 at a collection unit 248 . An exemplary embodiment of a collection unit 248 according to the present disclosure is described with reference to FIG. 5 . Collection unit 248 includes opening unit 224 , a steam box 250 , an inclined relaxing conveyor 252 , a platter 254 , and a fabric buggy 256 .
Fabric 212 exiting second rinse unit 246 is opened by opening unit 224 and travels through steam box 50 . Steam box 50 adjusts the moisture level of fabric 212 to between about 70% to about 80%. Without being limited to any particular theory, it is believed that the steam and moisture from steam box 250 is sufficient to insure the relaxation of fabric 212 prior to drying for purposes of controlling shrinkage of the fabric during drying.
Collection unit 248 then deposits fabric 212 on inclined relaxing conveyor 252 in a tensionless state. Fabric 212 exits conveyor 252 via platter 254 into buggy 256 .
Advantageously, the processes 10 , 110 , 210 according to the present disclosure are continuous processes that expose the fabric to atmospheric steam without the need for expensive closed steaming chambers and without the need from a drying step before steaming. Accordingly, the processes according to the present disclosure can dye the fabric at a rate as high as about 50 yards per minute, preferably between about 3 yards per minute and about 30 yards per minute, more preferably about 20 yards per minute, and any subranges therebetween.
It should be noted that the terms “first”, “second”, “third”, “upper”, “lower”, and the like may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.
While the present invention has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present invention not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this invention, but that this invention will include all embodiments falling within the scope of the present disclosure.
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Processes for dyeing fabric are provided. The process can include continuously moving the fabric in a machine direction; removing folds or creases from the fabric; spraying a first surface of the fabric with a dye; and exposing the fabric to atmospheric steam after spraying the dye on the first surface but prior to the dye drying on the first surface so that the dye migrates from the first surface to a second surface of the fabric and reacts with and affixes to a component of the fabric.
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BACKGROUND
[0001] This disclosure relates to a decorticator, a type of machine designed to separate the outer bast or bark fiber from the inner woody core of plant stalks such as hemp, flax, kenaf, jute, nettles, and other plants in a single operation, by means of an improved method of rapidly breaking the woody core of bast fiber stalks at very short intervals; rapidly scutching the finely broken core material from the bast fiber; and, accomplishing said action without causing mechanical damage to the bast fiber. This action is equally effective on plant stalks in wet, dry, unretted, or retted condition.
[0002] Past and present decortication machines, including but not limited to breakers, scutchers, hammermills, differential speed decorticators, and pre-disintegrators, invariably cause mechanical damage to bast fiber. This mechanical damage is commonly identified as “kink bands.” Typically, the drier the stalk and lesser the degree of retting then the higher the instance of mechanical damage. Most modern decortication systems operate on dry partially retted stalks. The kink bands substantially weaken the bast fiber, thereby limiting the range of end-use applications that it may be used. For example, when mechanically damaged bast fiber is subjected to wet processing, otherwise referred to as degumming, and, additional mechanical processing such as carding, fine cleaning, or cottonization, the mechanically damaged fiber breaks into short fiber under 10 mm in length. Fiber under 10 mm in length has little value and renders attempts to add value through further processing economically unfeasible.
[0003] A decorticating machine is described in U.S. Pat. No. 2,460,488, which employs a method of decortication that includes the following components 1) crushing rolls; 2) feed table; 3) gripping roll; 4) breaking roll; and, 5) scutching roll. The machine operates in the following manner.
[0004] Fibrous plant stalk material is fed longitudinally into two crushing rolls vertically aligned one on top of the other and made of smooth hardened metal. The crushing rolls rotate oppositely and drive the fibrous plant stalks onto a metal feed table which has a gripping roll made of hard rubber positioned above the feed table in close proximity to the feed table edge in order to hold the stalks while continuing to drive the stalks over the edge of the table into the orbit of the breaking roll and then the scutching roll.
[0005] Both the breaker and scutcher rolls have a plurality of solid metal blades extending outward longitudinally from the central shaft. The face of the blades is perpendicular to the directional flow of the fibrous materials being acted upon. The two rolls, breaker and scutcher, rotate in opposite directions and their respective blades intermesh in their respective orbital paths to a depth not greater than 1.5 inches.
[0006] The forward moving stalks are driven over the feed table edge into the orbital paths of the breaking and scutching rolls. The centers of the breaking and scutching rolls and feed table edge form an approximate 45-45-90 triangle with the ninety degree angle formed between feed table edge and the centers of the breaking and scutch rolls.
[0007] The center of the breaking roll is positioned straight out from the feed table edge relatively in line with the plane of the feed table. The orbital path of the breaking roll is down and toward the edge of the feed table. The orbital path clears the edge of the feed table by less than an inch thereby impacting the forward moving stalk bending it down approximately ninety degrees across the feed table edge.
[0008] The forward moving stalk continues into the orbital path of the oppositely rotating scutcher roll, which has an orbital path that clears the bottom of the feed table by less than an inch. The blades of the scutcher roll impact the forward moving stalk at substantially the same point of impact as the preceding impact with the breaking roll, but bending the stalk back and up at approximately ninety degrees. The method of decortication involves rapid back and forth bending which breaks, loosens, and allows the bast fiber to be cleaned of woody core without causing serious damage to the fiber. It also allows for operation on plant stalks of varying degrees of moisture content. This method has antecedent in U.S. Pat. No. 2,980, as well as U.S. Pat. No. 1,601,984.
[0009] Another decorticating machine is described in U.S. Pat. No. 2,162,780. In this particular decorticator, the breaking and scutching rolls are set at approximately forty five degree angles to the path of the fibrous materials, which are pulled through the breaker and scutcher rolls horizontally at a latitudinal or diagonal angle rather than longitudinally. This prior art also provides for means of arranging sections of blade in a regularly recurrent offset pattern longitudinally across the breaker and scutcher rolls, as well as for means of directing a stream of air from the central shaft of the top breaker roll from the base of the trailing faces of the breaker blades.
[0010] The previous prior art examples fail to provide or address the following points of innovation. A means of feeding and compressing a mat of plant stalks into the machine through feed belts position under and above the path of travel. A means of adjusting the angle of the feed table in such a manner that the distance between the point that the stalks clear the feed roller's grip and enter the orbit of the breaker roll can be controlled for optimal performance. A means of controlling the lateral diffusion of plant stalks between the crushing rolls and feed roller with lateral baffle plates. A means of controlling the lateral diffusion of the decorticated fiber through the zone of decortication by providing concave blade tips. A decortication element configuration consisting of a larger upper breaking roll and a smaller lower scutching roll, which results in a unique kinematic action embodied in a faster traveling lower scutcher that sweeps core from fiber. Significantly this sweeping action may be optimized by altering the pitch point of the lower scutcher in relation to the orbit of the upper breaker resulting in lesser or greater distances between the blades of the scutcher and breaker throughout their orbital intermeshing.
A means of directing jets of air through the breaking and scutching blades at the point of contact with the fibrous material. The smoothing and rounding of the feed table edge, breaking blades, and scutching blades. The application of slick hydrophobic coatings and finishes to the feed table, feed table edge, breaking blades, and scutching blades. The addition of longitudinal combing grooves in the feed table edge, breaking blades, and scutching blades that are directionally aligned parallel to the path of travel of the fibrous materials. A means of controlling the operational velocity relative to impact action of the decortication elements by providing a separate variable speed power drive for the feed system. An optimal configuration of crushing elements in relation to gripping element and decortication element, i.e., feed table edge, breaking roll, and scutching rolls. A simplified design for breaking and scutching roll lateral extension, based on a central spacer and two hubs that allow for multiple blade configurations, such as offset, helical, or straight.
SUMMARY
[0018] A first object of this invention is to provide novel pneumatic elements hereafter referred to as an “air comb” that are built into each breaking and scutching blade and capable of delivering a plurality of forceful jets of air at the point of contact with the fibrous material and throughput the orbital path from the tip or extremity of the blades in order to more effectively open fibrous materials, remove core, decrease intermeshing of blades, reduce fiber damage, increase throughput, remove moisture, prevent winding of fiber, and generally aid in material handling throughout the process of decortication.
[0019] A particular object of the air comb feature is to provide a means of delivering chilled air to enhance the effectiveness of core removal. Another particular object of the air comb is to provide a means of delivering heated air to enhance moisture elimination.
[0020] A particular object of the air comb blade is the concaved tip designed to prevent the fibrous material from escaping outside the lateral periphery of the air comb blades by providing a natural space for the fibrous material to fill into as it is acted upon during the course of decortication.
[0021] A second object of this invention is to provide a novel decortication element arrangement consisting of a upper breaking roll with a greater outer diameter than the lower scutching roll. As a result of this arrangement the lower scutching roll must travel at a proportionally faster peripheral speed than the upper breaking roll causing a unique kinematic action which can be adjusted by altering the outer diameter of the scutching roll or by moving the pitch point of the scutching roll blades in relation to the orbital path of the breaking roll blades. The overall effect of this kinematic action creates a highly beneficial cleaning action throughout the orbital intermeshing of the breaking and scutching roll blades. This kinematic action is best described as a sweeping action accompanied by additional bending and flexing of the fibrous material. The end result is cleaner fiber.
[0022] The third object of this invention incorporates or applies physically slick and hydrophobic resins, composite finishes, coatings, or materials to the air comb blades, feed table, and feed table edge as novel means to improve flow ability of fibrous materials, reduce frictions, and eliminate fiber damage.
[0023] The forth object of this invention provides for round and smooth edges on the feed table and air comb blades in order to minimize fiber damage.
[0024] The fifth object of this invention is to cut longitudinally aligned combing grooves running parallel to the path of travel of the fibrous materials in to the rounded and smoothed edges of the feed table edge and air comb blades in order to more effectively open fiber bundles and clean core.
[0025] The sixth object of this invention provides a breaker and scutcher assembly that will allow for ease of lateral extension with a central spacer and end hubs. Said arrangement also allows for multiple blade geometries such as symmetrically offset, straight, or helically spirally patterns. Said arrangement also provides for a means of locking blades in place.
[0026] The seventh object of this invention is to calibrate throughput velocity in relation to decortication impacts by means of separate variable speed drives for the feed element and decortication element.
[0027] The eighth object of this invention provides means for adjusting the angle of the feed table from 0 degrees up to 10 degrees in order to the increase or decrease the distance between the point of contact between the feed roller and the feed table in relation to the orbit of the upper breaking roll.
[0028] The ninth object of this invention provides means for adjusting the length of the feed table in order to increase or decrease the distance between the edge of the feed table and the orbit of the breaking.
[0029] The tenth object of this invention provides a novel feed element consisting of lower belt and upper belt which compress plant stalks into crushing rolls and continue to feed fibrous material over a feed table and under a gripping feed roll thereby creating a uniform continuous mat of material to be acted up in the decortication element.
[0030] The eleventh object of this invention provides a lateral baffle or guide between the crushing rolls and through the gripping feed roll in order to compress and guide the fibrous material into the action of the decortication elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] It is possible to thoroughly understand this invention and its benefits by referring to the following description of operating parts in relation to the drawings and subsequent explanation of the preferred method of operation.
[0032] FIG. 1 is a side elevation view of a fibrous plant stalk being driven through a two dimensional side perspective of the decortication element.
[0033] FIG. 2 is a three dimensional obtuse overview of the same operational configuration of the feed mechanism and decortication element.
[0034] FIG. 3 shows a means of constructing a polygonal rim segment for the breaking and scutching rolls with exterior ports and channels to the hollow interior.
[0035] FIGS. 4 , 5 , 6 , and 7 are perspective views of an air comb.
[0036] FIGS. 8 , 9 , and 10 are exploded perspectives of one side from the exterior to the center of the machine.
[0037] FIGS. 11 , 12 , and 13 are exploded perspectives of the opposite side from the exterior to the center of the machine.
[0038] FIG. 14 is a side view of a fibrous plant stalk decorticator.
[0039] FIG. 15 is a side view of another fibrous plant stalk decorticator.
[0040] FIG. 16 is a side view of another fibrous pant stalk decorticator having an adjustable feed table.
[0041] FIG. 17 is a perspective view of a fibrous plant stalk decorticator.
[0042] FIG. 18 is a top view perspective of a fibrous plant stalk decorticator.
[0043] FIG. 19 is a perspective view of a portion of a hub assembly.
[0044] FIG. 20 is another perspective view of the portion of the hub assembly of FIG. 18 .
[0045] FIG. 21 is a perspective view of a portion of a hub assembly.
[0046] FIG. 22 is another perspective view of the portion of the hub assembly of FIG. 20 .
[0047] FIG. 23 is a perspective view of an assembled hub.
[0048] FIG. 24 is a perspective view of a decorticator blade.
[0049] FIG. 25 is a perspective view of an assembly component for the decorticator blade of FIG. 23 .
[0050] FIG. 26 is a perspective view of a clamp for assembling the blade of FIG. 23 to the hub of FIG. 22 .
[0051] FIG. 27 is a perspective view of a hub and blade assembly.
DETAILED DESCRIPTION
[0052] The machine illustrated in FIGS. 1-2 and FIGS. 8-13 is mounted within a pair of solid upright frame structures indicated at 14 ( FIGS. 8-13 ). The frame structures 14 are adequately spaced to accommodate the width of the feeding mechanism 2 a , 2 b , 3 , and 13 , and decortication elements 5 , 6 , and 7 . The machine is supported by triangular legs 15 . There is an input port at 13 and output port at 35 . It should be readily evident from these drawings that said invention essentially represents a box which may be framed, mounted, and supported by a multitude of structural means. Specifically such box designs are ideal for implementation into forage and combine harvesting equipment.
[0053] There are a multitude of means available for feeding the stalks into the influence of the crushing rolls 2 a and 2 b . The machine illustrated in FIGS. 8-13 is fed by manual means via input port 13 .
[0054] FIG. 1 shows fibrous plant stalk 1 being fed into the oppositely rotating crushing rolls 2 a and 2 b , which are mounted on shafts 16 and 18 . In the drawings, FIGS. 8 and 9 , the shafts 16 and 18 fit into bearings 17 a - 17 b and 19 a - 19 b that are supported in structural frame 14 . FIGS. 11 and 12 show a manner in which crushing rolls 2 a and 2 b are driven in tandem with gripping roll 4 by means of drive shafts 16 , 18 , and 20 , which attach to their respective sprockets 38 , 39 , and 36 and are propelled by drive shaft 22 , which attaches to sprocket 37 , and drives chain 36 .
[0055] In the preferred embodiment of this invention, which is not shown in the drawings, but readily understandable, bearings 17 a and 17 b should be attached to suitable structural guides on both sides of the structural frame 14 . These structural guides support bearings 17 a and 17 b and allow vertical movement. These structural guides will allow suitable pressure yielding devices such as coil springs to be mounted in the structural frame 14 connected to bearings 17 a and 17 b in order to compress crushing roll 2 a into crushing roll 2 b.
[0056] In FIG. 1 , fibrous plant stalk 1 is crushed between crushing rolls 2 a and 2 b as it is propelled forward by the counter-clockwise rotation of crushing roll 2 a and the clockwise rotation of crushing roll 2 b . This flattening action serves to create a uniform layer of fibrous stalk material and begins to break down the bonds between the bast fiber and woody core. In addition, the squeezing action removes moisture from wet plant stalks.
[0057] Upon exiting the influence of crushing rolls 2 a and 2 b , fibrous plant stalk 1 is received on feed table 3 which is relatively thin and made of smooth metal or composite material. Feed table 3 is supported in structural frame 14 . It is beneficial to apply a slick hydrophobic coating or finish to feed table 3 in order to reduce friction and improve flow ability of fibrous plant stalk 1 . It is also beneficial to perforate the surface of feed table 3 , which similarly reduces friction and improves flow ability by providing moisture an escape route and air a means of blowing up through the holes due to the fanning action of scutching roll 7 and its attendant air combs 8 .
[0058] In the preferred embodiment of this invention gripping roll 4 is made of hardened rubber, polyurethane, or similar gripping polymer and positioned directly above feed table 3 and directly adjacent to crushing rolls 2 a and 2 b along the path of travel of fibrous plant stalk 1 . This compact design enables fibrous plant stalk 1 to be held under the dual influence of crushing rolls 2 a and 2 b , as well as, gripping roll 4 for as long a duration as possible thereby minimizing the chance of fibrous plant stalk 1 slipping into the decortication elements. This design also lends itself to uniquely optimized working diameters for crushing rolls 2 a and 2 b based on feed velocity and in relation to the diameter of scutching roll 7 and breaking roll 6 .
[0059] In the drawings, gripping roll 4 is mounted on shaft 20 , which is supported in structural frame 14 by bearings 21 a and 21 b . However, it is the preferred embodiment of this invention that gripping roll 4 also be mounted on vertically moveable bearings attached to structural guides that are built into structural frame 14 in order to engage a pressure applying device, such as a spring coil. Such a pressure device would be mounted to structural frame 14 and attached to bearings 21 a and 21 b , in order to compress gripping roll 4 against feed table 2 and firmly hold fibrous plant stalk 1 .
[0060] Gripping roll 4 rotates counter-clockwise at a slightly faster velocity than crushing rolls 2 a and 2 b , pulling the stalk forward and not allowing it bunch up as it is fed into the influence of the decortication element.
[0061] Upon exiting the grasp of gripping roll 4 , fibrous plant stalk 1 is propelled forward over feed table edge 5 and into the orbital paths of breaking roll 6 and then scutching roll 7 . Feed table 3 is extendable and retractable allowing feed table edge 5 to be moved in and out to accommodate fibrous plant stalks of varying stalk diameter, flexibility, and brittleness. In general feed table edge 5 does not exceed the furthest circumferential point forward of gripping roll 4 . This tangential point is perpendicular to feed table 3 . The distance between feed table edge 5 and the peripheral orbits of breaking roll 6 is adjustable within a range of 5 millimeters to 44 millimeters.
[0062] Breaking roll 6 and scutching roll 7 may be arranged in numerous manners with varying diameters and numbers of blades. However in the preferred embodiment of this invention, breaking roll 6 and scutching roll 7 are the same size and have the same number of blades. As can be seen in FIGS. 1-2 and FIGS. 8-13 , this symmetrical design necessitates that breaking roll drive shaft 28 intersect with the plane of feed table 3 and that scutching roll drive shaft 25 intersect with a tangential line dropped down from rounded feed table edge 5 that is relatively perpendicular to the directional flow of fibrous plant stalk 1 and in relative proximity to and behind feed table edge 5 . Such an arrangement of working parts forms an approximate 90-45-45 degree triangle between feed table edge 5 , breaking roll drive shaft 28 , and scutching roll drive shaft 25 . The 90 degree angle occurs between feed table edge 5 and break roll 6 and scutch roll 7 . This arrangement also insures that breaking roll 6 and scutching roll 7 impact fibrous plant stalk 1 at substantially the same location. As a result of this action fibrous plant stalk 1 is repeatedly bent back and forth causing the core to be thoroughly shattered and removed from fibrous plant stalk 1 , 1 a , and 1 c.
[0063] FIGS. 8 and 11 show means for securing breaking roll 6 and scutching roll 7 to both sides of structural frame 14 . Specifically, drive shafts 25 and 28 correspond to breaking roll 6 and scutching roll 7 respectively are secured in bearings 26 a - 26 b and 29 a - 29 b respectively. Both sets of bearings, 26 a - 26 b and 29 a - 29 b , may be mounted on swivels that are secured to structural frame 14 , in order to better control the angle of impact and depth of intermeshing between air comb blades 8 on the opposing rolls 6 and 7 .
[0064] FIGS. 1 and 2 depict beater roll 6 and scutcher roll 7 with a plurality of blades 8 of special construction, hereafter referred to as air combs. The preferred design for these air combs is illustrated in FIGS. 4-7 . FIGS. 4 and 5 show a single L-shaped piece of machined metal with grooves cut into the back exterior side 8 a and a rounded inner tip at the top 8 b . When two L-shaped pieces are placed back to back the resulting composite piece is an air comb 8 as shown in FIGS. 6 and 7 .
[0065] Air combs attach to breaking roll rim segment 9 and scutching roll rim segment 9 , which are shown in FIGS. 1 and 3 . FIG. 3 also shows the ports into which air combs 8 plug into rim segments 9 . FIG. 3 shows how these ports open into hollow shaft interior 10 which is also depicted in FIG. 1 . Compressed air is delivered to hollow shaft interior 10 via drive shafts 25 and 28 on the opposite side as the drive mechanisms, which in the present drawings corresponds to FIG. 11 . This air may be chilled or heated. In the preferred embodiment of this invention the compressed air is channeled through volume reducing grooves which effectively accelerate the air stream into jet blasts more effectively opening fiber bundles 1 a and removing core 1 c . The air combs also reduce the angles of impact and degree of intermeshing between the blades of breaking roll 6 and scutching roll 7 . Consequently, less impact force is required to remove the core 1 c from flattened and decorticated fibrous stalk material 1 a , which minimizes mechanical fiber damage to recovered fiber 1 b . The “air comb” as described in FIGS. 4-7 is an entirely novel device. However, it is not limited to this design. An air comb 8 may be simply constructed from a typical air knife or similar volume reducing jet nozzle type device that is capable of delivering pressurized air at the point of contact with the fibrous material and throughout the orbital path from the tip or extremity of the blades. Such air knives and nozzles are available on the open market. To make a suitable air comb with one of these devices one would reinforce the forward travelling side of said device with a suitable hardened material such as metal or composite to form a blade for breaking and scutching operations. An air knife, jet, or plurality of jets reinforced is such a manner is novel and the proposed application of such a device is novel.
[0066] Another feature with benefits that is not shown in the present drawings is combing grooves aligned parallel to the directional flow of fibrous plant stalks cut into feed table edge 5 and air comb 8 . Combing grooves facilitate the opening of fiber bundles, which improves core removal 1 c.
[0067] Feed table edge 5 and air comb 8 are all rounded and smooth finished, even with combing grooves. The surfaces of these parts also benefit from the application of slick hydrophobic coatings and finishes that reduce friction and improve the flow ability of fibrous plant stalks. These design measure allow fiber bundles to slip across impacting surfaces reducing the potential for mechanical damage.
[0068] Clean bast fiber 1 b is ejected from the decorticator through output port 35 .
[0069] A means of making rim segment 9 is shown in FIG. 3 . Rim segment 9 is manufactured from a cylinder or symmetrical polygonal shaft or pipe composed of metal or suitable hardened composite material. Rim segment 9 is constructed with ports in the outer surface to accept air comb blades 8 . These ports breach a hollow shaft interior 10 and permit air to enter the air comb 8 . Rim segment 9 is attached to the drive shafts 25 and 28 at the lateral ends of rim segment 9 by means of solid plate 12 , FIG. 2 , thereby creating sealed hollow shaft interior 10 which is capable of accepting pressurized air.
[0070] Rim segment 9 may be constructed as a single segment machine as depicted in the present drawings or rim segment 9 may be interlocked with multiple rim segment 9 pieces to create breaking and scutching rolls 6 and 7 of varying widths. When rim segment 9 is interlocked to form a multi-segment roll it is possible to arrange the blades in patterns, such as straight lines or as recurring offset patterns, like chevrons or helical spirals. Means for propelling breaking and scutching rolls 6 and 7 are illustrated in FIGS. 8 and 9 . Electric motor 34 drives chain 31 which loops around sprockets 27 and 30 propelling drive shafts 25 and 27 which correspond to breaking roll 6 and scutching roll 7 respectively. Chain 31 also drives sprocket 24 propelling drive shaft 22 , which drives crushing rolls 2 a and 2 b as well as gripping roll 4 .
[0071] Referring to FIG. 14 , system 110 includes a conveyor 112 for introducing fibrous plant stalks to compression zone 114 . Compression zone 114 is bound by conveyor 112 and belt 116 . Belt 116 may be a cogged drive or power transmission belt and be routed over rollers 118 , 124 and 126 . Roller 118 and roller 120 partially define the paths of belt 116 and conveyor 112 respectively and act as crush rollers to further compress the plant stalks fed to system 110 . This action creates a uniform mat of fibrous plant stalk. Beyond the crush rollers, the fibrous plant stalks are directed along a feed table 122 . Feed table 122 may be positioned in a fixed manner relative to breaker 120 and skutcher 130 . In other embodiments, feed table 122 may be adjustable to allow an operator to adjust the angle at which the fibrous plant stalks are introduced to the blades 132 on breaker 128 . Blades 132 are coupled to hub 134 of breaker 128 .
[0072] Each of breaker 128 and scutcher 130 are provided with a plurality of blades for impacting the fibrous plant stalk. Scutcher 130 is provided with blades 136 coupled to hub 138 . In particular, the blades 132 and 136 may overlap such that the fibrous plant stalk is bent back and forth as it passes through system 110 . Also, the overlap of blades 132 and 134 results in a stretching action as the tips of blades 132 and 136 are raked across the fibrous plant stalk. Upon exiting the region of overlap between breaker 128 and skutcher 130 , the fibrous plant stalk is directed through a discharge oriented perpendicular to a plane that is parallel to the axis of both breaker 128 and skutcher 130 .
[0073] FIGS. 15 and 16 , depict a fibrous stalk decorticator with an adjustable feed assembly 211 , large breaker 228 , and small scutcher 230 . Breaker 228 is composed 20 air comb blades 232 attached to hub 234 , whereas scutcher 230 is composed of 10 air comb blades 236 attached to hub 238 . Based on this breaker and scutcher configuration the gearing drive ratio between scutcher 230 and breaker 228 must be 2:1.
[0074] Feed table 211 can be seen in two positions. In FIG. 15 it is shown flat or straight on, while in FIG. 16 it is shown at an 8 degree angle of incline. The range of adjustability will fall within the range of 0 degrees to 10 degrees. Feed table 222 is composed of spacers 223 which may be removed and inserted as determined by machine operator for the purpose of shortening or lengthening the space between the edge of feed table 222 and the orbit of breaker 228 .
[0075] Frame 210 encases the fibrous plant stalk decorticator. Baffles 248 , 250 , and 251 protect the inside and direct shattered core to the bottom of the decorticator.
[0076] Fibrous plant stalks enter the machine at input port 214 . Upon entry fibrous plant stalks are flattened over rollers 218 and 220 . Roller 218 is part of feed belt assembly 211 . Rollers 218 and 224 are fixed to the structural frame by means suitable for applying pressure downward. Each roller 218 and 224 is capable of traveling up or down independent of one another by 0.5 inch. As fibrous plants stalks enter input port 214 , lateral baffle guide 215 prevents flattened fibrous material from laterally spilling over the edges of feed table 222 . Feed belt assembly 211 consists of feed belt 216 which is driven by roller 226 . Feed belt 216 is a cogged timing belt constructed of polymer such as polyurethane that provides gripping action. As previously described rollers 218 and 224 provide downward pressure and are capable of traveling up and down 0.5 inch. Rollers 218 and 224 are cogged. Tensioner 240 is composed of shafts 244 , pressure device 246 , and roller 247 . The purpose of tensioner 240 is keep feed belt 216 tight.
[0077] FIG. 17 shows the concaved tips for air comb blades 252 and 254 on both the upper breaker 228 and lower scutcher 230 .
[0078] FIG. 18 is a view from the above the fibrous plant stalk decorticator depicting feed table edge 255 inversely contoured to match the concaved air comb blade tip 252 . Lateral baffle 215 is also depicted in FIG. 18 . It will be noted that air comb blade 252 exceeds the width of feed path 256 . This extra spacing on the lateral periphery of feed path helps to contain the material flow and prevent lateral spill over.
[0079] FIGS. 19-27 depict the decortication element assembly. FIGS. 19 and 20 depict inner spacer 310 of the hub assembly. The space can be built to accommodate any operational width. Space 322 is hollow and accepts air from the central shaft. Holes 323 and 324 represent air channels from the interior space 322 to the exterior of the spacer. Air combs 510 are secured to external face 314 of the spacer and external face 414 of the outer wheel hubs. Each air comb 510 is attached by a blade clamp 610 by screws through points 614 , 518 , and 416 . A gasket may be inserted on face 314 to create an air tight seal between the spacer and the air comb.
[0080] FIGS. 21 and 22 depict the outer wheel hubs 410 . Outer wheel hubs 410 are bolted on both sides of inner spacer 310 with screws through screw insertion points 326 and 426 . Inner plate faces 415 and 420 of outer wheel hub 410 fits into corresponding plate faces 312 and 320 of spacer 310 . A rubber gasket seal may be inserted between rims 318 and 418 to form an airtight seal.
[0081] Space 422 accepts the central drive shaft which is anchored by a screw inserted through hole 432 . The outer face 434 of outer wheel hub 410 also has a protruding rim lip 430 and rim face 428 . Hole 432 extends through to rim lip 430 . A gasket or washer may be inserted around the central drive shaft and into space 422 to create an air tight seal. FIGS. 23 and 27 depict the entire wheel hub assembly without air combs 510 and with air combs 510 . FIG. 27 represents a complete decortication element.
[0082] FIG. 24 shows the air comb 510 which is assembled by placing two L-shaped blades 528 depicted in FIG. 25 back to back. The assembled air comb is attached to the hub assembly FIG. 23 with screws through points 518 . Blade face 514 extends out from the hub assembly and comes to a rounded tip 520 . Each L-shaped blade 528 has grooves cut into the back side of blade face 514 . When the two L-shaped blades are positioned back to back these grooves form air channels running from interior bottom 526 to the ports 522 located in the rounded blade tip 520 . Sides 512 seal these channels. Lateral side gap 513 may be sealed by welding or by resin.
[0083] FIG. 26 depicts the blade clamps which secure air combs 510 to the wheel hub assembly. Angles 612 correspond to angles 316 FIGS. 19 and 20 and angles 416 FIGS. 21-22 . Blade clamp 610 fits over the edges of air comb 510 . Screws inserted through holes 614 correspond to holes 518 in air comb 510 and holes 424 in outer wheel hub 410 . In addition, the method of decortication described in this disclosure provides a suitable means for constructing a highly efficient and effective decortication machine capable of achieving the rapid throughput capacities required to economically operate said decortication machine in cooperation with modern forage or combine harvesting equipment, as well as equal or exceed the throughput of modern stationary decortication systems.
[0084] There are undoubtedly numerous modifications and arrangement of parts that may be construed from this invention. The previous description provides guidelines for building and operating this invention and is not meant to limit the operation of this invention, in so far as potential modifications and arrangements relate to the following claims.
[0085] Consistent with the description herein and the appended drawings, some features of exemplary embodiments include:
[0000] 1) A variable throughput decortication machine possessing a unique decortication element, which effectively and efficiently isolates the outer bast fiber of plant stalks from the inner woody core thereof, comprising the following arrangement of working parts:
a. Feeding elements consisting of a lower and upper feed belt assembly that compresses plant stalks into a uniform mat and conveys said uniform mat over a feed table and under the influence of a gripping feed roll. It is the intention, ability, design, and purpose to achieve such result that is claimed novel. b. A feed table with an adjustable angle of inclination and length composed of metal or suitable composite material and coated with a slick hydrophobic coating or finish for reducing friction and improving flow ability as the uniform mat is driven over the feed table and under the influence of the gripping feed roll. c. An upper feed belt composed of a gripping polyurethane, such as “sure grip,” to securely hold the fibrous mat while simultaneously feeding it through the decortication element so that the entire length of the plant stalks contained in the mat are decorticated. d. A lateral baffle or guide assembly between the crushing rolls and through the gripping feed roll that contains the uniform mat and prevents it from lateral escape. e. A feed table edge that is inversely contoured to match the concave tip of the breaker air comb blade tips. f. The distance of clearance between the orbital circumference of the upper breaking roll and the edge of the feed table is adjustable within a range of 5 millimeters and 44 millimeters. This range of distance provides for optimal fiber cleaning, minimizes damage, and allows for operation on fibrous plant stalks of varying degrees of moisture content. g. Breaking and scutching rolls composed of 2 outer hubs and a hollow center spacer. The assembly is either circular or polygonal is shape and attaches to hollow central drive shaft capable of delivering air to the central spacer which is hollow. Air comb blades attach to the outer circumference of the hubs. The center spacer is hollow and has channels cut to the outer circumference that deliver air to the air combs. i. Air comb blades are made of metal or other suitable hardened material capable of withstanding rapid repeated impacts with fibrous materials of wet or dry physical state and capable of delivering forced air in any form: jet, stream, band, etc. in relative proximity to the point of contact with fibrous materials and from the extremity or tip of the air comb blade. It is understood that there are numerous means for achieving this result. It is the intention, ability, design, and purpose to achieve such result that is claimed novel. j. The orbital paths of the breaking and scutching rolls intermesh within the circumferential paths of the air comb blades. The degree or severity of intermeshing may be controlled by adjusting the height of the air comb blades on either the scutching or breaking rolls. k. A novel decortication element design consisting of an upper breaking roll that has a greater outer diameter than the lower scutching roll. Said assembly creates a uniquely beneficial sweeping action during the intermeshing of the orbital paths of the breaking and scutching rolls. Specifically, the lower scutching roll travels at a faster peripheral speed than the upper breaking roll. As a result, when the lower scutcher blade enters the orbital path of the upper breaking roll, a point in space referred to as the pitch point, it will gain distance from the trailing breaking roll blade and gain distance on the leading breaking roll blade throughout the period of intermeshing orbits. This action creates an additional bending and flexing of the fibrous material which advantageously loosens and frees core from the fiber. It will be noted that by altering the pitch point of the lower scutching roll blades' orbit in relation to the breaking roll blades' orbit that a variety of sweeping effects may be provided. Other novel aspects are not limited to this design innovation and may be incorporated in a breaking and scutching roll assembly that is composed of two rolls of equal outer diameter and number of blades. l. Air comb blades and feed table edge are rounded and smoothed in such a manner that there are no sharp edges that could sever or cut the fibrous material during decortication. These edges may either be smooth or cut with longitudinally aligned micro-combing grooves running parallel to the path of travel of the fibrous materials. The rounded and smooth edges minimize fiber damage by reducing friction and allowing fibrous materials to slip across the surface. The rounded edges with micro-combing grooves have similar benefits but also enhance the ability to open the fiber bundles during decortication which is beneficial.
2) A novel air comb design for breaking and scutching roll blades that functions to reduce fiber damage, improve fiber cleaning and opening, enhance material handling, and simplify construction and repair, consisting of:
a. Two L-shaped pieces of suitable metal with concaved tips and bases that attach to breaking and scutching hub and spacer assembly, otherwise referred to as rims, provide a unique blade assembly for the decortication element. The two L-shaped pieces are symmetrical and fit together back to back. They may be scaled airtight by welding together, resin, or any other suitable means. b. The outer surface of the air comb blade may be finished or coated with a slick hydrophobic coating or finish for reducing friction and improving flow ability. c. Air comb blades attach to the exterior rims and extend longitudinally across the surface. d. Air comb blades may be angled directly perpendicular to the directional flow of the fibrous material or at an offset angle forward or backward. e. Pluralities of channels are cut into the back side of the individual L-shaped blades that reduce in volume from the base to the tip of the individual blade. These channels form jet nozzles when the individual blades are joined together back to back. f. The base of the air comb blades have male key grooves and male ports that correspond to female key grooves and female ports that are cut into the exterior of the breaking and scutching rolls. Male-female key grooves and ports allow for simple fastening and detachment, as well as easy angular adjustment, forward and backward, with respect to direction of orbital travel by means of screws or similar control and fastening mechanism.
3) A novel breaking and scutching roll assembly consisting of 2 outer hubs and 1 inner spacer.
a. The inner spacer may be constructed to accommodate any lateral width. b. The outer hubs may be journal and keyed in to lock the air comb blades in place. c. The inner spacer is hollow to accept air from the central shaft and may include an internal baffle to direct air flow to a limited section of the inner circumferentially arc. d. The assembly may be sealed air tight by a variety of means including but not limited to gaskets, washers, and resins.
4) A decortication machine according to claims 1, 2, and 3 wherein the feed element and decortication elements are controlled by separate variable speed drives that allow the number of impacts per forward travel to be precision calibrated.
5) A plant stalks decortication method that isolates the outer bast fiber from the woody core thereof, consisting of the following beneficial actions.
a. An initial compression and crushing action between an lower and upper belt and pressure rolls serves to break down the bonds between the bast fiber skin and woody interior of the fibrous plant stalks, creating a uniform mat of flattened fibrous plant stalks for decortication, removes moisture and gums, and drives the mat forward over the feed table edge and into the orbit of the decortication elements. b. A second gripping feed roll that is part of the upper feed belt assembly grips the fibrous mat as it is fed forward and acted up by the decortication elements. The upper belt should be composed of a polymer such as polyurethane that is capable of gripping the material and not allowing it to slip forward. c. A third breaking action bends and flexes the fibrous material down over the feed table between 60 to 120 degree angle shattering the woody core and loosening the bast fiber from the core. d. A forth scutching action catches the advancing fibrous material in substantially the same place as the previous breaking impact bending the advancing fibrous material back the opposite direction at a 60 to 120 degree angle and forcing it to momentarily be subjected to additional bending and flexing as it is caught between the intermeshing orbits of the breaking and scutching roll blades orbital paths. The additional bending and flexing causes the shattered and loosened core to be beaten or whipped from the fiber. e. A fifth combing, opening, and cleaning action from combing grooves, micro or otherwise, that are cut into the feed table and tips of the air comb blades on both the breaking and scutching rolls and run parallel to the directional flow of the fibrous material that serve to open the fiber bundles and improve fiber cleaning. f. A sixth pneumatic cleaning action comprised of a forceful air blast delivered from the peripheral extremity of the breaking and scutching roll blades, such device otherwise referred to as air comb blades, and delivering said air blast at the point of contact with the fibrous materials thereby effectively removing core from the fibrous materials, opening the fiber bundles, reducing moisture, preventing fiber from wrapping around moving parts, and aiding in post-decortication fiber recovery. g. A seventh pneumatic action consisting of blasting chilled air through the pneumatic cleaning element, i.e., air comb, for the purpose of causing the woody core to more rapidly and easily separate from the fibrous materials. h. An eighth pneumatic action inversely consisting of blasting heated air through the pneumatic cleaning element, i.e., air comb, for the purpose of rapidly reducing the moisture content of the fibrous materials. i. A ninth decortication action derived from engineering the lower scutching roll to travel at greater peripheral speed than the upper breaking roll to increase the cleaning efficiency of said lower scutching roll. j. A tenth friction reducing action provided by the slick hydrophobic coating, finishing, or material applied to the feed table, feed table edge, and all air comb blade tips that allows the fibrous materials to slip and flow through and over the previously listed elements. k. An eleventh lateral guiding action throughout the process beginning in the feed element with lateral baffles and continuing through the breaking and scutching rolls with concave blade tips. Lateral control is also enhanced by a decortication element width that exceeds the feed element width by 0.5 or more inches on either side.
6) A plant stalk decortication method according to claim 5 that utilizes an air blasting feature located in the peripheral tips of the breaking and scutching blades, and otherwise referred to as an air comb, to minimize the duration and degree of contact between said blades and the fibrous materials, resulting in less severe bending and depth of intermeshing between the blades of the breaking and scutching roll air comb blades, which helps to minimize mechanical fiber damage while enhancing material handling post-decortication.
7) A plant stalks decortication method according to claim 6 that permits variable throughput capacities based on the operational width of the breaking and scutching rolls and that may be mounted on a harvest head implement, pick-up head implement, or utilized as part of a stationary mill.
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A fibrous pant stalk decorticator is disclosed. The decorticator includes a feeding device a breaker roll having a first plurality of blades, and a skutcher roll having a second plurality of blades. The skutcher is positioned such that the first and second pluralities of blades overlap. A plurality of air outlets pass through the blades and are configured to provided pressurized air to the fibrous plant stalk as it is passed through the decorticator.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] None
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] None
LATIN NAME OF THE GENUS AND SPECIES OF THE PLANT CLAIMED
[0003]
Malus domestica
VARIETY DENOMINATION
[0004] ‘Lady Laura’
BACKGROUND OF THE INVENTION
[0005] The present invention relates to a new and distinct variety of apple tree named ‘Lady Laura.’ The new tree resulted from a spontaneous limb sport mutation of ‘Cripps Pink’ (U.S. Plant Pat. No. 7,880). The ‘Cripps Pink’ tree containing the limb sport of the new variety was discovered growing in a cultivated area in Borenore NSW, Australia.
BRIEF SUMMARY OF THE INVENTION
[0006] The ‘Lady Laura’ variety is distinguished from other apple varieties due to the following unique combination of characteristics: the amount and intensity of over color of the fruit, and the earlier coloration of fruit in comparison to ‘Cripps Pink’.
[0007] Asexual reproduction of this new variety by budding and grafting shows that the foregoing characteristics come true to form, are firmly fixed, and are established and transmitted through succeeding propagations.
[0008] Certain characteristics of this variety, such as growth and color, may change with changing environmental conditions (such as light, temperature, moisture, nutrient availability, or other factors). Color descriptions and other terminology are used in accordance with their ordinary dictionary descriptions, unless the context clearly indicates otherwise. Color designations are made with reference to The Royal Horticultural Society (RHS) Colour Chart.
BRIEF DESCRIPTION OF THE DRAWING
[0009] FIG. 1 is a photograph showing typical fruit of the new variety.
[0010] The accompanying color photograph shows typical specimens of the fruit of this new apple tree variety and depict the color as nearly true as is reasonably possible to make the same in a color illustration of this character. It should be noted that colors may vary, for example due to lighting conditions at the time the photograph is taken. Therefore, color characteristics of this new variety should be determined with reference to the observations described herein, rather than from the photograph alone.
DETAILED DESCRIPTION
BOTANICAL
[0011] The following detailed description of the ‘Lady Laura’ variety is based on observations of the original limb sport and asexually reproduced progeny. The observed progeny are trees which were four years of age and growing on Exemla 9 rootstock (unpatented) in Taggerty, Victoria, Australia.
Scientific name: Malus domestica ‘Lady Laura’ Parentage: Spontaneous limb sport mutation of ‘Cripps Pink’. Tree:
Vigor.— Medium. Overall shape.— Upright. Height.— About 5 to 6 feet. Width.— Overall spread of about 4 feet. Caliper.— Approximately 3 inches. Trunk.— Medium stocky. Trunk bark texture.— Medium rough with lenticels. Trunk bark color.— Grey/Green/Cream (RHS 195B). Patches or other markings.— Lenticels one-fourth to one-half inch long. Primary branches.— Upright. Branch color.— One-year old branches are green (RHS 144B) in color, while two-year old branches are green-brown (RHS 199B) in color. Branch pubescence.— Present. Branch lenticels.— Medium density, approximately 38 per square inch; greyed-orange (RHS 164D) in color. Internodes.— Average internode length is about one and one-sixteenth inch on a one-year old shoot. Bearing.— Annual. No particular disease resistance or susceptibility observed.
Leaves:
Texture.— Medium thick. Sheen.— Medium dull. Length.— About 3½ inches to about 5 inches, averaging about 4¼ inches. Width.— About 2¼ inches to about 2¾ inches, averaging about 2½ inches. Petiole.— About 1 and one-eighth inches long; red-green in color (red RHS 179A and green 148D); about one-sixteenth inch in diameter. Margin.— Irregularly serrated. Tip shape.— Acutely pointed. Leaf color.— Upper leaf surface: Green (RHS 137A). Lower leaf surface: Light green (RHS 147B). Vein: Light green (RHS 147C). Pubescence.— yes. The length, width, thickness and other measurements were obtained from observations of ten typical leaves in late spring.
Flowers:
Size.— Medium size, typical flower measuring about 30 mm across. Color.— Unopened bud: Pink (RHS 67B). Opened flower: White to very pale pink (white RHS 155D and pink RHS 65D). Petals.— 5 petals per flower; round to ovate in shape; about five-eighths (to slightly larger) inch long. Stamen.— 16 stamens, each about 9 mm long and cream white (RHS 155D) in color. Anthers.— Pale yellow (RHS 6D) in color. Pistil.— Stigma is about 8 mm long; 5 styles, fused at base, and pale brown (RHS 162D) in color. Sepals.— About 6 mm and about 3 mm wide; recurved shape; light green (RHS 142D) in color; pubescence present. Fragrance.— Light. Bloom season.— Early to mid-full bloom observed. Timing varies depending on chill units.
Fruit: (Observations from a limited number of typical fruit in April 2005)
Size.— About 2 and seven-eighths inches long and 3 inches wide. Form.— Round oblong. Cavity.— Medium broad to deep. Basin.— About seven-sixteenths inch deep and about seven-eighths inch wide; pubescence present. Stem.— About five-eighths inch long and one-eighth inch in diameter; yellow green (RHS 152D) in color. Locules.— Mostly closed locules. Skin.— Medium thick. Lenticels.— Prominent. Color.— General color effect: Solid dark pink-red (RHS 47A-50A) over yellowish ground color (RHS 10B). Ground color: Green to yellow (RHS 10B). Overcolor: Dark pink to red (RHS 47A to 50A). Overcolor percentage of approximately 90% compared to ‘Cripps Pink’ of approximately 30-80%. The overcolor is more intense and there is a greater percentage of color and more even overcolor that ‘Cripps Pink.’ The fruit achieve overcolor approximately 14 days earlier than ‘Cripps Pink.’ Russetting: Absent. Fruit properties at maturity ( based on 10 apples tested in April 2005).—Firmness: About 8 kg, averaging about 8.5 kg/cm 2 . Soluble solids: Averaging about 15%. Flavor: Mild. Juiciness: Medium. Flesh color: Creamy white (RHS 4D). Aroma: Mild pleasant. Seed.— About 2 seeds per cell; acute shaped; about three-eighths inch long and about three-sixteenth inch wide; brown (RHS 174A) in color. Fruit production.— First picking date in Victoria, Australia was about 4 th of April, and last picking date was about 10 th of April 2005. Storage.— Fruit can be stored up to 4 months in cold storage (34° F.). Usage.— Eating.
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A new apple variety distinguished by the amount and intensity of over-color of the fruit and the earlier coloration of the fruit.
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TECHNICAL FIELD
The present invention relates generally to the field of optical mark scanning apparatus. More particularly, the present invention relates to a method and system for creating and scanning a customized survey form. This method and system has particular application in the creation of customized survey forms or questionnaires for use in conducting various types of market surveys and a wide variety of other data collection applications.
BACKGROUND ART
Optical mark reading (OMR) systems are well known in the prior art, and there are many applications for the use of OMR scannable in the large-scale gathering of information (e.g. student test scores, census information, consumer preference surveys or product survey forms). Typically, OMR systems have used a variety of preprinted scannable forms comprised of sheets of paper or other similar material that have a plurality of preprinted timing marks in a control mark column (often referred to as a timing track) and a plurality of response areas (often referred to as response bubbles) located on the sheet in a specified relationship with the timing marks. The timing marks are used to trigger the OMR system to scan or "read" the response area to detect whether a data mark is present at a particular response area.
OMR systems are well-suited for gathering information from a large number of documents containing data that can be stated numerically or categorically (i.e., multiple choice, yes or no). In a typical market survey application, a person would fill in the requested information on a scannable form by placing a data mark in the desired response areas. When completed, the scannable form is then fed into an OMR scanner that reads the data marks and transmits this data to a computer for editing, validation, and, ultimately, interpretation. While such OMR systems are an efficient means of gathering large amounts of information, it is generally not cost-effective to use current scannable forms with an OMR system to gather relatively small amounts of information (i.e. 5,000 surveys or less), particularly when the turn-around time for conducting a survey is limited or when a scannable form must be custom-designed for a survey.
The scannable forms for OMR systems of the type described above are either fixed format scannable forms having only response areas and no corresponding questions printed on the form (e.g., 50 true/false response areas), or custom scannable forms with specific questions (or other stimulus items, such as graphics) printed corresponding to each response area (e.g., a census survey). Fixed format scannable forms are inexpensive, but are limited in arrangement and require another document or a survey administrator to pose the questions, because fixed format scannable forms do not combine both the question and response area on a single document. Custom scannable forms are more flexible in their format, but are expensive and may require as many as 5,000 copies of the same form to be printed before the costs involved in designing and printing the forms by conventional offset printing methods are recovered. More importantly, the time required to print customized scannable forms by conventional offset printing methods is sometimes too long (requiring one to eight weeks from initial design to final printing), and does not meet the market needs of many potential OMR users, particularly when there is a shortened time requirement, as is often the case in market survey applications.
One of the difficulties in creating a customized scannable form for use in current OMR scanners is the low tolerance such scanners have for offset, misregistration, and poor print or paper quality. In particular, the timing tracks on scannable forms for such scanners must be printed to high standards of print quality and print alignment to insure that an acceptably high percentage of completed forms can later be properly scanned and scored. Current OMR scanners use the timing marks in the timing track to trigger when to scan the corresponding row of response areas in the response area. Consequently, if the response areas are not printed in relatively exact alignment with the corresponding timing mark, the OMR scanner may interpret the edge of a response area as a positive response or mark, rather than as a guide for the user filling in the data mark.
It would be desirable to allow an OMR user to custom design a survey form without the need to use conventional offset printing and design methods and without the limitations imposed by a fixed format scannable form. One example of a fixed format OMR system that permits limited customization of scannable forms is shown in U.S. Pat. No. 3,886,325. In this system, a format control sheet is used to custom control the scoring of a fixed format scannable form. That is, the format control sheet to select and group certain pre-printed response areas to be scored according to a predetermined format. This system does not allow for the use of custom text or stimuli to be printed on the scannable form. Moreover, it provides for only minimal flexibility and requires the user to learn another "language" to program the format control sheet.
Another possible solution is to create a customized survey form using currently available laser printers with, for example, standard paint and draw software programs (e.g., MacDraw). In general, however, such systems cannot replicate the print quality and alignment for the timing tracks required by current OMR scanners. Even if a blank scannable form having only a preprinted timing track were used as the paper stock for a laser printer, there is no way of establishing accurate alignment between the preprinted timing track on such a form and the corresponding rows of response areas to be printed by the laser printer.
Presently, there is no single system for creating and scanning a customized survey form that effectively allows all of the information generated during the design of the survey form to be used in scanning the survey form. For example, if a change in a customized survey form is made that would require a different scanning of the information being collected, there is no means for distinguishing that change during the eventual scanning of the forms because the scanning system is separate and distinct from the system that created the survey form. Also, it would be advantageous to allow the user to directly transfer details about all of the possible information being collected so that when the survey forms are scanned, this information does not have to be reentered into the scanning system. Currently, scanning systems require that the horizontal and vertical locations of response areas to be scanned and the information about the type of fields being scanned be manually entered or keyed into the system before a new survey form can be scanned. This process is duplication of effort and allows for errors and inaccuracies to be entered into the scanning system that may result in inaccurate scoring of the information on the survey form.
Although the existing OMR scanners and scannable forms may be satisfactory for other uses and applications, because of the problems recited above they are not well-suited for quickly gathering and analyzing information from a relatively small sample population by means of a customized survey form. Accordingly, there is a continuing need for a method and system to allow for the timely and cost-effective creation of customized scannable forms or survey forms that will be consistently and correctly scanned by current OMR systems. Moreover, there would be many advantages to a method and system for creating and scanning a customized survey form that integrates both the creation and the scanning of a customized survey form into a single, unified process.
SUMMARY OF THE INVENTION
In accordance with the present invention, a desktop survey system is provided in which customized survey forms may be created and scanned in a single, unified process. Generally, such a system includes a preprinted scannable form having a plurality of timing marks; a processing means for entering, editing, and formatting customized questions and corresponding response areas and for adjusting and aligning the locations of the questions and response areas to be printed on the scannable form, a printer for printing the customized questions and the corresponding response areas on the scannable form in proper alignment with the timing track to create a customized survey form or "questionnaire", and an OMR scanner and attached processing means for receiving information identifying and defining the fields to be scanned, scanning the survey forms and tabulating and analyzing the results.
More specifically, the present invention relates to a desktop survey system for creating and scanning a survey form to be completed by a survey respondent, the survey form being printed on a scannable form having a preprinted timing track that can be scanned by an optical mark scanner. The system is comprised of a computer for entering data specifying the questions and corresponding response areas to be printed on the survey form, the response areas being an outline in which the survey respondent may make a data mark indicating that response area was selected by the survey respondent. The computer allows the user to position both the questions and response areas by moving images on a computer display that correspond to the questions and response areas. To insure that the response areas will be consistently and correctly scanned by the OMR scanner, the computer only allows the user to position the response areas about a series of predetermined locations or dots that make up a grid pattern that is aligned in a specified relation with the preprinted timing marks on the scannable form. The positions of all of the response areas are then communicated by means of either a form key or a data fileto a computer that operates the OMR scanner. Each form key or data file specifies all of the selected positions for the response areas printed on the survey form and a unique form identification mark generated by the computer that controls the positioning of the response areas. The form key is printed on the scannable form with all of the selected positions for the response areas being filled in with marks that will be detected as data marks by the OMR scanner. The data file is read by the computer that operates the scanner and contains the same position information in a specified format. The computer that operates the scanner uses this position information when scanning the survey forms after they have been completed by the respondents to determine which response areas were selected by the survey respondents as indicated by the data marks within those response areas. Because any number of possible positions and combinations of response areas is possible with the present invention, the system provides for a unique form identification mark generated by the computer that controls the positioning of the response areas. This form identification mark is printed on each survey form or stored in each data file and verified when the survey forms are scanned to insure that the proper position information is being used to control the scanning of the survey form. The desktop survey system also provides for several other desirable features, including the ability to integrate or merge a data file containing individualized information with the survey forms, thereby producing individualized survey forms. A merge mark code is also printed on the survey form that allows the computer operating the scanner to relink the survey form with the appropriate record in the data file containing the individualized information after the survey form has been scanned.
Accordingly, a primary objective of the present invention is to provide a timely and costeffective method and system for creating and scanning a customized survey form.
Another objective of the present invention is to provide a method and system for creating and scanning a customized survey form that integrates both the creation and scanning of the customized survey form into a single unified process.
A further objective of the present invention is to provide a method and system for insuring that the response areas of a customized survey form will be printed in a specified relationship with the timing marks to insure that the survey forms will be consistently and correctly scanned by current OMR systems.
Another objective of the present invention is to provide a method and system for increasing the efficiency of such a system by only requiring the user to enter information relating to the position of the response areas on the survey form a single time.
These and other objectives of the present invention will become apparent with reference to the drawings, the detailed description of the preferred embodiment and the appended claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of the operative components of a preferred embodiment of a desktop survey system in accordance with the present invention.
FIG. 2a is a survey form produced by the desktop survey system of the present invention, including customized questions, response areas, and alignment marks, printed on a scannable form that is blank except for the bias bar and the timing track.
FIG. 2b is a form key produced by the desktop survey system of the present invention, including all of the response areas filled in and printed on a blank scannable form.
FIG. 3 is a depiction of a computer screen display showing the main screen for producing a customized survey form using the present invention.
FIG. 4 is a flowchart of the software program associated with the computer display screen shown in FIG. 3.
FIG. 5 is a flowchart for the software program associated with the Pull Down Menu.
FIGS. 6a-6f are depictions for computer screen displays for various options under the Pull Down Menu.
FIG. 7 is a flow chart for the software program associated with the Tools Menu.
FIG. 8 is a flow chart for the software program associated with the Content Area.
FIG. 9 is a flow chart for the software program associated with the Input/Output Menu.
FIG. 10 is a depiction of a computer screen display for the Input/Output Menu.
FIGS. 11a-11d are depictions of a scannable form during the steps that comprise the Alignment process of the present invention.
FIG. 12 is a depiction of a computer screen display for the Alignment process.
FIGS. 13a-13b are a flow chart for the software program associated with the Alignment process.
FIGS. 14a-14b are a flowchart for the software program associated with the Print process.
FIGS. 15a-15b are a depiction of a computer screen display showing two dialog boxes for the Print process.
FIGS. 16a-16b are a depiction of a computer screen displays for the Analysis and Define Questionnaire processes.
FIG. 17 is a flowchart for the software program associated with the overall flow of the Analysis process.
FIGS. 18a-18c are a flowchart for the software program associated with the Define Questionnaire process.
FIG. 19 is a depiction of three field types that may be defined for the response areas.
FIG. 20 is a depiction of a computer screen display for the Open-Ends window.
FIG. 21 is a flowchart for the software program associated with the Scan process.
FIG. 22 is a depiction of a computer screen display for the Scan Parameters window.
FIG. 23 is a depiction of a computer screen display showing the results of the Scan process.
FIGS. 24a-24b are depictions of two alternative methods of coding open-ended questions.
FIG. 25 is a flowchart for the software program associated with the Data File Management process.
FIG. 26 is a depiction of a sample standard report generated after all of the survey forms have been scanned by the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the operative components of a desktop survey system 10 in accordance with the present invention will generally include, a computer 12 coupled with a laser printer 14 for creating the customized survey forms 20, and a scanner 16 coupled to a second computer 18 for scanning the survey forms 20 once the desired information has been collected. Briefly, the specifications for the survey forms 20 are created using the computer 12 and then overprinted on blank scannable forms 22 (FIG. 2a) by the laser printer 14. Once the survey forms 20 are printed, they may be fielded using any number of collection methods to collect the desired information. After the survey has been fielded or the test has been administered, the completed survey forms 20 are scanned using the scanner 16 coupled with the second computer 18. When the scanning process is finished, the scanned information may then be edited and verified, responses to open-ended questions may be encoded, and the resulting data is now ready for analysis and interpretation.
In a preferred embodiment of the present invention, the computer 12 is an Apple Macintosh SE available from Apple Computers, Inc., of Cuppertino, Calif. The laser printer 14 is an Omni Laser 2115 available from Texas Instruments, Inc., Dallas, Tex. The scanner 16 is a NCS Sentry 3000 available from National Computer Systems of Eden Prairie, Minnesota and the second computer 18 is an IBM PS/2 Model 30 available from International Business Machines, Armonk, N.Y. The scannable form 22 overprinted to make survey forms 20 is described in detail in co-pending application entitled OVERPRINT REGISTRATION SYSTEM FOR PRINTING A CUSTOMIZED SURVEY FORM AND SCANNABLE FORM THEREFOR, filed in the United States Patent and Trademark Office on Apr. 1, 1988 and identified by Ser. No. 176,610, which is fully incorporated by reference herein.
Although the preferred embodiment utilizes two computers, a laser printer and a scanner, it should be understood that the present invention may work equally well with a number of different component configurations. For instance, while the preferred embodiment uses a laser printer for printing the survey forms, any printer capable of the resolution and control achieved by a laser printer could accomplish the objectives of the present invention. In an alternative embodiment, the information about the design of the survey form might be conveyed to an offset printing press with a computer interface to allow larger quantities of a particular customized survey survey form to be produced, while still taking advantage of the time and design savings realized by the present invention. The present invention is equally applicable to forms scanned either by a Trans-Optic method of scanning (light transmitted through the form) or by a reflective-read method of scanning (light reflected from the surface of the form). Though a scanner with a relatively small duty cycle is used in the preferred embodiment, it should be realized that a scanner with a larger duty cycle or processing rate may be used depending upon the number of the survey forms being produced. In another embodiment, a single computer might be used for both the production and scanning of the survey forms, instead of two computers as shown in the preferred embodiment. Two computers are used in the preferred embodiment because it allow for the design and production and the scanning and analysis to be two separate operations that may occur simultaneously for different surveys, e.g. a census survey may be scanned and analyzed while a consumer preference survey is being designed and produced.
Referring now to FIG. 2a, a survey form 20 overprinted on a scannable form 22 in accordance with the present invention is shown. In a preferred embodiment, the scannable form 22 is comprised of a generally rectangular paper sheet having a timing track 24 consisting of a row of uniformly spaced preprinted timing marks 26 located along one edge of the sheet and a plurality of preprinted quality assurance marks 30, 32, 34 and 36 preprinted in a known, predetermined relationship with timing track 24. The scannable form 22 may also be preprinted with bias bar 40 and skunk marks 42. The bias bar 40 is used to adjust the intensity level of the scanner 16. The skunk marks 42 may be used to verify the proper type of scannable form or to signal the end of the scannable form. The information overprinted on the scannable form 22 to make the survey form 20 includes: the customized questions 52, the corresponding response areas 54 and any open-ended questions 56, text areas 57, graphics 58 or mail-merge locations 60 and mail merge control codes 62.
To overcome the problems and disadvantages inherent in the prior art OMR systems, the present invention coordinates the entire process into a single unitary method and system for creating and scanning survey forms. The desktop survey system 10 coordinates the two distinct processes that are required to use an OMR system: (1) the form production process and (2) the completed form analysis process. In the present invention, the production process includes the steps of designing the survey forms, printing the survey forms, and fielding or administering the survey. The analysis process includes the steps of defining the fields and assigning values to the response areas being scanned, coding any open-ended questions with predetermined key codes, scanning the survey forms, key-entering any written open-ended questions, cleaning up the data, and analyzing the data. The present invention overcomes the problems and deficiencies in the prior art by coordinating these two processes, thereby allowing the user to avoid unnecessary duplication of effort in creating and scanning the survey forms. In one embodiment, the present invention uses a form key 68 (FIG. 2b) for communicating the locations of all of the response areas 54 on the survey form 20 computer 12 to computer 18. In another embodiment, a form definition file containing the relative positions of all of the response areas 54 might be used to communicate this information between the two computers or between two different software programs running on the same computer. In addition, the coordination and unitary approach to designing and scanning survey forms allows the present invention to overcome other problems involved in the creation of a customized survey form that do not exist when a fixed format survey forms used. For example, a minor variation in the format of a response area may result in the scanning system needing to redefine the fields for that particular question. If the earlier version of the survey form is used by mistake, that particular question will be incorrectly scored. The present invention resolves this problem by providing the survey forms 20 with form identification marks 70 and sequence number marks 72 as will be described further below.
PRODUCTION PROCESS
With reference to FIG. 3, a main screen 100 for the software program that comprises the production process is shown. In the preferred embodiment, the production process software program is written for an Apple Macintosh computer and uses the pull-down screen and icon format compatible with that computer system. All of the actions or events that a user may select are accessed through the main screen 100 that is divided into Pull-Down Menu 110, Tools 120, and Content Area 130. The flowchart for the overall flow of the software program that drives the main screen 100 is shown in FIG. 4. At Start Application 140, the user has selected the desktop survey system application and the software program is loaded into the computer 12. At Initialize 142, initial values and default values are set or reset. Now the program enters a polling loop waiting for directions from the user as to what actions or events are to be performed. At Event Menu 144, if the user has selected an event in Pull-Down Menu 110, the program transfers control to Do Menu 200. At Event Tools 146, if the user has selected an event in Tools 120, the program transfers control to Do Tools 300. At Event Content 148, if the user has selected an event in Content Area 130, the program transfers control to Do Content 400. After each of the Do routines (Do Menu 200, Do Tools 300 and Do Content 400), control is returned to the polling loop via Return 150.
Menu
FIG. 5 shows a flowchart for the software program that performs Do Menu 200 for processing any events selected by the user form Pull-Menu 110. If the event is Apple 202, the program passes control back to the operating system to perform whatever tasks outside of the desktop survey application that the user may want to run. If the event is File 204, the program passes to Do I/O 500, a routine that will be described in further detail below. If the event is Edit 206, the program displays the available edit options as shown in FIG. 6a and performs the selected option at the user's direction. If the event is Option 208, the program displays the available options as shown in FIG. 6b and sets or resets the selected option as indicated by the user. If the event is Font 210, the program displays the available fonts shown in FIG. 6c and sets the editor to the font selected. If the event is Size 212, the program displays the available font sizes as shown in FIG. 6d and sets the editor to the selected size. If the event is Style 214, the program displays the available styles as shown in FIG. 6e and set the editor to the selected style. If the event is Draw 216, the program displays the available draw tools and sets the toolbox option for Tools 120 to the one selected. Upon completion of the chosen event, the program returns control to the polling loop via Return 150.
FIG. 6a shows the main screen 100 as it appears when Edit 204 is selected. The options available to the user include Cut 222, Copy 224, Paste 226 and Clipboard 228. Each of these options works with a defined portion of the Content Area 130 that is defined by using the pointer tool 220. The user selects the pointer tool 220 by moving the cursor to Tools 120 and clicking on the pointer tool 220. The defined portion of the Content Area 130 is selected by moving the cursor to the desired portion of the screen and then clicking and dragging the cursor about that portion. Cut 222 cuts or deletes the defined portion of Content Area 130. Copy 224 puts the defined portion of Content Area 130 into the clipboard temporary storage. Paste 226 pastes or inserts whatever is in the clipboard temporary storage to the current position of the cursor. Clipboard 228 displays what is currently in the clipboard temporary storage.
FIG. 6b shows the main screen 100 as it appears when Options 206 is selected. The options available to the user include Bubble Grid 230, Guide Lines 232 and Mail Merge 240. Bubble Grid 230 is used to turn the grid display 234 for Content Area 130 on or off. The grid display 234 (shown in FIG. 6d) is a pattern of dots that indicate all of the possible positions for the response areas 54 in the Content Area 130. The grid display dots will not appear on the survey forms 20 when they are printed. Guide Lines 232 is used to turn the staple area display and center lines on or off. These lines assist the user in positioning the customized questions 52 and the response areas 54 in the Content Area 130. Mail Merge 240 allows the user to merge an external data file with individual records into the survey forms 20 when they are printed. A more detailed description of Mail Merge 240 is provided below.
FIG. 6c shows the main screen 100 as it appears when Font 208 is selected. The print fonts that are displayed on this menu are the fonts that are loaded into the operating system for the computer 12. FIG. 6d shows the main screen 100 as it appears when Size 210 is selected. The sizes determine what point size the print font will be displayed in. It is suggested that either 10L or 12L be used when working with the customized questions 52. FIG. 6d shows the main screen as it appears when Style 212 is selected. The print styles available include plain, bold, italics, underline, outline and shadow. For all three of these menus, the changes will be made to the defined portion of the Content Area 130 and to any additional test or graphics that are entered after a selection is made.
FIG. 6f show the main screen 100 as it appears when Draw 214 is selected. The options let the user select the line thickness for lines, ovals, boxes and arrows to be drawn using the options available under Tools 120. The user may also select the fill pattern to be used for filling any of the boxes produced above.
Tools
Referring now to FIG. 7, a flowchart for the software routine Do Tools 300 is shown. Do Tools 300 allows the user to select the tools in this menu that create and manipulate the customized questions 52, the response areas 54 and the text areas 57 and graphics 58. If the selected event is Pointer 302, the program sets the cursor to show a "pointer" (Pointer 220) and sets the pointer as the selected tool. If the selected event is Text 304, the program set the cursor to show an "I-beam" and sets the editor as the selected tool. If the selected event is Bubble 306, the program sets the cursor to show a "bubble" (Bubble 250 as shown in FIG. 6d) and sets the bubble as the selected tool. At Set Cursor 308, the program sets the cursor for the remaining events to a "+" sign. If the selected event is Rectangle 310, the program sets draw rectangle as the selected tool. If the selected event is Oval 312, the program sets draw oval as the selected tool. If the selected event is Line 314, the program sets draw line as the selected tool. If the selected event is Arrow 316, the program sets draw arrow as the selected tool. The selected tool defines the graphic symbol that the program will draw in the Content Area 130 when the user moves the cursor to a desired location and clicks it. These manipulations are handled by Do Content 400. Once the tool has been selected and the cursor has been set, control is passed back to the polling loop via Return 150.
Content Area
Referring now to FIG. 8, a flowchart for the software routine Do Content 400 is shown. Do Content 400 allows the user to create and manipulate the customized questions 52, the response areas 54 and the text areas 57 and graphics 58 in the Content Area 130 using the selected tool from Tools 120. The user enters this program by clicking the cursor once it has been moved to a desired location in the Content Area 130. When the user finishes using a tool, i.e., the cursor is moved out of the Content Area 130, control is passed back to the polling loop via Return 150.
If the selected tool is the Pointer 402, the user may move a block of text or a graphic shape by clicking on the object and dragging it to a new location. Larger areas including both blocks of text and graphics can be moved by clicking one corner of an area and dragging a dotted box around the desired objects. Then the user may click the cursor inside the dotted box and drag all of the selected objects to a new location. The response areas 54 may be clicked and dragged to new locations, but they cannot be cut or pasted. Because the response areas 54 must always line up with the grid dots of grid display 234 (whether grid display 234 is displayed or not), the program will only allow selected objects that include response areas 54 to be moved to a location where the response areas 54 will coincide with a new set of grid dots. Selected objects may be delected by clicking on an object or clicking and dragging on a group of objects and then entering the Delete or Backspace keys on the computer 12.
If the selected tool is Text 404, the user may enter text at the "I-beam" cursor using the standard text editor routines. Each text entry initiated by clicking the cursor will be treated as a separate block of text for purposes of using the pointer tool. The font, point size and style of the text that will be entered are determined by the current settings of the options in Font 208, Size 210 and Style 212.
If the selected tool is Bubble 406, the user may place or delete the response areas 54. No matter where the cursor is located when it is clicked, the program will "snap" the newly created response area 54 to the grid display 234 automatically, with the center of the response area 54 located concentrically about the nearest bubble grid dot to the current location of the cursor. The use of the bubble grid dots allows the present invention to overcome the alignment problems present in the prior art and insures that each row of response areas 54 will be properly aligned with its corresponding timing mark 24. In one embodiment, the bubble grid dots are vertically spaced apart 14 pixels or 0.200 inches and horizontally spaced apart 12 pixels or 0.166 inches when the grid display 234 is displayed on the main screen 100. This spacing corresponds to the positions for the response areas 54 on a scannable form having a 5 LPI (Lines Per Inch) format. The program determines which vertical and horizontal bubble grid dot to snap on by rounding the current cursor position to the nearest 12 and 14 pixels positions, respectively. It will be apparent that other spacing may be used for other formats, or that the program could translate the placement of the bubble tool on the main screen into the desired placement of the response areas 54 on the survey form 20 by the use of a conversion algorithm.
The remaining tools all allow the user to add simple graphic images to the Content Area 130. If the selected tool is Rectangle 410, the program allows the user to draw rectangles according to the options selected in Draw 214. To draw a rectangle box, click the cursor to anchor the upper right hand corner and then drag the cursor to the lower lefthand corner to expand the rectangle box. To change the size of a rectangle box already drawn, click on the rectangle box with the pointer tool 220 to select it and then click and drag on of the "handles" shown on the side of the rectangle box to size it. Similarly, if the selected tool is Oval 412, the program allows the user to draw oval figures. It should be noted that the oval tool is not used to draw the response areas 54 because the oval tool does not lock the ovals or circles that are drawn onto the bubble grid dots. If the selected tool is Line 414, the user may draw a line by clicking the cursor at one point to another the line and then dragging the cursor to the opposite end of the line. The line thickness is controlled by the options selected in Draw 214. Similarly, if the selected tool is Arrow 416, the user may draw lines with triangle arrow heads on one end.
Input/Output
Referring now to FIG. 9, a flowchart for the software routine Do I/O 500 is shown. Do I/O 500 controls the input and output operations of the production process. The menu presenting the available options for this program is shown in FIG. 10. The user selects the desired event or action from the File menu 510. If the event is New 520, the program closes and saves the current survey form in a file in the computer 12 and then clears the Content Area 130 to allow the user to create a new survey form. If the event is Open 522, the program closes and saves the current survey form in a file in the computer 12 and then clears the Content Area 130 and retrieves an existing file from storage and displays that file in the Content Area 130. If the event is Page Setup 524, the program transfers control to the operating system to modify the default printer settings used by the operating system for the computer 12. If the event is Alignment 526, the program transfers control to Do Alignment 600. If the event is Form Key 528, the program transfers control to Do Print 700 with instructions to print a form key, rather than an actual survey form. If the event is Print 530, the program transfers control to Do Print 700. If the event is Save 532, the program saves the current contents of the Content Area 130 in the currently specified file. Each page of a survey form should be saved as a new file. If the event is Save As 534, the program prompts the user for the new name of the file and then saves the current contents of the Content Area 130 as the newly specified file. If the event is Quit 536, the program queries the user whether any changes made to the Content Area 130 should be saved in the currently specified file and then exits the program, returning control back to the operating system for the computer 12.
Mail Merge
As shown in FIG. 6c, the user may select Mail Merge 240 as one of the options available when Options 206 is selected. Mail Merge 240 allows a separate file containing individualized information known as mail merge records to be merged with the survey forms when they are printed, thereby creating individualized survey forms. The result is seen at mail merge location 60 as shown in FIG. 2a. In one embodiment, a dialog box is displayed when Mail Merge 240 is selected, prompting the user to enter the number of lines and the length of the line for each mail merge record that will be integrated with the survey form 20. The mail merge records are created by the user prior to printing the survey forms 20 and are saved in a file named Mailmerge. The file may be in any number of different formats, including: Macintosh text fields separated by tabs and ending with a carriage return, an ASCII file transferred from a PC with the fields separated by quotations and commas, or an EXCEL file format with fields B through H being 1-40 alphanumeric. The first field of each mail merge control codes is a nine digit mail merge id 64. This is the link between the mail merge control codes and the survey results. The mail merge id is used to generate a mail merge control code 62 that may be scanned by the scanner 16. The mail merge control code 62 is printed on the survey forms 20 along with the mail merge id 64 and the individual mail merge record number 66. In one embodiment shown in FIG. 15b, both the mail merge control code 62 and the mail merge id 64 are printed on the bias bar 40 so as to minimize their observability to the survey taker and to lessen the likelihood of tampering with the mail merge control code 62.
Alignment
Referring now to FIGS. 11a-11d, a simplified explanation of alignment process performed by Do Alignment 600 is shown. While the preferred embodiment of the alignment process is described in detail in co-pending application OVERPRINT REGISTRATION SYSTEM FOR PRINTING A CUSTOMIZED SURVEY FORM AND SCANNABLE FORM THEREFOR, Ser. No. 176,610, it should be recognized that any alignment process that allows each row of the response areas 54 to be aligned within the tolerances established by the timing track 24 would be sufficient for purposes of the present invention.
Essentially, the alignment process of the preferred embodiment "stretches" the planned print area on scannable form 22 so that a plurality of overprint registration marks 80, 82, 84 and 86 will align with preprinted quality assurance (QA) marks 30, 32, 34 and 36. The object of the alignment process is to center overprint registration marks 80, 82, 84 and 86 within their respective QA marks 30, 32, 34 and 36. As shown in FIG. 11a, the first step in performing alignment process is to "target" the alignment by anchoring alignment form 90 with overprint registration mark 80 printed within the home QA mark 30 to establish a base reference point for the planned print area. In one embodiment, home QA mark 30 is located in the upper left hand corner of scannable form 22, at the corner of the edges opposite both timing track 26 and bias bar 40. After the three copies of an alignment form 90 are printed, an alignment screen 92 that shows overprint mark indicator 94 in proper alignment with QA mark indicator 96 is displayed, as shown in FIG. 12. The user examines all three copies of alignment form 90 and notes the average location of overprint registration mark 80. The user next enters the extent of deviation from the desired alignment by duplicating the average location of overprint registration mark 80 on alignment screen 92 by moving overprint mark indicator 94 to its observed average position with respect to QA mark indicator 96. Computer 12 then modifies the stored location information for overprint registration mark 80 based on the movement of overprint mark indicator 94 and prints another three copies of alignment form 90. This process is repeated until the user is satisfied that the average location of overprint registration mark 80 is centered as closely as possible within QA mark 30. This same process is repeated for each of the remaining QA marks 32, 34 and 36 as shown in FIGS. 11b-11d.
Referring now to FIGS. 13a-13b, a functional flow chart for the software program that comprises Do Alignment 600 is shown. The default alignment mark for starting the alignment sequence is set to overprint registration mark 80 and the default coordinates for that mark are set at Set Default Alignment Mark 604. The default coordinates for overprint registration mark 80 represent the distance from the top and left edges of scannable form 22 to the center of QA mark 30. Three alignment forms 90 are printed at Print Forms 606 with overprint registration mark 80 located at the default coordinates. After the three alignment forms 90 are printed, alignment display screen 92 is presented to the user at Display Screen 608 as shown in FIG. 12. If this is the first time through alignment process 600 (First Time 610), Retrieve Coordinates 612 places the default coordinates for the centered overprint registration marks 80, 82, 84 and 86 into temporary storage to be modified. At this point, the user is ready to enter the average position of overprint registration mark 80 with respect to home QA mark 30. In the right hand portion of alignment screen 92, menu 620 displays the three alternatives available to the user (Print, Okay and Cancel), along with the select registration mark designators (Home 630, Upper Right 632, Lower Left 634, or Lower Right 636).
The user may select among any of the alternatives presented in menu 620, or may change the currently selected registration mark designator. Print 622 will print three copies of alignment forms 90 with all of the overprint registration marks 80, 82, 84 and 86 currently selected or previously aligned. Next Mark 624 compares the select registration mark designators Home 630, Upper Right 632, Lower Left 634 and Lower Right 636, with the currently selected overprint registration mark. If the two are not the same, the user has selected a different alignment mark to be aligned and the program will reflect the change and then print three copies of alignment form 90 using the coordinates stored in temporary storage to position the newly selected alignment mark. Okay 626 updates the old alignment mark coordinates with the coordinates currently stored in temporary storage (Update Coordinate 616) and then returns to the main screen 100 via Return 150. Cancel 628 returns the control to the main screen 100 via Return 150 without updating the old alignment mark coordinates.
If none of the above options were selected, Evaluate Movement 650 examines the placement of registration mark indicator 94 with respect to QA mark indicator 96 as shown on screen 92. The program then determines the number of horizontal and vertical pixels that registration mark indicator 94 was moved on alignment screen 92. Using this information, the movements are translated from 72 pixels per inch to 300 pixels per inch, and then to increments in terms of thousandths of an inch. These horizontal and vertical movement increments are then added to or subtracted from the horizontal and vertical coordinates for the currently selected alignment mark as stored in temporary storage. The Menu 620 loop is then repeated until the user selects an option to exit from the loop.
The individual alignment coordinates and offset values determined by Do Alignment 600 are listed below. These parameters describe how the customized questions 52 and response areas 54 are placed in the print area of scannable form 22 to achieve appropriate alignment with timing track 24.
Home--the horizontal and vertical distances from the top and left edges of scannable form 22 to the center of QA mark 30.
Upper Right Vertical--the total distance from QA mark 30 to QA mark 32.
X-Column-Pixels--Upper Right Vertical divided by the maximum number of response areas 54 in a row, i.e. the distance between each vertical response area.
Upper Right Skew--any horizontal variance between the absolute value of the distance from the top edge of scannable form 22 and the center of QA mark 30 and at QA mark 32.
Lower Left Skew--similar to Upper Right Skew, any vertical variance between the absolute distance from the edge of scannable form 22 and the center of QA mark 30 and QA mark 34.
Lower Left Horizontal--total vertical distance from the center of QA mark 30 to the center of QA mark 34.
Y-Row-Pixels--Lower Left Horizontal divided by the maximum number of response areas 54 in a column, i.e., the distance between each horizontal response area.
Lower Right Skew--any horizontal variance between the center of QA marks 34 and QA marks 36.
Bubble-Y-Row-Max--52 response areas 54 in a row.
Bubble-X-Column-Max--45 response areas 54 in a column.
Print
The software program that comprises Do Print 700 is utilized for printing both the actual survey forms 20 and the form key 68. The only difference between the two options is that when the form key 68 is printed on the scannable form 22, none of the customized questions 52 or text areas 57 and graphics 58 are printed and all of the response areas 54 are printed as blackened-in ovals to be scanned by the scanner 16, rather than as ovals to be filled in when the survey form 20 is fielded. By printing the form key 68 in this manner, the scanner 16 will be able to detect only the positions of the response areas 54 that the user wants to have scanned. If the customized questions 52 or the text areas 57 or graphics 58 were printed on the form key 68, the analysis process would be required to differentiate those items from the response areas 54 that the user wants to have scanned. In a preferred embodiment of the invention, the alignment coordinates and offset values established by Do Alignment 600 are used to generate absolute vertical and horizontal placement values for the customized questions 52; the response areas 54 are then printed using the PostScript printer driver language. Other methods of establishing the alignment coordinates and offset values and other printer driver languages may used without departing from the spirit of the present invention.
Referring now to FIGS. 14a-14b, a functional flowchart for the software program Do Print 700 is shown. At Retrieve Alignment Coordinates 702, the alignment coordinates for Home 630, Upper Right 632, Lower Left 634 and Lower Right 636 are retrieved along with the offset values for X-Column-Pixels, Upper Right Skew, Lower Left Skew, Y-Row-Pixels, and Lower Right Skew. For each graphic image, response area, customized question or alignment mark to be located on the survey form 20, the element is offset by the absolute coordinates stored for Home 630. In effect, this offsets the entire print area of scannable form 22 by the targeted home coordinates.
At Text and Graphic To Print 704, the program determines whether there are any text areas 57, graphics 58 or customized questions 52 to print. If so, for each item the relative coordinates of that item are determined from the placement of the item by the user in the Content Area 130. At Place Text and Graphics 706, these relative coordinates are then modified with the alignment coordinates to determine where to place the item on the planned print area for scannable form 22. In a preferred embodiment, each text area 57, graphic 58 or customized question 52 is represented as a rectangle whose corner coordinates will define the location of the item on scannable form 22. In locating the item, the following values are calculated:
Column Print Position=(Upper Left Vert. Relative Coordinate)*(X-Columns-Pixels/12).
Top Row Print Position=(Upper Left Horiz. Relative Coordinate)*(Y-Row-Pixel/15).
Bottom Row Print Position=Lower Left Horiz. Relative Coordinate--((Lower Left Horiz. Relative Coordinate--Upper Left Horiz. Relative Coordinate)/15)*(15-Y-Row-Pixels)).
Once the graphic and text rectangles have been positioned, Bubbles To Print 708 determines whether there are any response areas 54 to be printed. If so, a unique form identification mark 70 is first calculated at Create Form ID Mark 710. The form identification mark 70 is based upon the number and positioning of the arrangement of the response areas 54 as located in the Content Area 130. It is used to identify the particular pattern of response areas 54 on this survey form 20 and to ensure that the proper version of the survey form will be scanned if more than one version of a survey form is created. In a preferred embodiment, the form identification mark 70 is based on the number of response areas 54 that will be printed according to the following equations:
For each Response area 54
Col.sub.-- Row.sub.-- Total=(100*Column.sub.-- Position)+Row.sub.-- Position
When all of the Response areas 54 are added together
Tempid=remainder(Col.sub.-- Row.sub.-- Total/10,000)
Tempid2=Tempid*Total.sub.-- Number.sub.-- Bubbles
Tempid3=remainder(Tempid2/10,000)
Formid=Tempid3+Current+Time(expressed in military format).
By using both the number and location of the positions of the response areas 54, a unique value is calculated for the form identification mark. In addition, the particular version of the survey form 20 is also uniquely identified by the time that the survey form 20 is printed. In one embodiment, the program converts Formid from a decimal to a binary format represented as a 2 **12 number. The form identification mark 70 is comprised of a string of data marks and non-data marks (mark coded format) representing the binary format of Formid and is printed in the print area below bias bar 30 by Locate Form ID Mark 712. One embodiment of a software program written in Pascal for calculating and printing the form identification marks 70 is as follows:
______________________________________Procedure DoFormIDMarks;BEGINDrawString(`newpath`);mark -- pos:=45;while mark -- code > 0 dobegin mark -- status:=mark -- code mod 2; if mark -- status = 1 then begin Cal -- x -- y -- Pos (mark -- pos, 51, false); DrawText (@formmark, 1, 30); end; mark .sub.-- pos:=mark -- pos - 1; mark -- code:=mark -- code div 2;end;END;______________________________________
At Locate Alignment Marks 714, alignment marks 80, 82, 84, and 86 are located in the print area based upon the alignment coordinate values of Home 630, Upper Right 632, Lower Left 634 and Lower Right 636. At Locate Response Bubbles 716, the center coordinates for each response area 54 to be printed are calculated based on the relative row and column values and the response area is located in the correct position in the print area. In locating response areas 54 and alignment marks 80, 82, 84, and 86, the following values are calculated:
Column Print Position=(Relative Row*Lower Left Skew)+(Relative Column*X-Column-Pixels).
Skew Max=(Relative Row/Bubble-Y-Row-Max)*(Lower-Right Skew/Bubble-Y-Row-Max).
Skew Offset=Skew-Max*(Relative Column/Bubble-X-Column-Max).
Row Print Position=(Relative Row*Y-Row-Pixels)+((Upper-Right-Skew +Skew-Offset)*Relative Column).
In addition to the use of the grid display in the Content Area 130, the present invention overcomes the problems present in the prior art by determining the individualized placement values for each response area 54 to be located in the print area. Conventional software drawing programs do not perform this individualized placement; rather, a string of response areas might be tied together and all of the subsequent placements for the response areas in the string would be based upon displacements from the original response area. This is also the case if all of the items are located in the print area based on displacement values from a single axis location. By including the Lower Left Skew, Skew Max and Skew Offset in the calculations for placing each response area 54, there is no accumulation of skew errors in either the horizontal or vertical dimension that would otherwise result in a later-placed response area 54 being misaligned with respect to its corresponding timing mark 26 and ultimately possibly scanned as a valid data mark. Because both the Column Print Position and the Row Print Position are rounded up or rounded down appropriately to the nearest pixel, the present invention achieves the finest resolution of which laser printer 14 is capable.
At Print Questionnaire 720, the print area for each survey form 20 has been completed and the survey form 20 is ready to be printed by laser printer 14. The user now has the option of entering a specific number of survey forms to be printed (Print Copies 722), or combining survey forms 20 with the mail merge file so that the individual records are inserted into each survey form as it is printed (Mail Merge 724). Referring to FIGS. 15a-15b, samples of the Print dialog boxes for both Print Copies 722 and Mail Merge 724 are shown. For the Print Copies 722 dialog box shown in FIG. 15a, the user may enter the number of copies 730 of the survey form 20 to be printed, the page number 732 of the survey form 20 (e.g., if there is more than one survey form comprising a survey booklet), and two print options--staple marks 734 and fold marks 736--as indications to the persons assembling the survey forms where to staple and fold the survey forms. If the user selects Number Questionnaire 738, each survey form 50 will be printed with a unique sequence number 74 and corresponding sequence number marks 76. For the Mail Merge 724 dialog box shown in FIG. 15b, the user may select number of copies 730, page number 732, staple marks 734 and fold marks 736, just as with Print Copies 722. Similarly, the user may also select Number Questionnaire 738. If the user selects Mail Merge Option 740, each survey form 20 is merged with a record from the Mailmerge file in the manner described above. For each survey form printed, the user has the option of selecting: what record in the Mailmerge file to start with, Record Number 742; whether the record number will be printed, Print Record Number 744; and whether the mail merge identification marks 70 will be printed, Print Mail Merge ID 746. After the survey forms 20 have been printed, control is returned to the main screen via Return 150.
Alignment of the individual survey forms 20 can also be checked automatically by scanner 16. In one embodiment, QA marks 32 and 34 are overprinted with alignment marks 82 and 84 and QA mark 36 is overprinted with alignment mark 86 during the printing of survey forms 20. To assist in verifying the accuracy of alignment between QA marks 32 and 34 and alignment marks 82 and 84 by scanner 16, alignment marks 82 and 84 are printed as circles larger in diameter than quality assurance marks 32 and 34, but smaller in diameter than the response areas 54. Alignment mark 86 is printed as a solid circle within QA mark 36. Computer 18 can be instructed to verify that scanner 16 properly detected alignment mark 86 as a valid data mark, and that scanner 16 did not detect any valid data marks at quality assurance marks 32 and 34, or any combination of valid and invalid data marks, thereby indicating that alignment marks 82 and 84 were not detected.
ANALYSIS
The analysis process of the present invention is primarily concerned with two functions: (1) defining the fields comprised of groups of response areas to be scanned, and (2) scanning the information contained in those fields. It will be apparent that, once the information has been properly scanned from the survey form 20 and is arranged in correctly defined fields, any number of statistical analysis programs or packages may be used to actually analyze and interpret this data. The analysis process of the present invention allows the user to more quickly and accurately accomplish the definition and scanning of the information, thereby allowing more time to be spent on the analysis and interpretation of that information.
With reference to FIG. 16a an Opening Menu 1000 for the software program that comprises the analysis process is shown. In a preferred embodiment, the analysis process software program is written for an IBM AT computer and uses the pop-up screen menus compatible with the windowing operating system for that computer system. All of the actions or events that a user may select are accessed through the Opening Menu 1000 that is divided into Define 1100, Scan 1200, Key Enter 1300, Data File Management 1400, StatPac 1500, and Utilities 1600. The flowchart for the overall flow of the software program that drives the main screen 1000 is shown in FIG. 17. At Start Application 1002, the user has selected the desktop survey system analysis application and the software program is loaded into computer 18. At Initialize 1004, all of the global variables for the software program are initialized. At Display Opening Menu 1006, the opening menu with all of the above-listed options is displayed and the program enters a polling loop waiting for directions from the user as to what option will be selected. Depending upon which option is selected, control is passed to that option to perform the selected task and then control will be returned to the Opening Menu 1000 via Return 1050.
Define
Referring now to FIGS. 18a-18c, the general flow of the Define Questionare 1100 option will be explained. At Select Questionnaire 1102 the user instructs the program whether to work on a new survey form or an existing survey form. At Enter File Name 1104, the user enters the name of the file for the desired questionnaire. This name will be used to designate the file where the information relating to all of the survey forms that comprise the questionnaire will be stored. Each survey form 20 is referred to as a page of the questionnaire being defined. At New File 1106, the program compares the data file name with the existing data file name to determine if a new file has been selected. If a new data file has been selected, at Enter Output Control Variable 1108, the user enters certain output control field information to be added to the questionnaire file. This information includes the batch, sequence number, data scanned, a user-defined constant and the identification number 74 for each questionnaire that is scanned. In one embodiment, this information is stored in the first 29 positions of an individual questionnaire's data record. If an existing file has been selected, at New Page 1110, the user decides whether to add another page to an existing questionnaire or to make changes to an existing page of an existing questionnaire. At Enter Existing Page Number 1114, the user selects the page number to be modified. At Enter New Page Number 1112, the user enters the new page number to be created. At Display Window 1120, the Define Questionnaire Window 1150 as shown in FIG. 16b is displayed on the screen for the computer 18. This window is where the fields of the survey form 20 will be defined.
The next step is to scan the form key 68 using the scanner 16. At Scan Form Key 1122, the user places the form key 68 face up in the scanner 16 with the form identification marks 70 and bias bar 40 entering the scanner 16 first. To start the scanning, the user presses the enter key on the computer 18 to activate the scanner 16. When the form key 68 is read by the scanner 16, black marks 1152 are displayed on the Define Questionnaire Window 1150 at the exact locations where the response areas 54 were filled in with blackened ovals 69 on the form key 68. The numbers 1154 and smaller marks 1156 along the right hand side of Define Questionnaire Window 1150 represent the individual timing marks 26 that comprise timing track 24 of the survey form 20 being scanned.
The user is now ready to define the fields corresponding to the response areas 54 whose positions were just scanned. Defining the fields is comprised of instructing the computer 18 what group of response areas 54 will be combined together to constitute a field and what values will be given to the individual response areas 54 in that field if that response area is marked on the survey form 20. At Select Fields 1124, the user moves the cursor to a particular groups of black marks 1152 on the Define Questionnaire Window 1150. At Modify 1126, the user moves the cursor to the first black mark position in the field. If the user is changing an existing field, the user selects this particular field by hitting the Enter key, deletes the current field definition by hitting the Delete key (Delete Old Definition 1128) and then hits the Enter key a second time to open the definition for the field type to be used for the selected field. At Enter Field Type 1130, the user selects the field type or definition that will be applied to the group of black marks 1152 currently pointed to by the cursor. The field type may be either a standard definition or the user may define a new field type. Examples of various field types are shown in FIG. 19. Other suggested field types might include:
__________________________________________________________________________1 Response this field type would be used to indicate single bubble fields. A data mark would score as a 1, no data mark would score as a 0.0-1 Horz these field types would be used to indicate a horizontal bubble1-2 Horz field of varying height. Each bubble a data mark in the first1-3 Horz bubble in the column would score as a 1, a data mark in the1-4 Horz second bubble in the column would score as a 2, etc, depending upon the number of bubbles in the column, no data marks in any bubble would be scored as a space.0-1 Vert these field types would be used to indicate a vertical bubble field1-2 Vert of varying length. Each bubble a data mark in the first bubble in1-3 Vert the row would score as a 1, a data mark in the second bubble in1-4 Vert the row would score as a 2, etc, depending upon the number of bubbles in the row, no data marks in any bubble would be scored as a space.0-1 Vert # these field types would indicate a vertical bubble field of varying1-2 Vert # length having a must respond option. If no data marks are found1-3 Vert # in any of the bubbles in the field, the field is scored as a "#" and shows up in an Exception Data Listing Report.__________________________________________________________________________
The field type may also be a linked field having two or more vertical or horizontal columns or rows linked together. In general, there are five different types of fields that the user may select from for the field definitions: Numeric-- -- , 0, 1, 2, 3, 4, etc.; Response-- -- , 1, 2, 3, 4, etc; Alphanumeric #, A, B, C, D, . . . Z, 1, 2, 3, etc.; Numeric Must Respond--#, 0, 1, 2, 3, 4, etc.; and Response Must Respond--#, 1, 2, 3, 4, etc. Other types of of formats may be created by the user as may be required. Once a new field type has been created, the user may specify a name for the field type and that type will be stored in a library and available for use in defining future questionnaires.
Referring to FIGS. 18a-18c again, once the user has designated the field type for the field of response areas currently selected by the cursor, the field is named at Name Field 1132. This entire process is repeated until all of the response areas 54 on the survey form 20 have been defined as indicated at End Fields 1134. Next, the user selects Open Ends 1136 to define the fields for the open-ended questions 56, if any, that might exist on the survey form 20. At Define Open End Questions 1138, the user may enter the characteristics about the open-ended question on the summary of field types that have just been defined and are displayed on the computer screen as shown in FIG. 20. The user moves the cursor in between the field types where the open-ended question data will be stored and hits Enter. This will open a new line for the user to type in information relating to the data record being defined for this page of the questionnaire, including: the starting column of the open-ended question data, the number of columns, the data type (A--alphanumeric, N--numeric, F--key entry field to be inserted after scanning), and the document page number that the question will be found on. It may be desirable to locate most of the open-ended question field at the beginning of the data record to speed the entry of the associated key entry field information to be entered after the survey forms are scanned as described below. The process is repeated until all of the open-ended questions for this page of the questionnaire have been defined. At Print Data File 1140, the user has the option of printing out a hard copy of all of the characteristics and field types that have been defined for the particular questionnaire (the questionnaire data file). With the survey form definition completed, the user is returned to the main menu at Return 1050.
Scan
Referring now to FIGS. 21 and 22, the actual scanning operation of the survey forms 20 is described. At Select File Name 1202, the user identifies the questionnaire data file to be scanned. Typically, the survey forms 20 will be returned from being fielded in smaller groups or batches of one hundred to two hundred forms. For quality control reasons, it is desirable to scan the survey forms 20 in these smaller batches. At Enter Batch Data 1204, the user enters the data file name that is the name of the file where the scanned data will be stored. The scanned data may also be appended to an existing data file or may replace an existing data file, if, for example, an entire batch of survey forms are rescanned. Next, the user enters the batch number that identifies the particular batch of survey forms being scanned. If the scanner 16 is equipped with a transport printer, the scanner 16 can print this 4-digit number on each of the survey forms 20 as they are being scanned. Next, the user enters a starting serial number to generate an individual serial number that will be assigned to each of the survey forms as they are scanned. Again, if the scanner 16 is equipped with a transport printer, each survey form can have the individual serial number printed on the survey forms 20 as they are scanned. The user is also allowed to enter an eight character constant value that will be placed in the questionnaire data file record and, if a transport printer is available, will be printed on each of the survey forms. It is a good idea to designate this constant as the same name as the data file previously assigned. Next, the user may designate several options that are used to control the scanning of the survey forms at Designate Options 1206. The various options include: Field Error, QA Error, Transport Printer, and Scan Report. The Field Error option allows the user to decide whether to have the scanner 16 pause if it detect a field with incorrect input, i.e. a must respond field that has no response, or whether the record will be flagged for later correction. The QA Error option allows the user to decide to have the scanner 16 pause if it detects a survey form 20 that did not pass the quality assurance alignment test described above, or the user may have the record flagged for later correction. The Transport Printer option allows the user designate whether the scanner 16 is equipped with a transport printer and whether the transport printer will be used to mark the batch number, sequence number, etc. on the survey forms 20 as they are scanned. The Scan Report option allows the user to elect to have the computer 18 produce a one page report to a peripheral printer attached to the computer 18 for each of the batches as they are scanned. The report lists the questionnaire name, data file name, number of questionaires scanned, and the data.
The actual scanning of the forms occurs at Scan Forms 1208. If the questionnaire is comprised of multiple pages, the page order should be determined by the particular scanner 16 being used with the system 10. In a preferred embodiment, the NCS Sentry 3000 scanner has a top down page order (page 3 on the bottom, page 2 next, and page 1 on the top), but the pages come out in reverse order after they are scanned (page 1 on the bottom, page 2 next, and page 3 on the top). It is a good idea to restaple multiple page surveys together after they have been scanned to insure that the survey forms remain in the scanned sequence.
At Report Errors 1210, the computer 18 checks for and displays a running tally of the results of the scanning operation as it is occurring in a format similar to that shown in FIG. 23. Any error messages are displayed in the Error Message Field 1250. Some of the typical error messages that might occur include:
Unexpected form identification mark--if the survey form 20 that was scanned did not have a form identification mark 70 that was identical to the form identificatioin mark 70 on the form key 68 for this questionnaire, an error condition will occur. This error may occur if the form identification mark 70 was printed on only one page of a multiple page questionnaire. If so, the user must rescan the entire questionnaire booklet because no data will be saved from a partially scanned questionnaire booklet.
Incorrect Number of Timing Marks Read--if the scanner 16 did not read the expected number of timing marks 26, an error condition will occur. The user should check the form for stray marks in the timing track 24.
Field with a Multiple Response--if a field has been defined to not allow multiple responses (*) and multiple data marks are detected for that field, an error condition will occur.
Field with No Response--if a field has been defined to require a response (#) and no data marks are detected for that field, an error condition will occur.
All of the survey forms 20 in this batch are scanned until End Batch 1214. If the Scan Report Option was selected by the user, a scan report for the batch is printed out at Print Scan Report 1216.
Key Enter
In general, there are two ways of entering data from the open-ended questions 56 that appear on a survey form 20. First, the data may be pre-coded into specially designated response area positions located on the survey form 20, as shown for example in FIG. 24a. An alternative approach to precoding uses a second survey form 20 that is comprised of a number of response areas fields for coding the information in response to corresponding open-ended questions 56 in a questionnaire booklet. To scan this information, these response areas are defined as special fields during the Define 1100 step. When the survey forms 20 are returned from the field, the user fills in the appropriate code in the special field and the survey forms are now ready to be scanned with the information from the open-ended questions 56 being collected in the special fields.
Another method for encoding information contained in the open-ended questions 56 occurs after the survey forms 20 have been scanned and the data file record for each survey form has been created and saved in the data file. In a preferred embodiment, the user selects the questionnaire and data file for which the information is to be included, and then enters the data directly into the individuals data file records using the preferred statistical package, StatPac Gold. It should be obvious that any number of data entry methods may be used to enter either coded or alphanumeric data directly into the data file records once they have been scanned in the system 10 by the scanner 16.
Data File Management
Referring now to FIG. 25, the routine that handles the data file management will be explained. At Print Cross-Reference 1402, the user may elect to print a report of the data file to be selected with the form identification number cross referenced with the file record number. At Print Standard 1404, the use may elect to print the standard report containing all of the data in the data file by file record number. An example of a sample standard report is shown in FIG. 26. At Print Exception 1406, the user may elect to list all of the data file records containing any type of field error. For each of these three options, the user identifies the desired data file at Select File 1408 and the selected report is printed out on a peripheral printer attached to the computer 18 at Print Report 1410. The user also has the option of manipulating the data in existing data files. At Merge Data 1412, the user may combine two different data files into a single data file. At Rearrange Data 1414, the user may reorder the data fields in a selected data file. After the desired event has been processed, control is returned to the main screen at Return 1050.
Statistical Analysis
In a preferred embodiment, the computer 18 transfer control to a statistical software package StatPac Gold, available from Walonick Associates, Minneapolis, Minn. Using this or any similar software package, the user may perform any number of statistical calculations on one or more of the data files created by the desktop survey system 10. For example, the user might first elect to edit the data to clean up any of the data field error identified in the Exception Report. After the data was cleaned up, frequency, standard deviation, distribution and other statistical information can be calculated. The results can be displayed in a variety of methods, including reports, bar charts, graphs, pie charts, distribution plots or a customized graphic display.
Although the description of the preferred embodiment has been presented, it is contemplated that various changes could be made without deviating from the spirit of the present invention. Accordingly, it is intended that the scope of the present invention be dictated by the appended claims rather than by the description of the preferred embodiment.
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A desktop survey system for creating and scanning a survey form to be completed by a survey respondent, the survey form being printed on a scannable form having a preprinted timing track that can be scanned by an optical mark scanner is comprised of a processor for entering, editing, and formatting customized questions and corresponding response areas and for adjusting and aligning the locations of the questions and response areas to be printed on the scannable form, a printer for printing the customized questions and the corresponding response areas on the scannable form to create a customized survey form, and an optical mark scanner and attached processing means for defining the fields to be scanned, scanning the survey forms and tabulating and analyzing the results.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a pelletizing additive for silicone rubber compositions, to a process for preparing the additive, to a pelletized silicone rubber material containing the additive, and to a process for preparing the pelletized material.
2. Description of the Related Art
There has been a longfelt need to provide pelletized silicone rubber. Such products are important, for example, for use in automated extrusion or injection molding processes. A problem is that it has not been possible to pelletize untreated silicone rubber since the untreated rubber clogs the pelletizing die or the knife.
U.S. Pat. No. 4,172,871 discloses the production of silicone rubber pellets, but the silicone rubber pellets adhere to one another in the untreated state. This adherence problem is solved by the '871 patentee by coating the pellets, for example with mica or talc.
BRIEF SUMMARY OF THE INVENTION
An object of the present invention is to improve upon the prior art silicone rubber pellets, and in particular to provide a pelletized material which has free-flowing properties and does not require surface-treatment with substances which, in some circumstances, could cause processing or performance difficulties. These and other objects are achieved by the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides a pelletizing additive composition which is prepared from at least one polyorganosiloxane, boric acid and water, and silicone rubber formulations containing such a composition as a pelletizing additive.
The polyorganosiloxanes are preferably linear polyorganosiloxanes, such as dimethylpolysiloxanes, phenylmethylpolysiloxanes, trifluoropropylpolysiloxanes or ethylpropylpolysiloxanes having a viscosity of from 10,000 to 9×10 6 mPa·s, preferably from 100,000 to 8×10 6 mPa·s and in particular from 6×10 6 mPa·s to 8×10 6 mPa·s. The polyorganosiloxane(s) preferably comprise from 30 to 90% by weight, more preferably from 40 to 80% by weight, and most preferably from 60 to 70% by weight, of the composition.
Boric acid preferably comprises from 2 to 20% by weight, more preferably from 3 to 14% by weight, and most preferably from 8 to 9% by weight, of the composition.
Preferably, the novel composition further comprises fatty acid salts. The fatty acid salts are preferably salts of the metals Al, Ba, Ca, Cd, Co, Cr, Cu, Fe, Li, Mg, Mn, Ni, Pb, Sn, Sr, or Zn with higher fatty acids, resin acids or naphthenic acids, for example stearates, palmitates, oleates, linoleates, resinates, laurates, octanoates, ricinolates, 12-hydroxystearates, naphthenates, tallates and the like. Preference is given to fatty acids having from greater than 12 to 30 carbon atoms, particularly to fatty acids having from greater than 16 to 26 carbon atoms, and most preferably stearates, especially calcium stearate. The composition preferably contains 1 to 10% by weight, more preferably from 2 to 6% by weight, and most preferably from 3 to 4% by weight, of the fatty acid salts.
The invention also provides a process for preparing the novel composition, where the components polyorganosiloxane, boric acid and water are mixed. In this aspect of the invention, the abovementioned components polyorganosiloxane, boric acid and preferably deionized water, and, if desired, from 8 to 60% by weight, preferably from 15 to 50% by weight, and more preferably from 25 to 40% by weight, of silica produced pyrogenically in the gas phase and having a surface area of from 150 to 300 m 2 /g, or precipitated silicic acid, are mixed together. Kneading is preferably carried out for from 2 to 4 hours, preferably at a temperature of from 120 to 190° C., and preferably under an atmosphere of nitrogen. The water which serves here as solvent for the boric acid is drawn off as a vapor.
The resultant composition serves as an additive for producing a pelletized material made from silicone rubber. This silicone rubber may be a peroxidically crosslinking or an addition-crosslinking silicone rubber. Surprisingly, this additive allows production of a pelletized silicone rubber material which has full free-flowing properties. The amounts of this additive added to the silicone rubber are preferably from 0.1 to 4% by weight, more preferably from 0.4 to 2% by weight, and most preferably from 0.8 to 1.2% by weight.
The novel silicone rubber is preferably a peroxidically crosslinking polyorganosiloxane material, which preferably comprises the following components.
Polyorganosiloxanes made of units of the general formula R r SiO 4 - r 2 , ( I )
where
R is identical or different and is an unsubstituted or substituted hydrocarbon radical and
r is 0, 1, 2 or 3 and has an average numerical value of from 1.9 to 2.1.
Examples of hydrocarbon radicals R are alkyl radicals such as the methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-pentyl, isopentyl, neopentyl and tert-pentyl radicals; hexyl radicals such as the n-hexyl radical, heptyl radicals such as the n-heptyl radical; octyl radicals such as the n-octyl radical, and isooctyl radicals, such as the 2,2,4-trimethylpentyl radical; nonyl radicals such as the n-nonyl radical; decyl radicals such as the n-decyl radical; dodecyl radicals such as the n-dodecyl radical; octadecyl radicals such as the n-octadecyl radical; cycloalkyl radicals such as cyclopentyl, cyclohexyl and cycloheptyl radicals and methylcyclohexyl radicals; aryl radicals such as the phenyl, biphenyl, naphthyl, anthryl and phenanthryl radicals; and alkaryl radicals such as o-, m-, and p-tolyl radicals, xylyl radicals and ethylphenyl radicals; aralkyl radicals, such as the benzyl radical and the α- and β-phenylethyl radicals.
Examples of substituted hydrocarbon radicals R are halogenated alkyl radicals such as the 3-chloropropyl radical, the 3,3,3-trifluoropropyl radical, and the perfluorohexylethyl radical, and halogenated aryl radicals such as the p-chlorophenyl radical and the p-chlorobenzyl radical.
The radicals R are preferably hydrocarbon radicals having from 1 to 8 carbon atoms, most preferably the methyl radical. Other examples of radicals R are the vinyl, allyl, methallyl, 1-propenyl, 1-butenyl and 1-pentenyl radicals, the 5-hexenyl, butadienyl, hexadienyl, cyclopentenyl, cyclopentadienyl, cyclohexenyl, ethynyl, propargyl and 1-propynyl radicals. The radicals R are preferably alkenyl radicals having from 2 to 8 carbon atoms, most preferably the vinyl radical. Among unsubstituted or substituted hydrocarbon radicals having from 1 to 8 carbon atoms, particular preference is given to the methyl, vinyl, phenyl and 3,3,3-trifluoropropyl radicals.
There are preferably alkyl radicals, most preferably methyl radicals, bonded to at least 70 mol % of the Si atoms present in the polyorganosiloxane (A) made of units of the formula (I). If the polyorganosiloxanes contain, besides Si-bonded methyl and/or 3,3,3-trifluoropropyl radicals, Si-bonded vinyl and/or phenyl radicals, the amounts of the latter are preferably from 0.001 to 30 mol %.
The polyorganosiloxanes (A) are preferably composed predominantly of diorganosiloxane units. The end groups of the polyorganosiloxanes may be trialkylsiloxy groups, in particular the trimethylsiloxy radical or the dimethylvinylsiloxy radical. However, it is also possible for one or more of these alkyl groups to have been replaced by hydroxyl groups or by alkoxy groups, such as methoxy or ethoxy radicals. The polyorganosiloxanes (A) may be liquids or highly viscous substances. The viscosity of the polyorganosiloxanes (A) is preferably from 10 3 to 10 8 MPa·s at 25° C. It is possible to use either just one type of polyorganosiloxane (A) or a mixture of at least two different types of polyorganosiloxanes (A).
The crosslinking agents preferably used in the novel silicone rubber materials are peroxides, such as dibenzoyl peroxide, bis(2,4-dichlorobenzoyl) peroxide, dicumyl peroxide or 2,5-bis(tert-butylperoxy)-2,5-dimethylhexane, or mixtures of these, preferably a mixture of bis(2,4-dichlorobenzoyl) peroxide and 2,5-bis(tert-butylperoxy)-2,5-dimetylhexane. Another preferred crosslinking agent is a mixture of bis-4-methylbenzoyl peroxide (PMBP) and 2,5-dimethyl-2,5-di-tert-butylperoxyhexane (DHBP) in a ratio of from 1:0.4 to 0.5:1, preferably in a ratio of 1:0.4.
The polyorganosiloxanes (A) according to the invention also preferably comprise reinforcing and/or nonreinforcing fillers. Examples of reinforcing fillers are pyrogenic or precipitated silicas with BET surface areas of at least 50 m 2 /g.
The silica fillers mentioned may have hydrophilic character or may have been hydrophobicized by known processes. Reference may be made here, for example, to DE 38 39 900 A (Wacker-Chemie GmbH; application date Nov. 25, 1988) or to the corresponding U.S. Pat. No. 5,057,151. The hydrophobicization generally takes place using from 1 to 20% by weight of hexamethyldisilazane and/or divinyltetramethyldisilazane and from 0.5 to 5% by weight of water, based in each case on the total weight of the polyorganosiloxane material. These reagents are preferably added to an initial charge of the polyorganosiloxane (A) in a suitable mixing apparatus, e.g. a kneader or internal mixer, prior to incorporating the hydrophilic silica gradually into the material.
Examples of nonreinforcing fillers are powdered quartz, diatomaceous earth, calcium silicate, zirconium silicate, zeolite, metal oxide powders, such as aluminum oxide, titanium oxide, iron oxide, or zinc oxide, barium silicate, barium sulfate, calcium carbonate, calcium sulfate and polytetrafluoroethylene powder. Other fillers which may be used are fibrous components, such as glass fibers and synthetic polymer fibers. The BET surface area of these fillers is preferably less than 50 m 2 /g.
The novel polyorganosiloxane materials which can be crosslinked to give elastomers preferably comprise from 1 to 200 parts by weight, more preferably from 30 to 100 parts by weight of filler (B), based in each case on 100 parts by weight of polyorganosiloxane (A).
Depending on the particular application, additives (C), for example processing aids such as plasticizers, pigments, or stabilizers such as thermal stabilizers, may be added to the novel polyorganosiloxane materials which can be vulcanized to give elastomers.
Examples of plasticizers which can be used as additives (C) are polydimethylsiloxanes with a viscosity of not more than 1000 mm 2 /s at 25° C. and having trimethylsilyl and/or hydroxyl terminal groups, or biphenylsilanediol.
Examples of thermal stabilizers which can be used as additives (C) are transition metal salts of fatty acids, such as iron octoate, cerium octoate and titanium bythylate, transition metal silanolates, such as iron silanolate, and also cerium(IV) compounds, and oxides, e.g. iron oxide and titanium oxide and mixtures of these.
In the case of each of the components used to prepare the novel materials, a single type of a given component may be used, or else a mixture of at least two different types of that component. The novel pelletizing aids preferably comprise no other substances other than those previously described.
The amount of the novel additive added to this peroxidically crosslinked silicone rubber is preferably from 0.1 to 4% by weight, more preferably from 0.4 to 2% by weight, and most preferably from 0.8 to 1.2% by weight. Pelletization follows, using conventional means of pelletizing, e.g. a pelletizing die and rotating knife, giving a fully free-flowing pelletized material.
An addition-crosslinking polyorganosiloxane material is preferred for the silicone rubber. All of the abovementioned substances except the peroxidic crosslinking agent may also be used with the addition-crosslinking polyorganosiloxane materials. In the case of the polyorganosiloxane rubber materials which cure via hydrosilylation at an elevated temperature to give elastomers, polyorganosiloxanes (D) having Si-bonded hydrogen atoms and hydrosilylation catalysts (E) are also present.
The polyorganosiloxane crosslinking agents (D) may be linear, cyclic or branched, and preferably contain at least 3 Si-bonded hydrogen atoms. The polyorganosiloxanes (D) used are preferably polyorganosiloxanes of the general formula (II)
H g R 2 3−g SiO(SiR 2 2 O) k (SiR 2 HO) 1 SiR 2 3−g H g (II),
where
R 2 is as defined for R,
g is 0 or 1, and
each of k and 1 is 0 or an integer from 1 to 100.
Examples and preferred examples for the radicals R 2 have been listed above in the examples for the radicals R. The radicals R 2 are preferably saturated alkyl radicals or phenyl radicals.
Each of k and 1 is preferably 0 or an integer from 1 to 50. The sum of k and 1 is preferably from 1 to 50, in particular from 1 to 20.
Particular examples of polyorganosiloxanes (D) are copolymers made of dimethylhydrogensiloxane units, methylhydrogensiloxane units, dimethylsiloxane units and trimethylsiloxane units, copolymers made of trimethylsiloxane units, dimethylhydrogensiloxane units and methylhydrogensiloxane units, copolymers made of trimethylsiloxane units, dimethylsiloxane units and methylhydrogensiloxane units, copolymers made of methylhydrogensiloxane units and trimethylsiloxane units, copolymers made of methylhydrogensiloxane units, diphenylsiloxane units and trimethylsiloxane units, copolymers made of methylhydrogensiloxane units, dimethylhydrogensiloxane units and diphenylsiloxane units, copolymers made of methylhydrogensiloxane units, phenylmethylsiloxane units, trimethylsiloxane units and/or dimethylhydrogensiloxane units, copolymers made of methylhydrogensiloxane units, dimethylsiloxane units, diphenylsiloxane units, trimethylsiloxane units and/or dimethylhydrogensiloxane units, and also copolymers made of dimethylhydrogensiloxane units, trimethylsiloxane units, phenylhydrosiloxane units, dimethylsiloxane units and/or phenylmethylsiloxane units.
The amount of polyorganosiloxane (D) used is preferably sufficient to supply from 0.5 to 6 gram atoms, more preferably from 1 to 3 gram atoms, and most preferably from 1.5 to 2.5 gram atoms of Si-bonded hydrogen atom per mole of ethylenically unsaturated bonds in the radicals R 1 of the polyorganosiloxane (A).
The hydrosilylation catalyst (E) used may in principle be any catalyst conventionally used in addition-crosslinking silicone rubber materials. These include the elements and compounds of platinum, rhodium, palladium, ruthenium and iridium, preferably platinum. The transition metals may, if desired, have been fixed on finely divided support materials such as active carbon, metal oxides such as aluminum oxide, or on pyrogenically prepared silicon dioxide.
Preference is given to the use of platinum and platinum compounds. Particular preference is given to platinum compounds soluble in polyorganosiloxanes. Examples of soluble platinum compounds which may be used are the platinum-olefin complexes of the formulae (PtCl 2 .olefin) 2 and H(PtCl 3 .olefin), preferably using alkenes having from 2 to 8 carbon atoms, such as ethylene, propylene or isomers of butene or of octene, or cycloalkenes having from 5 to 7 carbon atoms, such as cyclopentene, cyclohexene or cycloheptene. Other soluble platinum catalysts are the platinum-cyclopropane complex of the formula (PtCl 2 .C 3 H 6 ) 2 , the reaction product of hexachloroplatinic acid with alcohols, with ethers or with aldehydes or with mixtures of these, or the reaction products of hexachloroplatinic acid with methylvinylcyclotetrasiloxane in the presence of sodium bicarbonate in ethanolic solution. Preference is given to finely divided platinum on support materials such as silicon dioxide, aluminum oxide, or activated wood charcoal or animal charcoal; to platinum halides such as PtCl 4 , hexachloroplatinic acid and Na 2 PtCl 4 .nH 2 O; platinum-olefin complexes, e.g. those with ethylene, propylene or butadiene; platinum-alcohol complexes; platinum-styrene complexes as described in U.S. Pat. No. 4,394,317; platinum-alcoholate complexes; platinum-acetylacetonates; reaction products prepared from chloroplatinic acid and monoketones, e.g. cyclohexanone, methyl ethyl ketone, acetone, methyl n-propyl ketone, diisobutyl ketone, acetophenone or mesityl oxide; and platinum-vinylsiloxane complexes as described, for example, in U.S. Pat. Nos. 3,715,334, 3,775,452 and 3,814,730, such as platinum-divinyltetramethyldisiloxane complexes with or without detectable amounts of inorganic halogen; all in amounts sufficient to promote the curing of the composition at a temperature of up to about 250° C., where the organohydrogensiloxane and the hydrosilylation catalyst are initially in different parts of the two or more component curable composition. Particular preference is given to complexes of platinum with vinylsiloxanes, such as sym-divinyltetramethyldisiloxane.
The hydrosilylation catalyst (IV) may also be used in microencapsulated form, in which case the catalyst is present in a finely divided solid insoluble in polyorganosiloxane, for example a thermoplastic (polyester resins, silicone resins). The hydrosilylation catalyst used may also be in the form of an inclusion compound, for example in a cyclodextrin.
The amount of hydrosilylation catalyst used depends on the desired rate of crosslinking and also on economic factors. When the common platinum catalysts are used, the content of platinum metal in the curable silicone rubber material is in the range from 0.1 to 500 ppm by weight (ppm=parts per million parts), preferably from 10 to 100 ppm by weight, of platinum metal. If desired, the catalyst may also be used together with an inhibitor, preferably in amounts of from 0.01 to 5% by weight.
A preferred preparation for an addition-crosslinking HTV silicone rubber is carried out as follows:
75 parts of a dipolyorganosiloxane end-capped by trimethylsiloxy groups, and consisting of 99.7 mol % of dimethylsiloxane units and 0.3 mol % of vinylmethylsiloxane units, having a viscosity of 8×10 6 mPa·s at 25° C., and 25 parts of a polydiorganosiloxane end-capped by trimethylsiloxy groups, consisting of 99.4 mol % of dimethylsiloxane units and 0.6 mol % of vinylmethylsiloxane units, having a viscosity of 8×10 6 mPa·s at 25° C., are mixed in a kneader at 150° C. with 45 parts of silicon dioxide produced pyrogenically in the gas phase having a BET surface area of 300 m 2 /g, and 7 parts of a dimethylpolysiloxane having one Si-bonded hydroxyl group in each terminal unit, having a viscosity of 40 mPa·s at 25° C., and kneaded for 2 hours. After cooling the mixture to room temperature, 5 ppm by weight of platinum, in the form of a 1% strength solution of hexachloroplatinic acid in isopropanol, and 0.2 ppm by weight of benzotriazole are admixed, the ppm by weight figures in each case being based on the entire weight of the mixture described above. A portion of a methylhydrogenpolysiloxane end-capped with trimethylsiloxy groups and having a viscosity of 20 mPa·s at 25° C. is then added to the mixture.
The novel additive, preferably in an amount from 0.1 to 4% by weight, more preferably from 0.4 to 2% by weight, and most preferably from 0.8 to 1.2% by weight, is added to the addition-crosslinking silicone rubber. Pelletization follows using conventional means of pelletizing, such as a pelletizing die and a rotating knife, giving a fully free-flowing pelletized material.
The advantage of the novel additive is that a fully free-flowing pelletized material is obtained without adding pyrogenic silicon dioxide. The purpose of the addition of pyrogenic silicon dioxide has been to reduce the tack of the silicone rubbers, which per se are tacky. The storage stability of mixtures of this type is no more than 24 hours, since the rubber stiffens completely within a few hours. The novel pelletized silicone rubber material of the present invention, however, has a storage stability of at least 6 months, and therefore can be satisfactorily processed throughout this period.
EXAMPLE 1
Preparation of the Additive
100 parts of a dimethylpolysiloxane with a viscosity of 8×10 6 mPa·s are mixed in a kneader with 13 parts of boric acid, 46 parts of silicon dioxide produced pyrogenically in the gas phase and having a surface area of 150 m 2 /g, 5 parts of calcium stearate, and 30 parts of deionized water and kneaded for 3 hours at 150° C. under nitrogen. During this time, the water serving as solvent for the boric acid is drawn away.
EXAMPLE 2
Preparation of the Peroxidically Crosslinking Silicone Rubber
100 parts of a diorganopolysiloxane end-capped with trimethylsiloxy groups, consisting of 99.93 mol % of dimethylsiloxane units and 0.07 mol % of vinylmethylsiloxane units and having a viscosity of 8×10 6 mPa·s at 25° C., are mixed in a kneader operated at 150° C., first with 50 parts of silicon dioxide produced pyrogenically in the gas phase, having a surface area of 200 m 2 /g, then with 1 part of dimethylpolysiloxane end-capped with trimethylsiloxy groups and having a viscosity of 96 mPa·s at 25° C., then with 7 parts of a dimethylpolysiloxane having an Si-bonded hydroxyl group in each terminal unit and having a viscosity of 40 mPa·s at 25° C., then again with 1 part of dimethylpolysiloxane end-capped with trimethylsiloxy groups and having a viscosity of 96 mPa·s at 25° C., and finally with 2.8 parts of a paste made of equal parts of bis(2,4-dichlorobenzoyl) peroxide and of a dimethylpolysiloxane end-capped with trimethylsiloxy groups, having a viscosity of 250 mPa·s at 25° C. Added to the kneader is then 0.8% of the additive of Example 1, and the mixture is processed without difficulty to give a fully free-flowing pelletized material. The production equipment for pelletization is an extruder with a rotating knife on the die.
Comparative Example 1
Example 2 is repeated without the novel additive. The resultant silicone rubber cannot be pelletized, but simply clogs the pelletizing die and knife.
EXAMPLE 3
Preparation of the Addition-crosslinking Silicone Rubber
Preparation of Component A
75 parts of a diorganopolysiloxane end-capped with trimethylsiloxy groups and consisting of 99.7 mol % of dimethylsiloxane units and 0.3 mol % of vinylmethylsiloxane units having a viscosity of 8×10 6 mPa·s at 25° C., and 25 parts of a diorganopolysiloxane end-capped with trimethylsiloxy groups, consisting of 99.4 mol % of dimethylsiloxane units and 0.6 mol % vinylmethylsiloxane units having a viscosity of 8×10 6 mPa·s at 25° C., are mixed in a kneader operated at 150° C. with 45 parts of silicon dioxide produced pyrogenically in the gas phase having a BET surface area of 300 m 2 /g, and 7 parts of a dimethylpolysiloxane having a Si-bonded hydroxyl group in each terminal unit, having a viscosity of 40 mPa·s at 25° C., and kneaded for 2 hours.
0.19 g of a platinum catalyst, composed of 97 parts by weight of a polydimethylsiloxane and 3 parts by weight of a platinum-divinyltetramethyldisiloxane complex, and 0.07 parts by weight of ethynylcyclohexanol as an inhibitor, are added to 100 parts by weight of the initial silicone mixture after cooling the material to room temperature, and homogenized in a kneader.
Preparation of Component B
A mixture is prepared as described under component A, except that, after cooling the material to room temperature, 4 parts by weight of a polydimethylsiloxane-co-hydromethylpolysiloxane and 0.03 parts by weight of ethynylcyclohexanol, as inhibitor, are added to 100 parts by weight of this initial silicone mixture, instead of the platinum catalyst and inhibitor.
Each of component A and component B is mixed with 0.8% of the additive of Example 1, homogenized in a kneader, and processed without difficulty to give fully free-flowing pelletized materials. The production equipment for this is an extruder with a rotating knife on the die.
Comparative Example 2
Example 3 is repeated without adding the novel additive. The resultant silicone rubber components cannot be pelletized, but simply clog the pelletizing die and knife.
While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. The novel compositions preferably contain only the previously described components. The terms “a” and “an” mean “one or more” unless indicated to the contrary.
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The invention relates to compositions which can be prepared from at least one polyorganosiloxane, boric acid and water, and which may serve as a pelletizing additive for crosslinkable silicone rubber formulations. A small proportion of the pelletizing additive, when added to a ore component crosslinkable silicone rubber, or to individual components of a two or more component silicone rubber formulation, allow production of free flowing pellets which retain storage stability for extended periods of time.
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This application is a continuation-in-part, of U.S. patent application Ser. No. 07/374,379, filed Jun. 30, 1989 (abandoned).
FIELD OF THE INVENTION
The present invention pertains to optical disk memory systems and, particularly, to optical disk read/write heads. More particularly, the invention pertains to optical disk heads using reflective diffracting optical elements.
BACKGROUND OF THE INVENTION
Many of the optical memory disk systems in the related art have read/write heads that are relatively large and bulky for the desired performance characteristics of today's systems. Also such systems are quite expensive. A typical optical system head may have three or four lenses, a polarizing beam splitter, four prisms bonded together as a unit, and quarter-wave length plate, among other parts. Despite the disadvantages, such heads may have approximately 80 percent signal throughput.
In an effort to address some of the above-mentioned disadvantages, one company has developed a compact read/write optical head that incorporates a transmissive holographic element which replaces the beam splitter and some of the optical elements in the larger systems. The major components of this device are a laser diode, a solid state detector, and a holographic element. The immense disadvantage of this compact head is that the signal throughput is very low, that is, approximately one percent. Such a typical device is disclosed in U.S. Pat. No. 4,731,772, entitled "Optical Head Using Hologram Lens for Both Beam Splitting and Focus Error Detection Functions."
SUMMARY OF THE INVENTION
The present invention is an optical read/write head that is very compact, lightweight and inexpensive, and has a high signal throughput that should approximate 40 percent. A reflective diffracting (binary) optical element is used in the optical head. The essence of the element is a planar metallic mirror containing a deep lamellar fringe grating. The lamellar grating provides very high diffraction efficiency. Selection of the grating period leads to operation near the second so-called Wood anomaly. This grating operation results in a wide separation between the diffraction efficiency peaks of the TE and TM polarizations which, in turn, gives rise to a dramatic increase in signal throughput. Additionally, the use of an appropriate fringe pattern to define the lamellar contours permits the addition of astigmatism to the wavefront for focus control and thereby eliminates the need for an extra cylindrical lens. This binary element is a high quality diffractive element consisting of a continuous, segmented surface relief structure, which can be fabricated by means of standard lithographic and dry etch techniques common to the microelectronics industry. The element may be reproduced from a master binary element. Such reproduction paves the way for dependable low cost and high volume productivity.
The invention has application as a lightweight, compact and low cost optics for WORM (write once, read many) optical storage disk systems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a-f are graphs showing reflective diffraction efficiency in the first order versus the wavelength/grating period for TE and TM polarizations.
FIG. 2 represents the operation of the invention from the optical fiber/laser diode source to the media.
FIG. 3 represents operation of the invention from the media to the quad-detector.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The crux of the present invention is a particular application of the binary element in an optical head specifically designed to incorporate the element with ensuing high signal throughput of the head. Such application involves a binary grating element design which results in a high reflectance in zero order for one polarization (i.e., TM) and in first order for the other polarization (i.e., TE). The occurrence of this effect in a lamellar (binary) diffraction grating was first observed by R. W. Wood in 1902. Shortly after, this effect was dealt with from a theoretical perspective by Lord Rayleigh. FIGS. 1a-f are graphs that show examples of diffraction efficiency in the first order versus the wavelength/grating period for TE (dashed line) and TM (solid line) polarizations with a lamellar grating. The abscissa of each graph is marked by five arrows denoting the location of the first five Rayleigh points for each grating. The Rayleigh points occur in order from right to left in each graph. In the neighborhood of each Rayleigh point, there is a sharp separation in reflectivity between the two polarizations. These regions around the Rayleigh points are referred to as the Wood anomalies. The grating of the present invention is designed to function just prior to the second Rayleigh point where only zero and first diffraction orders propagate and the remaining orders are evanescent (i.e., non-propagating).
FIGS. 2 and 3 reveal the layout geometry and principal components of the invention. Laser source 12 may be a laser diode or a fiber optic having a appropriate modification for individual beam divergence. Laser source 12 is designed and adjusted to emit linearly polarized radiation of a 0.78 micrometer wavelength, diverging with conical angle of approximately 10 degrees as illustrated in FIG. 2. Source 12 is oriented so that laser beam 14 is polarized in the TM (transverse magnetic) mode measured with respect to the binary reflective element. In this mode, the oscillating magnetic field vector is perpendicular to the plane of the paper in FIG. 2. Binary reflective element 16 is positioned at about 45 degrees with respect to the direction of source 12 and to that of pickup lens 18. Front face 20 of element 16 is etched to form a lamellar diffraction grating having an array of fringes with a surface cross-section consisting of rectangular peaks and grooves (thereby giving rise to the name "binary grating"). Unlike most other gratings, binary grating 16 has curved fringes on face 20, rather than parallel straight lines. The curved fringe pattern adds optical "power" to element 16 and effectively causes element 16 to functionally behave like a cylindrical mirror.
This is the same as a computer generated hologram wherein the diffraction phase pattern is mathematically constructed to create astigmatism. Calculations of astigmatism and reflection are made through the use of a commercially available optical design computer program CODE V. This program is one of several in the market of programs. The program provides the specifications of fringe contours in the form of C 11 X 2 +C 12 XY+C 21 Y 2 +C 22 X 4 + . . . The program also provides the numerical values for the constants C 11 , C 12 , . . . Determination of the reflectivities is obtained through the use of another available program entitled "DIFFRACT." This program involves providing numerical solutions to electromagnetic field equations. There is electromagnetic interaction of the wavefront with the diffractive structure. The fringe contours for the present embodiment are in the form of C(X 2 +3Y 2 ).
Binary element 16 is made beginning with the generation of the pattern on a binary disk using state-of-the-art equipment used to generate lithographic mask patterns for integrated circuits. Standard pattern generators in the art use either a laser, electron or ion beams to trace the pattern in a positive resist on the surface of a glass substrate. The pattern generated on the mask is subsequently transferred to a resist-coated substrate and given a reflective coating to form the reflective and diffractive optical element. A layer of resist is spun onto the substrate to a thickness corresponding to the desired depth of the final surface relief grating. Then, a thin layer (500 angstroms) of chrome-aluminum is sputtered and on top of this, a thin layer (1000 Å) of resist is applied. A conformable mask, made by contact printing with the e-beam generated mask, is contact printed under vacuum on the top thin layer of resist. The exposed substrate is then wet-etched so that the binary pattern is transferred to the top thin layer of metal. The substrate is then reactive ion etched in an oxygen plasma which selectively etches the resist, leaving the remaining metallization intact. Reactive ion etching is a highly anisotropic process, so that the high edge acuity of the desired rectangular profile is preserved. The final step of the process is to evaporate a thin film of gold onto the relief pattern to achieve the high conductivity necessary for efficient diffraction. During evaporation, the substrate is rotated between approximately plus or minus 45 degrees to assure uniform coating of the side walls and corners.
In the present invention, the fringe contours are designed to add astigmatism to the wavefront in order to provide an energy distribution at quad-detector 22 which is sensitive to focus. Thus, the astigmatism feature provides for focus control and eliminates the need for a cylindrical lens that is needed in a conventional design.
Binary element 16 has front face 20 designed with a grating depth and period to operate near the second Rayleigh point. In this configuration, only the zero (i.e., specular) and first orders propagate in a fashion such that the TM polarization has a high efficiency in the zero order and TE polarization has a high efficiency in the first order. Source 12 is positioned so that element 16 reflects the initial source radiation of a TM polarization in the zero order angle with respect to the position of element 16 and lens 18. Detector 22 is positioned so that it receives the radiation of a TE polarization in the first order reflected by element 16 from optical media 24 through lens 18. Both orders of radiation are measured relative to a 45 degree incident angle of radiation to element 16. Optional power monitor 26 may be added provided the grating of element 16 is designed to give a small first order contribution of reflected radiation and monitor is located at the first order angle.
In operation, binary grating element 16 reflects the incident TM polarized radiation with high efficiency in the zero order onto quarter-wave plate 28 in FIG. 2. Upon transmission through quarter-wave plate 28, the radiation beam is converted from linear TM polarization into left circular polarization. The diverging beam is then collected and focused onto optical storage media 24 by pickup lens 18. The intensity of the radiation reflected by media 24 depends on the information content encoded into media 24. The reflected beam undergoes a phase shift of 180 degrees and thus propagates as right circularly polarized light. The returning beam in FIG. 3 is converted into linear TE polarized radiation by quarter-wave plate 28. Due to the Wood anomaly, the beam is reflected by binary grating element 16 with high efficiency in the first order to detector 22. The radiation at detector 22 is decoded and any needed focus is determined and appropriate focus adjustment signals are sent to pickup lens 18.
A preferred binary grating element 16 is an element etched in fused quartz and coated with silver via evaporation. The present embodiment of the present invention utilizes radiation having a wavelength of 0.78 micrometers. The precise specification of the fringe contours depends on the exact details of source 12, quad-detector 22, and the associated geometry. In the design of element 16, sufficient astigmatism may be added to face 20 as to sufficiently affect the wavefront of the radiation. Two other parameters to be determined are the depth and the average period of the grating. The average period is determined from the requirements that only the zero and first orders propagate, that the angular separation between these orders be minimized, and that the device operate near a Rayleigh point. These requirements are best determined for a second order angle that just exceeds 90 degrees.
From the grating equation,
sinφ.sub.m =sinφ.sub.o +m /L
where m is the diffraction order, φ o is the zero order incident angle, φ m is the angle of the m diffracted order, is the wavelength, and L is the grating period, L is found to be 0.9138 micrometers. Also, for good reflectivity, the grating depth is equal to one-half of the wavelength.
From these grating parameters, the reflectivities can be calculated in the zero and first orders for TM and TE polarizations using the computer models. The grating reflectivity for the TM polarization in the zero diffraction order is 54.2 percent and in first diffraction order it is 2.4 percent. The grating reflectivity for the TE polarization in the Zero diffraction order is 14.8 percent and in the first diffraction order it is 80.3 percent. These contrasting reflectivities assure satisfactory operation of the invention as described above. FIGS. 1a-f indicate that better separation between the polarizations can be obtained with greater design optimization.
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A ultra-compact optical readout device utilizing a binary optical element that provides a wide separation between diffraction efficiency peaks of different polarization modes so that sending and returning light can take distinct paths at the light source and detector, respectively, and also take the same paths at other regions of the device, enabling the simultaneous emission and detection of light for reading information from optical media. The specially designed contour of the binary optical diffracting element also provides the device with focussing capabilities without the need for a cylindrical lens at the detector or light source.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional patent application No. 61/049,820, the disclosure of which is hereby incorporated by reference herein.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to a fluid delivery system for surgical instruments. More particularly, the present disclosure relates to a fastener for releasing treatment material to clamped tissue.
[0004] 2. Background of Related Art
[0005] During certain surgical procedures as is often necessary to clamp tissue, such as, vascular tissues, to prevent leakage therethrough during surgeries. The procedure typically involves placing clips or clamps within an applicator device and applying the clamps to the tissue on one side of an area, for example a diseased section of vascular tissue or colonic tissue, and placing another set of clamps on the opposing side of the diseased section. Thereafter, the diseased section can be excised and the resulting free ends of the tissue reattached.
[0006] During surgery certain problems may arise. For example, manipulation of surrounding tissue, as well as fluid pressure within the tissue, may cause loosening of the clamp and resulting leakage or even possible detachment of the clamp. Additionally, it is often desirable to provide certain medicament or treatment materials such as, for example, biomechanical mediums or antimicrobials solutions to the tissues during the surgery.
[0007] Therefore, it is desirable to provide a mechanical fastening device having a securing mechanism for maintaining the fastening devices in a closed position during the surgery. It is further desirable to provide a mechanical fastening device capable of applying medicament or treatment materials to the tissues during the surgery.
SUMMARY
[0008] There is disclosed a toothed fastener for securing tissue. The toothed fastener generally includes an upper leg and a lower leg, each of the upper and lower legs having a row of teeth, each tooth having a proximal face and a distal face. The toothed fastener further includes a longitudinally extending securing member. A hole of predetermined diameter is formed in each of the proximal and distal faces and is of sufficient size to allow passage of the securing member therethrough. The upper or lower legs are movable from an open position to a closed positions placing all the holes in longitudinal alignment such that the securing member can pass through all the holes in the teeth of the upper and lower legs.
[0009] In a specific embodiment, each tooth has a pair of spaced apart holes formed in each of the distal and proximal faces. In this embodiment, the securing member has first and second legs for passage through the pair of spaced apart holes. The securing member includes a backspan such that the first and second legs extend distally from the backspan.
[0010] In one embodiment, the hole formed in the distal face of the distal most tooth is sized to engage the securing member in a friction fit fashion.
[0011] In a particular embodiment, each of the teeth are hollow or define a receptacle for receipt of material such that passage of the securing member through the holes of the teeth releases the material into the space between the first and second legs. The material may be contained within a puncturable capsule.
[0012] In the disclosed toothed fastener each leg has a base, each base having an opening to the interior of the tooth for passage of material into the tooth. A membrane is provided covering the openings in each leg to retain the material within the teeth.
[0013] In one embodiment, a connector is affixed to a proximal end of each of the first and second legs. In a specific embodiment, the connector is a living hinge. In a more specific embodiment, the living hinge is formed integrally with the proximal ends of the first and second legs.
[0014] There is also disclosed a system for applying a fastener to tissue including an applicator having a first and a second jaw and a toothed fastener positionable within the first and second jaws. The toothed fastener includes an upper leg and a lower leg, each of the upper and lower legs having a row of transverse, longitudinally extending teeth, each tooth having a proximal face and a distal face. The toothed fastener also includes a longitudinally extending securing member. A hole of predetermined diameter is formed in each of the proximal and distal faces and is of sufficient size to allow passage of the securing member therethrough. The upper or lower legs are movable from an open position spaced apart to a closed position substantially adjacent each other placing all the holes in longitudinal alignment such that the securing member passes through all the holes in the teeth of the upper and lower legs. The first and second jaws of the applicator are operable to move the upper and lower legs between the open and closed positions.
[0015] In one embodiment of the system, each tooth has a pair of spaced apart holes formed in the proximal and distal faces and the securing member is a staple bar having a backspan and first and second legs extending distally from the backspan. The first and second legs being configured to pass through the pairs of spaced apart holes to secure the upper and lower legs in the closed position.
[0016] The applicator further includes a pusher, engageable with the backspan of the staple bar, to drive the staple bar distally relative to the toothed fastener.
[0017] The present disclosure contemplates a fluid delivery system having an actuating handle assembly, a pair of jaws operably connected to the handle assembly, the pair of jaws each having teeth defining openings, and a puncturing member receivable in the openings of the teeth, the teeth defining at least one receptacle containing a fluid. In certain embodiments, the pair of jaws includes a first jaw and a second jaw arranged for clamping onto tissue. The fluid may be a medicament, tissue sealant or tissue adhesive. The fluid may be disposed in a puncturable capsule, the securing member having a tip for puncturing the puncturable capsule.
[0018] The present disclosure contemplates a tissue fastener having a first leg and a second leg pivotably connected to one another, the first leg and second leg each having teeth defining openings, and a securing member receivable in the openings of the teeth. A surgical instrument for applying the tissue fastener to tissue includes a pair of jaws and a handle assembly operably arranged to move the jaws between a closed position for clamping tissue and an open position for releasing the tissue. The jaws of the instrument are arranged to receive the tissue fastener and securing member. The surgical instrument includes a pusher for advancing the securing member through the openings in the teeth of the fastener. The teeth may define at least one receptacle containing a fluid. The fluid may be a medicament, tissue sealant or tissue adhesive.
[0019] In a further aspect, a toothed fastener comprises an upper leg and a lower leg, each of the upper and lower legs having a row of transverse longitudinally extending teeth, each tooth having a proximal face and a distal face; a longitudinally extending securing member; and a hole of predetermine diameter formed in each of the proximal and distal faces. The upper or lower legs are movable from an open position spaced apart to a closed position wherein all of the holes are in longitudinal alignment enabling the securing member to pass through the holes to maintain the fastener in the closed position.
[0020] In certain embodiments, each of the teeth are hollow for receipt of material such that the material is released into spaces defined between the upper and lower legs. The material may be contained within a puncturable capsule. Each of the upper and lower legs may have a base, each base having an opening to the interior of the tooth for passage of material into the tooth. In certain embodiments, a membrane covering the openings in each leg to retain the material within the teeth.
DESCRIPTION OF THE DRAWINGS
[0021] Various embodiments of the presently disclosed toothed fastener are disclosed herein with reference to the drawings, wherein:
[0022] FIG. 1 is a perspective view of one embodiment of a toothed fastener and applicator instrument;
[0023] FIG. 2 is a perspective view of the toothed fastener of FIG. 1 ;
[0024] FIG. 3 is a perspective view of an alternative, two part toothed fastener;
[0025] FIG. 4 is a perspective view of the toothed fastener of FIG. 1 with parts separated;
[0026] FIG. 5 is a side sectional view taken along line 5 - 5 of FIG. 2 ;
[0027] FIG. 6 is an end sectional view taken along line 6 - 6 of FIG. 5 ;
[0028] FIG. 7 is a perspective view of the distal end of one leg of the toothed fastener of FIG. 1 ;
[0029] FIG. 8 is a perspective view of the toothed fastener of FIG. 1 in an initial position on the applicator;
[0030] FIG. 9 is a perspective view similar to FIG. 8 during initial puncturing and securement;
[0031] FIG. 10 is a side sectional view taken along line 10 - 10 of FIG. 9 ;
[0032] FIG. 11 is a perspective view of the toothed fastener during final puncturing and securement; and
[0033] FIG. 12 is a side sectional taken along line 12 - 12 of FIG. 11 .
DETAILED DESCRIPTION OF EMBODIMENTS
[0034] Embodiments of the presently disclosed fluid delivery system will now be described in detail with reference to the drawings wherein like numerals designate identical or corresponding elements in each of the several views. As is common in the art, the term ‘proximal” refers to that part or component closer to the user or operator, i.e. surgeon or physician, while the term “distal” refers to that part or component further away from the user.
[0035] Referring to FIG. 1 there is disclosed a toothed fastener for use in a surgical instrument 12 . Surgical instrument 12 can be of the type for open surgery or laparoscopic surgery. In the present disclosure, surgical instrument 12 generally includes a handle 14 having an elongate tubular member 16 extending distally from handle 14 . The surgical instrument has an end effector at a distal end of the tubular member 16 , including an upper jaw 18 and a fixed jaw 20 that are movable with respect to one another. An actuator or trigger 22 is movably mounted on handle 14 and is operable to drive a securing and puncturing mechanism of fastener 10 into position as described in detail herein below. The handle 14 has a clamping handle 15 for moving the upper and lower jaws 18 and 20 to clamp tissue therebetween. Surgical instrument 12 additionally includes a rotation collar 24 , affixed to elongate tubular member 16 , to orient upper and lower jaws 18 and 20 during surgery.
[0036] Referring now to FIG. 2 , fastener 10 generally includes an upper leg 26 and a lower leg 28 . In this embodiment, upper leg 26 and lower leg 28 are connected by a flexible, living hinge 30 . Living hinge 30 allows upper leg 26 and lower leg 28 to move between an open position substantially spaced apart to a closed position wherein upper leg 26 is substantially adjacent to lower leg 28 . Upper leg 26 generally includes a base 32 having a row of transverse teeth 34 extending lengthwise along base 32 . The teeth 34 are hollow so as to define a receptacle in each tooth. Upper leg 26 additionally includes a distal most tooth 36 (or differ slightly to incorporate a locking mechanism as described in more detail herein below). Base 32 includes a plurality of base openings 38 that communicate with a corresponding receptacle in a corresponding tooth, and distal most tooth 36 . Openings 38 are provided to receive materials to be dispensed to tissue as described in more detail herein below.
[0037] Lower leg 28 also includes a base 40 having a row of transverse teeth 42 . The teeth 42 are also hollow so as to define a receptacle in each tooth. Lower leg 28 also includes a distal most tooth 44 on base 40 . It should be noted here in that, while the following specific descriptions of configurations, features and/or components of legs 26 and 28 may be given with respect to one of legs 26 and 28 , legs 26 and 28 may have the same or different configurations, features and components and are identical in all respects. Teeth 42 of lower leg 28 each include a distal face 46 and proximal face 48 . Similarly, distal most tooth 44 includes a distal face 50 and a proximal face 52 . Pairs of holes 54 are provided through distal face 46 and proximal face 48 of hollow teeth 42 . Living hinge 30 is also provided with a pair of holes 56 which are similar in size and spacing to holes 54 . Additionally, in a particular embodiment, distal most tooth 44 has a pair of spaced apart holes 58 in proximal face 52 . Distal face 50 of distal most tooth 44 as a pair of spaced apart holes 60 which can differ from holes 54 and 58 in size and may form part of a locking mechanism as described in more detail herein below. In the alternative, holes 60 may be similar to holes 54 and 58 and the pair of spaced apart holes in a distal face of distal most tooth 36 in upper leg 26 may differ from the pairs of spaced apart holes in teeth 34 to form the disclosed locking mechanism.
[0038] Upper leg 26 may be provided with a longitudinally extending membrane 62 which serves to cover base openings 38 and secure materials within hollow teeth 34 and 36 .
[0039] Referring for the moment to FIG. 3 , there is disclosed an alternative, two-part toothed fastener 64 which is substantially identical to toothed fastener 10 except for the lack of a living hinge. Fastener 64 generally includes an upper leg 66 and a lower leg 68 . Upper leg 66 includes a base 70 and a row of transverse, hollow teeth 72 . Upper leg 66 also includes a hollow distal most tooth 74 . A membrane 76 is provided across base 70 and functions similar to membrane 62 described hereinabove. Similarly, lower leg 68 includes a base 78 having rows of transverse, longitudinally extending hollow teeth 80 and a hollow distal most tooth 82 . Each of hollow teeth 80 includes a distal face 84 and a proximal face 86 . Hollow distal most tooth 82 also includes a proximal face 88 and a distal face 90 . A pair of spaced apart, holes 92 are provided in distal faces 84 and proximal faces 86 of teeth 80 . Likewise, proximal face 88 of distal most tooth 82 includes a pair of spaced apart holes 94 . In a specific embodiment, distal face 90 includes a pair of spaced apart distal holes 96 which differ in size from holes 94 and 92 and serve as a locking mechanism which functions similar to that which will be described herein below with respect to toothed fastener 10 . As shown, upper leg 66 includes a membrane 76 . As noted hereinabove, descriptions of the upper and lower legs of the various embodiments of the toothed fastener include similar components, such as the addition of a membrane to lower leg 68 , except for variations in distal most tooth 74 and distal most tooth 82 . Additionally, the operation of toothed fastener 64 , with the exception of a living hinge, functions the same as that described with respect to toothed fastener 10 hereinbelow.
[0040] Referring now to FIG. 4 , toothed fastener 10 also includes a securing member 100 which serves several functions. Securing member 100 has a backspan 102 and a pair of legs 104 and 106 extending distally from backspan 102 . Legs 104 and 106 terminate in distal tips 108 and 110 . Securing member 100 is provided to secure upper leg 26 and lower leg 28 in the closed position. Specifically, in the closed position, holes provided in teeth 34 and 36 of upper leg 26 are in direct longitudinal alignment with holes 54 , 58 and 60 in lower leg 28 . Thus, by driving securing member 100 , and specifically legs 104 and 106 , distally through holes 56 in backspan 30 and through holes 54 , 58 and 60 in lower leg 28 and the corresponding holes in upper leg 26 , upper leg 26 is secured in the closed position relative to lower leg 28 . Additionally, as tips 108 and 110 , of legs 104 and 106 , passed through the holes of the teeth as described herein, tips 108 and 110 puncture capsules of material, such as capsules 112 in upper leg 26 and capsules 114 ( FIG. 4 ) in lower leg 28 , to release materials contained therein onto tissue captured between upper leg 26 and lower leg 28 . Capsules 112 and 114 may contain a variety of materials for treatment or joining of tissue, such as, for example, biomedical mediums, antimicrobial solutions, etc. Materials disclosed in WO 2006/044800, the disclosure of which is hereby incorporated by reference herein, may be used. Lower leg 28 is provided with a membrane 116 to secure capsules 114 within hollow teeth 42 and 44 . Finally, tips 108 and 110 , in conjunction with smaller diameter holes 60 in distal face 50 of distal most tooth 44 , may act as a locking mechanism to prevent staple bar 100 from “backing out of” upper leg 26 and lower leg 28 as described below. The leg 104 and leg 106 may be sized to functionally engage the interior surface of the fastener teeth inside holes 60 , or the leg 104 and/or leg 106 have a textured surface for engaging inside the holes 60 , or both.
[0041] Referring now to FIGS. 5-7 , the details of teeth 34 and 36 of upper leg 26 will now be described. As noted hereinabove, upper leg 26 includes a distal face 118 of teeth 34 and proximal and distal faces, 120 and 122 , respectively, of teeth 36 . Teeth 34 include holes 124 which are similar in size to holes 54 in teeth 42 of lower leg 28 . Similarly, distal most tooth 36 includes a pair of spaced apart holes 126 formed in proximal face 120 which are also substantially the same as holes 54 . Distal face 122 of distal most tooth 36 includes a pair of spaced apart holes 128 which, together with tips 108 and 110 of securing member 100 , may form a locking mechanism to secure staple bar 102 within upper and lower legs 26 and 28 . Specifically, holes 124 and 126 may have a diameter d 1 which is greater than the diameter d 2 of pair of holes 128 in distal face 122 of distal most tooth 36 . Diameter d 1 of holes 124 and 126 are sized to be greater than the diameter of legs 104 and 106 of staple bar 100 so as to allow materials released from capsules 112 and 114 into the space between upper leg 26 and lower leg 28 in the closed position. Diameter d 2 of pair of holes 128 may be sized so as to grasp tips 108 and 110 of staple bar 100 in friction fit fashion thereby locking staple bar 100 in position within upper leg 26 and lower leg 28 . The teeth of upper leg 26 define receptacles for a fluid material. The lower leg 28 has teeth defihning receptacles and holes that are similar to those discussed above.
[0042] Referring now to FIGS. 1 and 8 - 12 , the use of toothed fastener 10 in applicator 12 will now be described. As shown in FIG. 1 , toothed fastener 10 is attached to jaws 18 and 20 of applicator 12 , such as, for example, by a snap-fit. Once jaws 18 and 20 have been properly positioned around tissue (not shown), clamp handle 15 can be actuated to initially move the jaws to the closed position relative to one another. As best shown in FIG. 8 , this brings upper leg 26 into close cooperative alignment with lower leg 28 . In this position, teeth 34 of upper leg 36 interengage or interdigitate with teeth 42 of lower leg 28 . Depending upon the longitudinal orientation of upper leg 26 relative to lower leg 28 within upper jaw 18 and lower jaw 20 , one of distal most tooth 36 of upper leg 26 or distal most tooth 44 of lower leg 28 will become a distally most extending tooth of toothed fastener 10 . It should be noted that, depending upon which distal most tooth 36 or 44 becomes the distally most extending tooth, that tooth may be provided with holes of the smaller diameter d 2 in the distal face thereof to secure securing member 100 . Securing member 100 is in a proximal most position within elongate tubular member 16 . Applicator 12 is provided with a pusher 130 positioned against backspan 102 of securing member 100 .
[0043] Referring now to FIG. 9 , as trigger 22 is actuated, pusher 130 urges securing member 100 distally within elongate tubular member 16 . As securing member 100 moves distally, tips 108 and 110 of legs 104 and 106 pass through holes 56 in living hinge 30 . Referring specifically to FIG. 10 , as legs 104 and 106 (not shown) moves distally tips 108 and 110 passed through holes 54 in teeth 42 of lower leg 28 and holes 124 of teeth 34 of upper leg 26 . As legs 104 and 106 pass through holes 54 and 124 , tips 108 and 110 of legs 104 and 106 penetrate or puncture capsules 112 and 114 of material M thereby releasing material M into the spaces defined between teeth 42 and 34 . In this manner, toothed fastener 10 is capable of delivering material M to tissues captured between upper leg 26 and lower leg 28 . Additionally, the passage of legs 104 and 106 through holes 54 and 124 serve to secure upper leg 26 in the closed position relative to lower leg 28 .
[0044] Referring now to FIGS. 11 and 12 and initially with regard to FIG. 11 , as pusher 130 advances securing member 100 completely through upper leg 26 and lower leg 28 , tips 110 and 108 passed through holes 128 in distal face 122 of distal most tooth 36 . As noted hereinabove, holes 128 may have a diameter d 2 which is sufficiently small to engage tips 110 and 108 in friction fit fashion. In this manner, securing member 100 is “locked” into position within upper or lower legs 26 and 28 , respectively, thereby preventing staple bar 100 from inadvertently pulling out of upper and lower legs 26 and 28 . Additionally, the friction fit of tips 110 and 108 within holes 128 serves to seal holes 128 against any leakage of material M therethrough.
[0045] Referring to FIG. 12 as leg 106 passes through holes 126 in proximal face 120 , capsule 112 is punctured and material and is released. As shown, when distal most tooth 44 of lower leg 28 is not the distally most extending tooth of tooth fastener 10 , holes 60 in distal face 50 are of the same diameter as holes 54 in proximal face 52 to allow passage of material M therethrough as capsule 114 is penetrated. When the jaws of the surgical instrument are released from the tissue, through operation of the clamp handle 15 , the toothed fastener is secured onto the tissue, as the securing member 100 is retained in the teeth of upper leg 26 and teeth of lower leg 28 . Further, the material has been deployed to the tissue site.
[0046] It will be understood that various modifications may be made to the embodiments disclosed herein. For example, the teeth of the legs may be formed with a single hole in each of the proximal and distal faces for receipt of a single bar therthrough. Further, the tips of the staple bar may be enlarged to engage the distal most hole in rivet fashion. Additionally, the holes of the teeth may be covered be a penetratable membrane and the material provided as a fluid within the teeth. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.
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There is provided a penetratable toothed fastener for clamping tissue during surgery. The toothed fastener includes first and second legs each having longitudinal rows of transverse teeth and a securing member configured to pass through the transverse teeth to hold first and second legs closed relative to each other and about tissue. A locking mechanism is provided to retain the securing member within the first and second legs of the toothed fastener. The toothed fastener additionally includes receptacles for the receipt of medicant materials and holes in the teeth to dispense the materials to clamped tissue.
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CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority benefit under 35 U.S.C. §119 (e) to U.S. Provisional Patent Application No. 61/521,697 filed Aug. 8, 2011 by Linda Grimes, entitled “Voice decibel application and a method for a cellular phone”. The present application incorporates the foregoing disclosure herein by reference.
TECHNICAL FIELD OF INVENTION
Embodiments of the present invention generally relate to a voice decibel application and a method for a cellular phone and in particularly relates to the application and the method for a cellular phone to measure the voice decibel during a phone call. The said voice decibel application is incorporated into the user's electronic computing device (e.g. cellular phone), and is configured to measure the voice decibel during a phone call and alert the user by sending a signal in case the voice decibel exceeds or goes below a preset voice decibel threshold level.
BACKGROUND OF INVENTION
With the development of wireless communication and information processing technology, portable electronic devices such as mobile phones are now in widespread use. Consumers may now enjoy the full convenience of high technology products almost anytime and anywhere. Mobile communication devices are used in many different environments, due to their portable nature.
Sometimes individuals talking on mobile phones are either fully or partially unable to detect or perceive at least some frequencies of voice. The loudness of the voice heard is measured in decibel and may be ranked as mild (about 30 dB), moderate (about 60 dB), severe or profound (more than about 90 dB) depending upon the decibels. The individual may need to vary their voice decibel level depending on their respective time and location. For example, the person needs to vary his voice decibel level depending upon if they are at a construction site or at his office so as to make them audible.
Therefore in general the cellular phone user may need to adjust their voice decibel level while talking on the cellular phone such as mobile phone and it has therefore become a matter of increasing concern in the recent years. For example, any voice sound above 85 dB can cause hearing loss, and the loss is related both to the power of the sound as well as the length of exposure.
Therefore there is a need in the art to measure the voice decibel while talking on the phone and alert the user if the voice decibel exceeds or goes below a preset voice decibel threshold level.
SUMMARY OF THE INVENTION
The present invention in general relates to a voice decibel computer program product, such as a mobile application, and a method for its use on an electronic computing device (e.g. cellular phone or smartphone with Internet connectivity) to measure the user's voice decibel during a phone call. The voice decibel application is incorporated into the user's device, and is configured to measure the voice decibel during a phone call and alert the user by sending a signal in case the voice decibel exceeds or goes below a preset voice decibel threshold level. In an alternative embodiment, both parties on the phone call may monitor their voice decibels levels concurrently if their respective electronic computing device has the software application of this invention installed.
According to an embodiment of the present invention there is provided a voice decibel application and method that is incorporated into the user's phone wherein the application will actively measure the voice decibel during a phone call. The application and method is incorporated into the user phone by a plurality of means including but not limited to downloading from Internet, installation through crystal disc (CD) or direct hardwire to device. The application will send a signal if the user's voice increases to a level to a hearing level not comfortable to the listener (recipient) that is predefined by the application by considering and implementing several factors, comprising: the talking behavior of the User, environmental and surrounding conditions and noises. Furthermore, the application and method installed on the user phone will also notify the user through a plurality of means including but not limited to vibration, blinking light, beep sound etc., if the voice decibel increases or decreases to a level which is unpleasant or hard to understand by the recipient.
According to an embodiment of the present invention there is provided a voice decibel application and method that sends the signal to the user in case the voice decibel exceeds or goes below a preset voice decibel threshold level. The signaling means could be any mechanism to seek the speaker's attention, such as an alarm or a light or a vibration or a text message or a multi media message etc., but not limited to these alone.
The embodiment of the present invention is advantageous because it will help the users to recognize their talking habits and assist them in improving their talking habits such as couples in counseling, workers in negotiations or students in speech therapy. According to an embodiment of the present invention there is provided a voice decibel application and method that can be incorporated into a cell/mobile phone by one of the many ways known in the art including but not limited to software downloading from internet, or software download from computer, or by the software purchased individually. The device can also be incorporated by way of a direct hardware or modifications to existing hardware using any number of existing strategies well known to those in the art.
According to an embodiment of the present invention there is provided a voice decibel application and method that includes transmission of signals to alert or notify the user in case the voice decibel exceeds or goes below a preset voice decibel threshold level during a call. The signals generated from the phone can include any number of mechanisms such as the following immediate feedback from the phone such as the vibration, emission of sound or light to alert or notify the user. Furthermore, there could also be self-adjusting mechanisms provided in the cell/mobile phone that are configured to adjust the voice decibel to appropriate settings such as place or confidentiality to help Speaker (User) maintain desired volume, improve speaking skills and communicate better.
According to an embodiment of the present invention there is provided a voice decibel application and method that transmits the signal to alert or notify the user in case the voice decibel exceeds or goes below a preset voice decibel threshold level during a call. The signal generated could be in form of the automatic termination of the phone call or even a delay with a subsequent freeze on accepting the in and out going phone calls.
According to an embodiment of the present invention, said signal generated could be in form of an electronic message that is sent via text or electronic mail. The said electronic message can contain details that provide the frequency and time in which the established parameters of voice decibel were exceeded, and as well as the average decibel system value showing both the high and low value.
In another embodiment of the present invention, the said electronic message can be generated from the receiver's phone or the listening party and could be sent via a signal to the speaking party to alert or notify said speaking party if the voice decibel fell below or above the predefine threshold level during a prescribed call.
According to an embodiment of the present invention said signal can be prompted by any individual or combination of event(s) such as exceeding or below a targeted threshold based on the occurrence, frequency of occurrence, or any other combinations.
According to an embodiment of the present invention there is provided a voice decibel application and method that work effectively in a tandem network. Both the user and the recipient may receive feedback on their voice decibel levels if the software application of the present invention is installed on their respective device. In an alternative embodiment, the software application installed on the user's device may concurrently monitor both the user's and recipient's decibel levels.
According to an embodiment of the present invention there is provided a voice decibel application and method that prevents the amplification of background noise during periods of silence on the network call.
According to an embodiment of the present invention there is provided a voice decibel application and method that does not cause oscillation of the voice signal.
According to an embodiment of the present invention there is provided a voice decibel application and method for controlling a mobile device's ringer or vibration or speaker volume based on the surrounding environment's noise level.
According to an embodiment of the present invention there is provided a voice decibel application and method for preparing user friendly reports or text messages or emails or any other form of communication using mathematical calculations and algorithms providing the speaking patterns of User for any period of time and any suggestions for improvement.
In accordance with one or more embodiments, an application and method for measuring the voice decibel of a mobile device is provided. The application and method comprises a voice decibel value preset in the mobile device; recording and measuring voice decibel while the mobile phone user makes a call; signaling the user when the measured voice decibel goes below or above the preset voice decibel.
In an alternative embodiment of the invention, the software application may record, measure, analyze and report on the decibel levels of the voices of user's engaged in person-to-person conversations, such as couples therapy and anger management training. The software is installed on electronic computing devices that with the capabilities to record conversations.
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description. This summary is provided to produce a selection of concepts in a simplified form. This summary is not intended to identify key features or claimed features of the present invention, nor is it intended to be used to limit the scope of the claimed invention.
BRIEF DESCRIPTION OF DRAWINGS
The above and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 is an illustration of exemplified messages and alarms received on a user's electronic computing device when the user's voice decibel level goes above or below the pre-set thresholds.
FIG. 2 is a flowchart of steps using the computer program product installed on an electronic communications device to measure the voice decibel of a user during an electronic voice conversation.
FIG. 3 is a schematic diagram of an exemplified electronic communications device with “Voice Decibel Monitoring” software installed on the device.
FIG. 4 is an illustration of an exemplification of a report sent to a user's email account as viewed on their electronic computing device's GUI.
Reference will now be made in detail to the present preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or the like parts.
DETAILED DESCRIPTION OF THE INVENTION
The present invention in general relates to a voice decibel application and a method for a phone and in particular relates to the application and the method for a phone to measure the voice decibel during a phone call. The said application is incorporated into the user's phone and is configured to measure the voice decibel during a phone call and send a signal to the user in case the voice decibel exceeds or goes below a preset voice decibel threshold level.
Glossary of Terms
As used herein, the term “Electronic Computing Device” refers to any electronic device comprising a central processing unit (i.e. processor) with the ability to perform decibel calculations, and may comprise devices with cellular phone capacity and/or with Voice over Internet Protocol (VoIP) phone capability via a web connectivity, such as: laptops, desktops, Android® tablets, iPads, and mobile electronic communications devices—e.g. smartphones, cell phones, and personal digital assistant devices.
As used herein, the term “Graphical User Interface” or “GUI” refers to the screen or display of the computing device wherein the content item is displayed, the text message or email comprising the report showing the user's decibel level.
As used herein, the term “Content” refers to any kind of digital information displayed on the screen of a computing device (e.g. smartphone), such as messages (IM, SMS, email, etc.).
As used herein, the terms “Module” and “Algorithm” and “Code” refer to a portion of a computer program or software that carries out a specific function and may be used alone or combined with other modules or algorithms of the same program.
As used herein, the term “Software” refers to computer program instructions adapted for execution by a hardware element, such as a processor, wherein the instruction comprise commands that when executed cause the processor to perform a corresponding set of commands. The software may be written or coded using a programming language, and stored using any type of non-transitory computer-readable media or machine-readable media well known in the art. Examples of software in the present invention comprise any software components, programs, applications, computer programs, application programs, system programs, machine programs, and operating system software.
As used herein, the term “System” may be used to claim all aspects of the present invention wherein it refers to the entire configuration of devices, hardware and software in all embodiments, such as an electronic computing devices with the present invention's computer program product installed.
FIG. 1 illustrates an electronic computing device (e.g. a smartphone) with the computer program product installed. During a wireless telephone conversation, or a web Voice over Internet Protocol (VoIP) conversation (e.g. Skype® installed on a smartphone with 4G), the voice decibel of the user of the device is calculated by the software in the mobile phone according to one embodiment of the present invention. The application and method comprises a voice decibel value preset in the mobile device by the user. The voice decibel application incorporated into the mobile phone measures the voice decibel of the user speaking on the mobile phone and further determines when the measured voice decibel goes below or above the preset voice decibel threshold value. The application and method installed on the user phone will send a signal, for example, if the user's voice increases to a level of causing noise pollution or unpleasantness to the recipient. Further said application and method installed on the user phone will also send a signal to the user if the voice decibel decreases to a level which is unpleasant or hard to understand by the recipient. Signals comprise: generating a vibrating sensation or an audible alarm (e.g. voice, music, beeps, rings, etc.) emitted from the phone; termination of the call; email/SMS/chat message; and so forth.
In a preferred embodiment, the user engages in a three way conference call with the recipient, wherein the user's (and the recipient's) conversation is recorded on the alternate call line. The recording is then used by the software to analyze the user's decibel level and generate a report, which may be transmitted electronically to the user's device. This maybe particularly useful in the event the electronic computing device manufacturer has installed protective devices that limit the recording or monitoring of a call directly from their device. The third-party recording services are well known to those in the art.
A flowchart of steps in the decibel monitoring of a phone conversation of the present invention is illustrated in FIG. 2 , wherein the module or software comprises commands that when executed cause the electronic computing device's processor(s) to perform the following steps: (a) installation of voice decibel software application on the user's electronic computing device 210 ; (b) setting by the user of the maximum and minimum decibel threshold levels on the device using the software 220 ; (c) the software calculating and storing the voice decibel while the user converses on the device 230 ; (d) the software comparing the stored decibel value with the max/min threshold levels 240 ; (e) the software generating an alarm and/or action on the device if the decibel value is outside of the max/min threshold levels 250 ; and (f) the software generating a report on the user's speaking pattern and behavior 260 .
The voice decibel system will alert or notify the user if the voice decibel of the call goes below or above the predetermined threshold value by providing a vibration or audible alert during the call as each incident occurs, or by termination of the call at a single point of defined point of deviation of the voice decibel value, or by sending an electronic mail/text/chat message with a report that provides details on the frequency and time in which the established parameters of voice decibel were exceeded, and as well as the average decibel system value showing both the high and low value for analysis.
System Architecture of a Mobile Device
As illustrated in FIG. 3 , the system architecture for the preferred embodiment of the present invention comprising the computer program product installed on the electronic computing device 300 , comprises: an internal telephone microphone/speaker; a central processing unit (CPU) 310 ; a graphical processing unit (GPU) 315 ; a User interface with touchscreen data input keypad or keyboard or keys 320 ; memory 330 such as random access memory (RAM), read only memory (ROM), nonvolatile memory such as EPROM or EEROM, flash memory or hard drive memory; a transceiver 340 functionally connected to an antenna to receive and transmit data in a wireless network; and Voice Decibel Monitoring Software Application 350 of the present invention stored on an additional internal memory chip. The transceiver may operate according to standards commonly known in the art by the skilled practitioner, such as for GSM, GPRS, wireless local and personal area network standards, and Bluetooth.
GPU 315 comprises a graphics rendering module configured to perform various tasks related to calculating and displaying the screen images. Screen manager 370 with a software or firmware process that manages content displayed on the GUI 320 . The screen manager monitors and controls the physical location and type and appearance of content data displayed on the GUI 320 .
The electronic computing devices further comprise hardware/software for Internet connectivity to receive emails, SMS texts, chat messages, and engage in VoIP conversations. The devices comprise Enhanced Data Rate for Global Evolution (EDGE), 3G, and/or 4G data transfer capabilities.
Monitoring Signals Hardware Components
The device further comprises a signaling, sensor, and/or triggering components to transmit a physical, audio, and/or a messaging signal to the user when the user's voice decibel level is outside of the pre-set threshold. The type, frequency and duration of the signal may be adjustable by the device user.
For example, the computing device may comprise a “vibrating component” that generates a vibrating sensation from the device each time the user's voice decibel level goes above or below the pre-set thresholds. Vibrations are generated on an electronic computing device by methods well known in the art, such as using a haptics motor installed within the device.
The device may further comprise an “audio component” that generates an audible signal from the speaker of the electronic computing device each time the user's voice decibel level goes above or below the pre-set thresholds. The signal may be a short burst (e.g. beep), voice recording, a melody, etc. and as enabled by the “Voice Decibel Monitoring” software. The type, frequency, and duration of the audible signal may be adjustable by the device User or 3 rd party administrator such as a therapist or employer or teacher.
The device may further comprise hardware/software to enable the user to receive an electronic message during or after the conversation. For example, the user may receive an email, text, or chat room message immediately after each incident of the user's voice decibel level going above or below the pre-set thresholds. Likewise, the user may receive an electronic message after the conversation is complete, wherein the message (e.g. an email) comprises a report detailing the user's voice decibels levels throughout the conversation and related statistics.
Computer Program Product
The computer program product comprises program instructions recorded on a non-transitory computer readable medium, wherein upon execution on a computer, said program instructions monitor a user's voice decibel level while conversing on an electronic computing, said program instructions comprising the steps of FIG. 2 .
As shown in FIG. 3 , the computer program product 350 is stored on the device's memory 300 and is executed by the client computer's CPU 310 . It will be appreciated by one with skill in the art that the application might be installed on the client computer from a number of sources. For example, it may be: downloaded over the Internet from a server, or bundled with software provided by another software manufacturer (such as a Web browser provided by a Web browser manufacturer). In another embodiment of the present invention, the voice decibel application is hardwired from the electronic computing device manufacturer into the device. The enhancement of the software is performed by downloading the required files from the Internet. It will be appreciated that the application will function in substantially the same manner regardless of the installation source or method.
Recording and Filtering Conversation
In order to calculate and analyze the voice decibel level of one speaker in a two way conversation, the system must: record the audio content of the conversation; filter out one of the speakers (i.e. the recipient); and analyze the content of the remaining speaker for decibel levels frame-by-frame. For the system to analyze the conversation and trigger the alarms in real-time (e.g. vibrations, audio signals, call termination when user's voice goes outside the pre-set decibel max/min levels), then the computer program product must receive, filter out the recipient's voice, and analyze the remaining user's decibel level in real-time. In cases where both speakers are recorded (e.g. in person conversations) then the software filters and analyzes each speaker's voice decibel levels separately.
Therefore, the computer program product has the ability to record the audio content of a wireless or VoIP conversation, or to utilize the recordings from another source in real-time. For example, the computer program product may comprise modules that analyze a VoIP conversation conducted on a three way line between two users, wherein the third line is used for voice recording and analysis.
Methods of recording the audio content of a telephone conversation by a third source (i.e. not the computer program product of the present invention) on an electronic computing device are well known in the art. In a preferred embodiment of the present invention, the conversation is conducted via VoIP (e.g. Vonage, Skype, etc.), using any one of a variety of methods. For example, software such as Evaer, Pamela, KishKish SAM, PowerGramo, Acrobits Softphone, etc. can be downloaded to the electronic computing device and used to record VoIP calls directly to electronic computing device's hard disk with side-by-side, separate files, audio-only, local-webcam-only and remote-webcam-only mode. The audio-only file would then be filtered for removing the recipient speaker's voice; and then analyzed by the computer program product of the present invention for decibel level content.
In another embodiment, the cellular telephone conversation may be recorded on an electronic computing device (e.g. iPhone) by again using third party software installed on the devices, such as Google Voice, iPhone Recorder by Retronyms, iSpoofCard, etc.
Telephones without Mobile Application Abilities
The present invention may be used with phones that do not have the ability to install software applications, such as the current computer program product. The present invention may still be used to analyze a user's voice after the conversation is complete by recording the conversation using hardware near and/or features installed on the phones, and then playing the conversation back near a computing device that can digitally record the playback, and analyze it with the computer program product.
Most electronic computing devices (e.g. most cell phones and smartphones) have the ability to record telephone conversations under the “Options” feature of the phone. The conversation would then be played back, or uploaded to an electronic computing device with the computer program product of the present invention installed upon it.
For electronic communications devices that do not have the ability to record a conversation, then the user may use hardware comprising a LED connected to a voice recorder, wherein the LED comprises a cord with an earpiece. The user then places the earpiece in their ear, and the phone near their ear, and the recorder will record the user's voice as they speak.
Methods of filtering audio content from a digital voice recording are well known by the skilled artisan. In a preferred embodiment of the present invention, the computer program product would comprise modules/algorithms/code to filter out the recipient's voice before analyzing the decibel levels of the user's voice.
Report Generation
The computer program product further comprises modules/algorithms/code for calculating the user's voice decibel levels as a function of time and generating a report that graphs this (e.g. decibel level “Y” axis, and time on the “X” axis). The report would then be sent via email to the user after the conversation was completed. The user could use the report to learn to modify their voice for future conversations so as to stay within the boundaries of their max/min decibel threshold levels.
FIG. 4 provides an exemplification of a report sent to a user's email account as viewed on their device's GUI. On the x-axis we have the volume in dB and on the y-axis we have the time of the conversation. The dB measurement of the speaker is recorded during the call which enables a complete graphing illustration of the full range of the dB spoken.
Although the invention has been described with reference to specific embodiments thereof, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that such modifications can be made without departing from the spirit or scope of the present invention as defined.
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The present invention in general relates to a voice decibel application and a method for a phone and in particularly relates to the application and the method for a phone to measure the voice decibel during a phone call. The application incorporated into the user's phone is configured to measure the voice decibel during a phone call and send a signal to the user in case the voice decibel exceeds or goes below a preset voice decibel threshold level. The present invention is advantageous because it will help the users to recognize their talking habits and assist them in improving their talking habits.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improvement in a baking and drying furnace for containers such as cans for canned food, which are coated or printed.
2. Description of the Prior Art
Where containers such as cans have been coated or printed for ornamental purposes, after which they are dried and baked, it has been heretofore customary to use a baking and drying furnace or oven known as a "pin oven". Coated and printed cans move while being hung on pins through the furnace under the atmosphere of high temperature. The furnace of this system is suffered from disadvantages in that since the can is heated only from the surface thereof, the heating efficiency is poor and that since the pin is in contact with the inner surface of the can, the furnace cannot be used to dry and bake the coating of the inner surface.
On the other hand, a baking and drying furnace has been recently made practicable, of the type in which a suction hole is disposed partly of an opening of a can which moves while being placed with an opening thereof directed downwardly through the furnace under the atmosphere of high temperature, and after the high temperature atmosphere within the furnace has been once flown into can from the other portion of the opening of the can, it is suctioned from the suction hole. (For example, see Japanese Patent Application Laid-open No. 52-143548)
The furnace of the type as described has various advantages in that since the can is heated from both inner and outer surfaces thereof by the high temperature atmosphere, the heating efficiency is extremely high, and that only the open edge of the can comes to contact with the transporting belt during the drying and baking, and the inner and outer surfaces of the can may be simultaneously coated and simultaneously dried and baked.
However, the can is retained on the transporting belt during the drying and baking only by a pressing force caused by a difference between atmospheric pressure within the furnace and atmospheric pressure within the can which is suctioned to be lowered. Because of this, a trouble in tumbling of cans during transportation occurs owing to curves or vibrations of transporting belts which often comprise metal belts such as stainless, and especially in cans such as beverage cans frequently used recently, the height of the can is greater than the diameter thereof and the centroid position thereof is high whereby the trouble of this kind tends to occur.
On the other hand, if an attempt is made to increase the pressing force by lowering the atmospheric pressure within the can, the suction force of the suction opening is naturally increased, as a consequence of which there poses problems in that the air stream is formed into a turbulent flow to blow down the can, or a coating on the surface of the can is carried away resulting in an uneven coated film, and as the case may be, the coating falls down and droplets thereof are suctioned and adhered to the inner surfaces of the can. Thus, the problems have not been solved merely by increasing the suction force. force.
SUMMARY OF THE INVENTION
This invention is to improve the aforementioned baking and drying furnace to thereby provide a furnace which is free from tumbling of cans.
A first object of the present invention is to improve a flow passage of hot air within the furnace to thereby prevent cans from being tumbled by a turbulent flow.
A second object of the invention is to improve a suction nozzle for suctioning hot air within the can to thereby increase a pressing force of the can with respect to a transporting belt thus preventing tumbling of cans.
A third object of the invention is to always maintain a transporting surface of the transporting belt on a stabilized plane to thereby prevent tumbling of cans.
In order to achive the first object, a row of nozzles for supplying and suctioning hot air into the can are made greater in width than that of the can to suction hot air even from the outside of the can, whereby a stream of hot air downwardly flowing along the outer surface of the can is prevented from being formed into a turbulent flow, and tumbling of the can is prevented by said turbulent flow.
In order to achieve the second object, the diameter of the nozzle for suctioning hot air within the can is made larger to minimize a pressure loss resulting from a resistance of the nozzle, as a consequence of which a difference in pressure between inner and outer portions of the can is made greater to increase a pressing force of the can against the transporting belt resulting from the pressure difference.
In order to achieve the third object, a groove is provided in a passage of the transporting belt and the belt having a greater thickness than that of prior art belts is used to thereby prevent lateral displacement or twist of the belt and a suction nozzle is provided on the bottom of the groove to thereby prevent the belt from being levitated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a baking and drying furnace in accordance with the present invention;
FIG. 2 is a perspective view showing a nozzle arrangement in a can transporting section;
FIG. 3 is a view for explanation of the operating principle in a well-known device;
FIG. 4 is a sectional view of a can transporting section in a first embodiment in accordance with the present invention;
FIG. 5 is a sectional view of a can transporting section in another embodiment;
FIG. 6 is a plan view showing a nozzle arrangement of a well-known device;
FIG. 7 is a plan view of a nozzle arrangement of the device in accordance with the present invention;
FIG. 8 is a graph showing the relation between the rate of occurrence of can tumbling and the nozzle diameter;
FIG. 9 is a graph showing the relation between the rate of coating dripping and the nozzle diameter;
FIG. 10 is a graph showing the relation between the nozzle diameter and the usable blown negative pressure;
FIG. 11 is an enlarged sectional view of a transporting conveyor sliding portion of a well-known device; and
FIG. 12 is an enlarged sectional view of a transporting conveyor sliding portion of the device in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a sectional schematic view of a baking and drying furnace of the present invention which is at a right angle with respect to a transporting belt. A furnace body comprises an upper hot air supply chamber 3, a can passage chamber 4 and a hot air recovering chamber 5. Hot air for heating cans which pass through the furnace while being placed on a can transporting conveyor belt 7 is heated by means of a burner 1, delivered into the hot air supply chamber 3 by means of a recirculation blower 6, injected from a hot air blow nozzle 8 to heat the cans, and suctioned by means of a hot air suction nozzle 9 for recirculation. In the drawings, reference numeral 2 designated a heating control device and 15 denotes an auxiliary recovering nozzle for rendering an air stream within the can passage chamber steady state.
FIG. 2 is a partially cutaway perspective view showing a state wherein a can 13 is transported on the hot air blow nozzle 9 by means of the can transporting belt 7. The can 13 integrally formed with a bottom by drawing, contouring, etc. is placed with an open portion thereof directed downwardly on the transporting belt 7 for transportation. In the drawings, reference numeral 14 designates a partitioning wall between the can passage chamber 4 and the hot air recovering chamber 5.
FIG. 3 illustrates the retaining force of the can and a hot air flow passage in a well-known baking and drying furnace of the type as described. That is, hot air blown downwardly from the blow nozzle 8 provided on a blow nozzle plate 17, which is detachably disposed by means of suitable clamping means, bolting, etc., is suctioned through the suction nozzle 9 and recirculated as described hereinbefore. At this time, in a portion where the suction blow nozzle 9 is covered with the can 13 as shown, hot air of a volume portion in the can is suctioned into the recovering chamber 5 by negative pressure produced by the recirculation blower 6 through the suction nozzle 9. Therefore, atomspheric pressure within the can lowers so that hot air within the can passage chamber 4 is suctioned into the can through an outer suction nozzle 9A. Namely, there is established the following relation:
P.sub.5 <P.sub.4 <P.sub.2 <P.sub.1
where P 1 is pressure within the hot air supply chamber, P 2 is pressure within the can passage chamber, P 4 is pressure within the can, and P 5 is pressure within the hot air recovering chamber. Due to the pressure difference as just mentioned, hot air is injected into the can passage chamber from the hot air supply chamber to heat the can 13, suctioned into the can to heat the interior of the can, then suctioned into the recovering chamber 5 and recirculated by the blower. At the same time, let S represent the sectional area of the can 13, then the pressing pressure as given below is generated due to said pressure difference,
P=S (P.sub.2 -P.sub.4)
and the can 13 is pressed against the can transporting belt 7 to thereby act as the can retaining force.
Generally, at this time, the outer suction nozzle 9A is arranged in width within the width substantially equal to the diameter of the open portion of the can. This imparts a symmetricalness to air streams internally and externally of the can, imparts an automatic centering action to the can position on the transporting belt 7 and imparts the stability to the conveyance of the can.
Because of this, however, in a portion at a right angle with respect to the moving direction, the flow of hot air along the wall surfaces of the can is extremely weak as compared with other portions to partly deteriorate the heat treatment effect of the can and hot air blocked at the end of the suction nozzle constituting member 12 is turbulent to conversely result in impairment of the stability of the can conveyance.
On the other hand, in the suction nozzle of the present invention, if the outer suction nozzle is disposed in width sufficiently greater than the diameter of the open portion of the can, the flow of hot air along the wall surfaces of the can at the portion at a right angle to the moving direction is also uniformed by the air stream suctioned by the nozzle 9B externally of the can, as shown in FIG. 4, and it becomes possible to achieve the uniform heat treatment effect for the can.
In order to further increase such an effect as described, it is preferable that as shown in FIG. 5, externally of the transporting belt 7 and between the recovering chamber 5 and the suction. nozzle constituting member there is provided a hot air reservoir 18 having suction nozzles 9A and 9B on the upper surface thereof and extending lengthwise of the transporting belt 7.
The air stream for heating the can 13 forms its flow passage in which said air stream once enters the reservoir 18 from the can passage chamber 4 through the suction nozzle 9B, flows into the can from the suction nozzle 9A and is then recovered by and into the hot air recovering chamber 5 from the suction nozzle 9. Let P 3 represent the pressure within the reservoir 18, then the relationship given below is established similarly to the foregoing:
P.sub.5 <P.sub.4 <P.sub.3 <P.sub.2 <P.sub.1
and the can retaining force is likewise given by
P=S (P.sub.2 -P.sub.4).
However, between the reservoir and the can passage chamber there generates a pressure difference given by
P.sub.3 -P.sub.4
and all the suction nozzles externally of the transporting belt 7, except those covered by the cans including the inner nozzle 9A not covered with the can, function as suction nozzles whereby no turbulence and irregular flow occur in the neighbourhood of the can 13 and suction nozzle 9, thus rendering possible extremely effective heat treatment of can and stabilized conveyance thereof.
As described hereinbefore, finally, the hot air flowing down from the blow nozzle 8 is recovered from the suction nozzle 9 provided halfway of the transporting belt 7 but since normally, the open area of the suction nozzle is much smaller than the open area of the blow nozzle, it has been necessary to have a high suction air velocity caused by great negative pressure. However, the suction air velocity and suction negative pressure are necessary to be determined by taking various factors such as heat treatment effect relative to the can, transporting attraction of the can, flow- and falling off of coatings coated on the can surface into consideration and cannot be determined only by the balance between the blow air quantity and suction air quantity. Thus it has been difficult to secure stabilization of the stream of hot air.
In the furnace of the present invention, a row of auxiliary recovering nozzles, as indicated at 15 in FIG. 1, are evenly or discontinuously disposed parallel to the can transporting belt over the full length of the furnace. Thereby, the suction air quantity and air velocity of the suction nozzle 9 may be set to an optimum value while always flowing a sufficient amount of hot air of the blow nozzle and the difference between the blowing quantity and suctioning quantity may recovered from said auxiliary recovering nozzle row 15 to thereby maintain the maximum performance of the entire furnace.
As the setting conditions of the suction nozzle 9 change, the opening rate of the auxiliary recovering nozzle 15 is varied steplessly, for example, by a shutter, or the nozzle constituting member having the nozzle row of various opening rates is detachably mounted so that they may be exchanged as necessary. In this manner, the air stream within the can passage chamber 4 may be made steady to avoid an occurrence of irregular turbulence.
In accordance with the present invention, the suction nozzles not covered with the cans are provided on both external sides of the can transporting belt as described hereinbefore to thereby form the flow of hot air along the can walls into a steady flow and to form the flow of hot air in the can passage chamber into an ordery flow by means of the auxiliary recovering nozzles, thus preventing troubles such as tumbling of cans caused by the turbulence and rapidly increasing the heat treatment ability of the can portion at a right angle to the transporting direction to render the uniform drying and baking possible.
On the other hand, in the prior art devices, it has been considered to be reasonable that uniform treatment may be applied to the entire circumference of the can by arranging hot air suction nozzles distributed as even as possible and with high density facing to the can passage, and therefore, it has been customary that the open orifice diameter of the individual nozzle 9 is normally made to have a small diameter which is 1/10 or less of the diameter of the open end of the can, as shown in FIG. 6.
However, the present inventor has discovered as the result of various experiments that it is desirable to make the open orifice diameter of these nozzles larger instead as shown in FIG. 7.
The reason therefor is considered as follows: As mentioned hereinbefore, hot air blown from the hot air supply chamber through the nozzle 8 is suctioned from the suction nozzle 9 for recirculation. At this time, in the portion where the suction nozzle 9 is covered with the can 13 as shown, hot air of a volume portion within the can is suctioned into the recovering chamber 5 by negative pressure generated by the recirculation blower 6. Because of this, atmospheric pressure within the can lowers so that hot air within the can passage chamber 4 is suctioned into the can through the outer suction nozzle 9A. At this time, let P 1 represent the pressure within the hot air supply chamber 3, P 2 the pressure of the can passage chamber 4, P 4 the pressure inside the can, and P 5 the pressure of the hot air recovering chamber 5, then the following relation is established
P.sub.5 <P.sub.4 <P.sub.2 <P.sub.1.
If the resistance of the suction nozzle 9 is great, the suction pressure P s =P 4 -P 5 is high, and the retaining force P h =P 2 -P 4 of the can 13 becomes small. In addition, as already mentioned, if the suction pressure is high, the suction flow velocity is high, giving rise to troubles such as a drip of coatings.
On the other hand, if the diameter of the suction nozzle is made greater, the suction resistance caused by the nozzle lowers and thus, the pressure P s =P 4 -P 5 becomes small whereas the retaining force P h =P 2 -P 2 increases through that amount, whereby the great retaining force of the can is produced by the small negative pressure of the recovering chamber 5. The experiment results in connection with the above-mentioned facts are shown in FIGS. 8 and 9.
FIG. 8 shows the rate of occurrence of can tumble relative to the nozzle diameter d in the case the suction pressure of the nozzle 9 is changed, in which example of experiment, if the nozzle diameter d as in those heretofore used is smaller than 1/10 of the diameter of the can, it is not possible to make the rate of can D tumble zero unless suction negative pressure is above -100 mm Aq, whereas if the diameter d is 0.5 D, it is possible to make the rate of can tumble almost zero under negative pressure of only -20 mm Aq.
On the other hand, with respect to the rate of occurrence of coating drip, as seen in FIG. 9, in the case the dried and coated film is 150 mg/dm 2 , if the nozzle diameter d is equal to 0.1 D with respect to the can diameter D, the rate of occurrence will be zero under the suction negative pressure of -65 mm Aq or below, whereas if d is equal to 0.08 D, the rate of occurrence of tumble will never be zero even in terms of the fact (mark x in the figure) that the measurement of the rate of occurrence of tumble is made impossible due to the occurrence of can tumble.
FIG. 10 is a view in which FIGS. 8 and 9 are combined. As is apparent from FIG. 10, in the value smaller than the nozzle diameter d=0.1 D heretofore used, no region of negative pressure is present which can make both the rate of occurrence of a can tumble and the rate of occurrence of a coating drip zero.
The larger the nozzle diameter d as compared with the can diameter D, the better. However, as shown in FIG. 7, the can diameter D need to cover the nozzle 9, the transporting belt 7 and outer suction nozzle 9A, and when the outer suction nozzle 9A is excessively small, hot air flowing into the can is minimized to decrease the heating effect from the interior of the can.
Therefore, a limit of the diameter of the nozzle 9 is 0.5 D. It is therefore desirable from the above-described reasons that the diameter of the outer suction nozzle 9A is in the range of d=1/10D-1/3D.
In the prior art devices, since the transporting belt 7 is installed along the upper surface of the suction nozzle constituting member 12, as shown in a fragmentary sectional view of FIG. 11, the belt 7 is carried away by hot air W directly suctioned and flown into the suction nozzle 9 between the cans 13 and a phenomenon wherein spacing D is changed has been appeared. In addition, the belt 7 involves minor twist and internal stress so that sometimes, the belt 7 is flapped by the hot air W and is then levitated from the upper surface of the nozzle constituting member 12, which results in a tumble of the can 13 to be transported.
This tendency is further encouraged, even in a portion where the can 13 is placed on the transporting belt, by the fact that the hot air flowing down along the can 13 impinges upon the end of the suction nozzle constituting member 12 into a turbulent flow as shown in FIG. 3. That is, if the can 13 is shaken by said turbulent flow, a tendency is increased in which the belt 17 is inwardly carried by the air stream passed under the levitated can 13 and directly suctioned by the suction nozzle 9 along the upper surface of the suction nozzle constituting member 12, thus increasing a tendency in which the shaking can 13 tends to be tumbled.
On the other hand, in accordance with the apparatus of the present invention, there is provided a set of conveyor belts composed of two belts, along the passages of which are provided belt sliding guide grooves 10 which are slightly shallower than the thickness of the belt 7, and the belts 7 are laid in said grooves and belt attracting nozzles 11 are disposed in the bottom of the grooves.
With this arrangement, it is possible to prevent the spacing of the belt 7 from being narrowed by hot air W directly sunctioned by the suction nozzles between the cans placed on the belt.
Even if the thickness of the belt is increased, the gap between the can 13 and the upper surface of the suction nozzle constituting member 12 can be made smaller, and therefore, the hot air suctioned into the can is one which merely passes by the suction nozzle 9A externally of the belt to circulate the hot air deeply into the can 13 and to decrease the force laterally acting on the belt 7 at that portion.
It is possible to prevent the belt 7 from being levitated by the belt attracting nozzle 11 at the bottom of the groove 10, but there is no air stream passed under the belt 7 from the side and attracted by the nozzle 11 even if the belt 7 is slightly distorted because of the presence of the groove, whereby the belt 7 may be positively attracted.
By these marked operations and effects as described above, it is possible to extremely effectively prevent cans from being tumbled in the baking and drying furnace.
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This invention relates to a baking and drying furnace wherein hot air is supplied from the top of containers such as cans passing through the furnace in an inverted attitude and the hot air within the cans are suctioned whereby the hot air may flow along internal and external surfaces of the containers, the improvement wherein the containers are prevented from being tumbled by being flapped by a stream of hot air.
First, in order to prevent cans from being tumbled by being flapped by a turbulent flow of hot air which downwardly flows along the outside of containers such as cans resulting from impingement of hot air upon a can transporting passage, nozzles for suctioning hot air are arranged along said transporting passage to arrange the flowing direction of downwardly flowing hot air.
Secondly, in order to increase the force for pressing the containers to prevent them from being tumbled, a suction resistance of nozzles for suctioning hot air within the containers is decreased, and the diameter of a nozzle is determined so that a difference in pressure between internal and external sides of the container becomes its maximum.
Thirdly, in order to prevent the transporting belt from being displaced or levitated, the belt is slidably moved within the groove and suction nozzles are disposed on the bottom of the groove to attract the belt.
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CLAIM OF PRIORITY TO PRIOR APPLICATION
[0001] This application claims the filing date of U.S. Provisional Patent Application Ser. No. 62/191,588, filed on Jul. 13, 2015, entitled “Adjustable Pole With Foot Rests to Aid in Human Fecal Matter Evacuation From the Rectum”, the entire disclosure of which is hereby incorporated in its entirety and by reference into the present disclosure
BACKGROUND OF THE INVENTION
[0002] Many studies have been published showing that the Western method of moving bowels is problematic. The natural position for humans to move bowels is in a squatted position. This position opens up the pathways and results in smooth bowel movements. Western toilets cause humans to move bowels in an unnatural position that results is strained muscles and other issues. There have been many devices that attempt to remedy this problem by providing a more natural squatting position for bowel movements. However, these devices either require expensive new toilet fixtures or take up so much space they are unlikely to be used. These bulky units are a hassle to place and store around the toilet, or have stationary one-size-fits-all pedal heights that do not fit the needs of multiple household members. There has been a long felt need in the art of a simple, portable, storable fecal matter evacuation device.
BRIEF DESCRIPTION OF THE INVENTION
[0003] The present invention is a simple, portable, storable fecal matter evacuation device. The device relaxes the puborectalis muscle for easier fecal matter evacuation. The invention has foot rests that can be raised or lowered. In addition, the invention can be placed off to the side out of the way of normal urination practices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] A better understanding of the present invention may be had from the drawings as described in greater detail in the DETAILED DESCRIPTION OF PREFERRED EMBODIMENT section which follows:
[0005] FIG. 1 Isometric projection view of the preferred embodiment of the invention.
[0006] FIG. 2 front facing view of the preferred embodiment of the invention.
[0007] FIG. 3 side perspective view of the preferred embodiment of the invention.
[0008] FIG. 4 top down view of the preferred embodiment of the invention.
[0009] FIG. 5 bottom up view of the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The present invention allows the puborectalis muscle to relax for easier fecal matter evacuation. The invention does this by allowing the feet to rest comfortably on the height appropriate steps, taking the pressure off of the puborectalis muscle, relaxing the colon for fecal matter evacuation.
[0011] The invention differs from what currently exists. Current units are bulky, more permanent items that become obstacles during normal urination use, and allow the opportunity for additional hygiene issues due to spraying. This invention is a light weight, portable unit that can collapse and be hidden away from view. While current units are not height adjustable for persons that may be smaller or taller than the average user, the foot pedals on the Claimed Invention can be adjusted to the user's optimum height for ease of evacuation.
[0012] As seen in FIGS. 1-5 , the preferred embodiment of the present invention includes a Foot Rest Assembly 100 and a Foot Pedal Assembly 200 . The Foot Rest Assembly 100 is composed of the Vertical Outer Pole 110 , Nonslip Rubber Foot Rest 120 , and the Unlocking Button 130 . The Foot Pedal Assembly 200 is composed of the Vertical Inner Pole 210 and the Foot Pedals 220 .
[0013] The Vertical Outer Pole 110 is designed so that it will fit over the Vertical Inner Pole 210 . For example, in the preferred embodiment a prefabricated ½ square, or round, pole is cut to 24 inches as the Vertical Outer Pole 110 . In this example, the Vertical Inner Pole 210 is an additional pole with a diameter slightly smaller than ½ inches, so as to fit inside the Vertical Outer Pole 110 , which should be cut to 24 inches as well. The Vertical Inner Pole 210 has Locking Holes 211 drilled through each side at ½ inch intervals. The heights for the Locking Holes 211 are marked and annotated on the device and can be adjusted to various intervals based on aesthetic or other preferences. The type of pipe (square or round) is to be made out of any industrial material designed to support substantial weight and can be adjusted depending on aesthetic preferences.
[0014] In the preferred embodiment, the device can telescope from 24 inches to 48 inches. The height of the Nonslip Rubber Foot Rest 120 can be adjusted every ½ inch with either hole and pin connectors, rods, slides, or other devises to lock the rung to the ideal height. In some embodiments, the Nonslip Rubber Foot Rest 120 includes Spring Hinges 121 so that the foot rest can further fold up against the Vertical Outer Pole 110 for storage. The Unlocking Button 130 used to unlock the foot rests so they can be folded for easy storage and to unlock and lock the Vertical Outer Pole 110 .
[0015] The Vertical Inner Pole 210 is attached to the Foot Pedal Assembly 200 . In some embodiments, the Vertical Inner Pole 210 can be attached and detached from the Foot Pedal Assembly 200 by screws or other methods for shipping and packing considerations. The Foot Pedal Assembly 200 includes the Foot Pedals 220 . In the preferred embodiment, there are four Foot Pedals 220 . Each Foot Pedal 220 includes a Nonslip Rubber Foot Pad 221 to be placed at the bottom of each Foot Pedal 220 . The Nonslip Rubber Foot Pads 221 are rubberized foot pads to prevent the device from sliding while in use.
[0016] In general use, the device is placed in front of the user with the telescoping height extended to adjust to ideal height for the user. The user places feet on the Nonslip Rubber Foot Rest 120 and performs the act of evacuation. When the task is complete, the device can collapse back to storage height and be placed to the side of toilet or in another storage area.
[0017] In alternative embodiments, Nonslip Rubber Foot Rest 120 or Nonslip Rubber Foot Pads 221 do not need to be made out of rubber but can be made out of another nonslip product. In other embodiments Nonslip Rubber Foot Pads 221 may be eliminated. In others, the Nonslip Rubber Foot Rest 120 may be stationary and nonadjustable or the pole height can be fixed and nonadjustable, and instead, the height can be adjusted by the two poles interlocking with each other and having the foot rests stationary.
[0018] While the principles of the disclosure have been described above in connection with specific methods, it is to be clearly understood that this description is made only by way of example and not as limitation on the scope of the disclosure. Whether now known or later discovered, there are countless other alternatives, variations and modifications of the many features of the various described and illustrated embodiments, both in the process and in the device characteristics, that will be evident to those of skill in the art after careful and discerning review of the foregoing descriptions, particularly if they are also able to review all of the various systems and methods that have been tried in the public domain or otherwise described in the prior art. All such alternatives, variations and modifications are contemplated to fall within the scope of the present invention.
[0019] Although the present invention has been described in terms of the foregoing preferred and alternative embodiments, these descriptions and embodiments have been provided by way of explanation of examples only, in order to facilitate understanding of the present invention. As such, the descriptions and embodiments are not to be construed as limiting the present invention, the scope of which is limited only by the claims of this and any related patent applications and any amendments thereto. With reference again to the figures, it should be understood that the graphical representation of the system is an exemplary reference to any number of devices that may be implemented by the present invention.
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The invention is a simple, portable, storable fecal matter evacuation device. The device relaxes the puborectalis muscle for easier fecal matter evacuation. The invention has foot rests that can be raised or lowered. In addition, the invention can be placed off to the side out of the way of normal urination practices.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to detonators, and more particularly to an apparatus for reliably achieving detonation when there is a gap between the donor and acceptor charges and they are not in axial alignment.
2. Description of the Prior Art
The basic problem is that of obtaining the detonation of a second charge (the acceptor) upon the detonation of a first charge (the donor) where the two charges are separated by a gap or by a barrier and a gap and are axially offset from each other, i.e., they are not in perfect axial alignment. Detonation of the acceptor is achieved by the impact of the fragments of the exploded casing of the donor upon the acceptor casing with sufficient velocity and in a high enough density pattern. Thus the axial and lateral components of the distance separating the two charges are key variables because of their direct effect upon the aforementioned impact velocity and pattern.
Presently, detonators are typically comprised of donor and acceptor charges that are cylindrically shaped with flat ends that face each other. To ensure reliable detonation of the acceptor charge, it is desirable to axially align the two charges, i.e., position the axis of revolution of the two cylinders on the same line. However, operative vibration, structural design constraints, and random error occurring in assembly often cause misalignment, i.e., offset, between the two.
Assembly errors are dealt with by tightening the tolerances and simply absorbing the reduction in production rate and concomitant increase in unit cost. Another approach is to increase the explosive charge of the donor. This increases the possibility of damage to surrounding structures and components and may necessitate the installation of protective shielding for such, thus increasing the weight, a crucial design variable in flight vehicles. A third technique is to increase the target area of the acceptor charge. Structural design constraints may negate this possibility; also, this approach will increase the explosive charge of the acceptor and thus the problem of providing shielding to avoid potential damage to adjacent structures and components arises.
In addition, detonation across a gap and with a considerable angle between the respective axes of revolution of the donor and acceptor charge cylinders, e.g., around a corner, is currently highly unreliable.
The present invention increases the reliability of transmitting detonation from one charge to another across an intervening gap or barrier when the two charges are not axially aligned by shaping the tip of the donor charge to cause its casing fragments to disperse with a significant radial as well as axial velocity component. The tip of the acceptor charge is also shaped in order to increase the impact density of the casing fragments originating from the tip of the donor charge.
Through the use of the present invention, detonation may reliably be obtained around corners as well as for virtually any angular orientation between two or more separated charges.
SUMMARY OF THE INVENTION
The present invention transmits detonation from one charge to another across an intervening gap even when the two charges are not in axial alignment. Such is accomplished by shaping the opposing tips of the charges to provide the casing fragments of the donor charge tip with a radial velocity component and also to increase the impact density of such fragments upon the tip of the acceptor charge.
STATEMENT OF THE OBJECTS OF THE INVENTION
An object of the present invention is to reliably provide detonation of one charge by another charge.
Another object of the present invention is to provide detonation of one charge by another charge across an intervening gap.
Still another object of the present invention is to provide detonation of one charge by another charge across an intervening gap when the two charges are not axially aligned with each other.
Yet another object of the present invention is to provide detonation of one charge by another charge when the two charges are not positioned parallel to each other.
A further object of the present invention is to provide detonation of one charge by another charge when the two charges are located perpendicular to each other.
Another object of the present invention is to reliably provide simultaneous detonation of a plurality of charges by a single charge.
Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 1A show perspective and side views, respectively, of the detonation apparatus of the prior art comprised of two charges being cylindrically shaped and having flat opposing ends;
FIGS. 2 and 2A show perspective and side views, respectively, of one embodiment of the present invention comprised of two charges of cylindrical shape with truncated conical tips;
FIG. 3 is a graph based upon test firings comparing the performance of the truncated conical tip embodiment of the present invention with the flat tip configuration of the prior art;
FIG. 4 shows a side view of another embodiment of the present invention comprised of two charges of cylindrical shape with hemispherical tips;
FIG. 5 is a side view of another embodimet of the present invention illustrating how it may be used to achieve detonation around a corner by using a donor charge with a tip having a rectangular cross section and an acceptor charge having a flat end. FIG. 5A is a frontal view of the donor charge; and
FIG. 6 illustrates a T-shaped layout whereby a donor charge with a tip having rectangular cross section may be used to simultaneously detonate two acceptor charges having flat ends.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 1A, respectively, show perspective and side views of prior art detonator apparatus 11. Apparatus 11 comprised of donor charge 12 composed of cylindrical body casing 13 and flat end 15 and acceptor charge 17 composed of cylindrical body casing 19 and flat end 21, both containing explosive material (not shown). Ends 15 and 21 are axially separated by gap X. The axes of revolution of cylindrical body 13 and cylindrical body 19 are parallel and laterally offset by distance Y. In operation, the detonation of donor charge 12 will cause fragments of the casing from end 15 to impact upon end 21 of acceptor charge 17 and thereby cause charge 17 to detonate. The probability that the detonation of charge 12 will be transmitted to charge 17 (or vise versa) is reduced as X and Y are increased.
FIGS. 2 and 2A, respectfully, show perspective and side views of apparatus 23 comprising one embodiment of the present invention. Apparatus 23 is comprised of donor charge 25 and acceptor charge 27.
Donor charge 25 is composed of cylindrical casing 28 and truncated conical tip casing 29, both containing explosive material (not shown). Acceptor charge 27 is composed of cylindrical casing 31 and truncated conical tip casing 33, both containing explosive material (not shown). As shown with respect to the prior art in FIGS. 1 and 1A, X denotes the axial separation of charges 25 and 27, while Y denotes the lateral offset between the parallel axes of revolution of cylindrical casings 28 and 31.
It has been found that shaping the tips of the charge casings in the form of truncated cones increases the radial velocity component of fragments of tip casing 29 upon the detonation of charge 25 and also serves to increase the impact density of such fragments on tip casing 33. This has the effect of increasing the maximum offset Y at which detonation of acceptor 27 will reliably occur at any given gap X over that of the prior art.
This improvement in reliability over the prior art is shown in the graph comprising FIG. 3, the data points of which were obtained from tests of apparatus 23 of the present invention and from comparison tests conducted using prior art apparatus 11.
The upper pair of lines illustrates the performance of apparatus 23 of the present invention at various offsets, Y, and gaps, X, and the bottom pair shows the performance of prior art detonator apparatus 11. For each pair, respectively, the upper of the two lines indicates the maximum value of Y for which acceptor detonation could possibly occur for each X, i.e., the probability that a detonation of the acceptor will occur at a particular X for a Y greater than the upper line is remote. The lower line of each pair shows the maximum value of Y for each X for which detonation of the acceptor will reliably occur. The cross-sectioned area in-between shows the values of Y for which the probability of acceptor detonation is not precisely determined.
FIG. 3 clearly indicates that the embodiment of the present invention having a truncated conical tip shape, i.e., apparatus 23, will achieve reliable detonation at an appreciably larger offset Y over a range of gaps varying from 0.0 through 0.200 of an inch compared to prior art apparatus, i.e., apparatus 11.
With respect to both the donor and acceptor charges of both tested apparatus.
(1) the casing was constructed of stainless steel;
(2) the casing thickness was 0.005 of an inch;
(3) hexanitrostilbine (HNS) was the explosive material; and
(4) the casing diameter was of 0.190 of an inch.
With respect to the tested configuration of apparatus 23 of the present invention, the interior diameter E of tips 29 and 33 was 0.050 of an inch and the tip lengths L were both 0.050 of an inch.
It should be noted that the maximum reliable detonation curve, i.e., of the lower curve of each pair, is dependent upon the casing material, casing thickness, explosive material, and casing diameter. However, it has been found that for a given set of such variables the curve for an appropriately shaped tip of the present invention will provide a higher maximum reliable offset Y for every feasible operative gap X than the corresponding curve for the apparatus of the prior art, i.e., apparatus 11.
FIG. 4 shows detonation apparatus 35, an embodiment of the present invention comprised of donor charge 37 and acceptor charge 39. Donor charge 37 is comprised of cylindrical casing 41 and hemispherical tip casing 43, both enclosing explosive material (not shown). Acceptor charge 39 is comprised of cylindrical casing 45 and hemispherical tip casing 47, both containing explosive material (not shown).
It has been found that using hemispherical shaped tips 43 and 47 increases the reliability of achieving detonation across the gap separating charges 37 and 39 in the illustrated situation where cylinder casings 41 and 45 are at a skewed angle with respect to each other. i.e., where the axes of revolution of cylinder casings 41 and 45 are not parallel.
FIG. 5 shows a side view of apparatus 51, an embodiment of the present invention which has been found to provide reliable detonation around corners, i.e., in situations where the donor and acceptor charges are perpendicular to each other. Apparatus 51 is comprised of donor charge 53 and acceptor charge 55.
Donor charge 53 is comprised of cylindrical casing 57 and rectangular tip casing 59, both filled with explosive material (not shown). Acceptor charge 55 is comprised of cylindrical casing 61 having flat end 63, and encloses an explosive material (not shown). (Acceptor charge 55 may also have a rectangular shaped tip having a flat end.)
FIG. 5A is a frontal view of donor charge 53 taken along line AA of FIG. 5; it illustrates the rectangular cross section of tip casing 59.
Apparatus 51 is shown in a typical operational application of providing detonation around corner 65. Such is accomplished by the rectangular shape of tip casing 59 of charge 53 which, when used in conjunction with flat end 63 of charge 55, provides exploded fragments of tip casing 59 with an appreciable velocity component normal to the surface of end 63 and ensures a sufficient density of impact of such particles upon end 63 to thereby detonate charge 55.
FIG. 6 shows apparatus 71, an embodiment of the present invention which is used to simultaneously detonate two acceptor charges with one donor charge. Apparatus 71 is comprised of donor charge 53 and acceptor charges 73 and 75.
Donor charge 53 is comprised of cylindrical casing 57 and rectangular tip casing 59 and was previously discussed in detail in conjunction with apparatus 51 (shown in FIGS. 4 and 4A). Acceptor charge 75 is comprised of cylindrical casing 77 having flat end 79. Acceptor charge 73 is comprised of cylindrical casing 81 having flat end 83; both cylindrical casings 77 and 81 are filled with explosive material (not shown). (Acceptor charges 73 and 75 may also have the rectangular shaped tip having a flat end.)
When donor charge 53 is detonated, it propels fragments of casing 59 radially relative to the axis of revolution of cylindrical casing 53 and, therefore, normal to both flat ends 79 and 83. The normal velocity component of such casing fragments and their high impact density upon ends 79 and 83 is sufficient to cause the simultaneous detonation of acceptor charges 75 and 73, respectively.
It should be noted that in all of the embodiments hereinbefore disclosed as well as any other shapes that are within the scope of the present invention, the operative roles of donor and acceptor charges may be reversed. It is also within the scope of the present invention to use a plurality of acceptor charges with any given donor charge, the respective shapes being dependent upon the orientation of the charges as dictated by the particular operational usages and such shapes not being limited to those specifically disclosed herein.
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Detonation of an acceptor charge by a donor charge across an intervening where the two charges are not axially aligned is achieved by shaping the respective charges to control the direction of the fragments of the donor charge and their impact pattern upon the acceptor charge.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation application of U.S. patent application Ser. No. 11/855,822, filed on Sep. 14, 2007, which is a continuation application of U.S. patent application Ser. No. 11/680,658, filed on Mar. 1, 2007, now U.S. Pat. No. 7,292,688, issued Nov. 6, 2007, which is a continuation application of U.S. patent application Ser. No. 11/342,880, filed on Jan. 31, 2006, now U.S. Pat. No. 7,203,302, issued Apr. 10, 2007, which is a continuation application of U.S. patent application Ser. No. 10/789,977, filed on Mar. 2, 2004, now U.S. Pat. No. 7,054,432, issued May 30, 2006, which is a continuation application of U.S. patent application Ser. No. 10/388,635, filed on Mar. 17, 2003, now U.S. Pat. No. 6,724,882, issued Apr. 20, 2004, which is a continuation application of U.S. patent application Ser. No. 09/977,697, filed on Oct. 16, 2001, now U.S. Pat. No. 6,563,917, issued May 13, 2003; which is a continuation application of U.S. patent application Ser. No. 09/207,275, filed on Dec. 8, 1998, now U.S. Pat. No. 6,330,324, issued Dec. 11, 2001, which claims the benefit of U.S. Provisional Application No. 60/069,114, filed on Dec. 9, 1997, the contents of which are expressly incorporated by reference herein in their entireties.
1. FIELD OF THE INVENTION
The present invention generally relates to systems for routing telephone calls to appropriate numbers. More particularly, the present invention relates to an Advanced Intelligent Network (AIN) based system and methods for routing telephone calls based on the location of the calling party.
2. ACRONYMS
The written description provided herein contains acronyms which refer to various communication services and system components. Although known, use of several of these acronyms is not strictly standardized in the art. For purposes of the written description herein, acronyms will be defined as follows:
AIN—Advanced Intelligent Network AMA—Automatic Message Accounting CCIS—Common Channel Interoffice Signaling CO—Central Office CPN—Calling Party Number CPR—Call Processing Record DN—Dialed Number Trigger DRS—Data Reporting System EO—End Office (EO) ISCP—Integrated Service Control Point LSP—Local Service Provider NPA—Number Plan Area, i.e., area code NXX—Central Office Code RTN—Routing Telephone Number SCE—Service Creation Environment SCP—Service Control Point SCCP—Signaling Connection Control Part SMS—Service Management System SPC—Signaling Point Code SS7—Signaling System 7 SSP—Service Switching Point STP—Signaling Transfer Point TAT—Terminating Attempt Trigger TCAP—Transaction Capabilities Applications Protocol
3. DESCRIPTION OF THE RELATED ART
In recent years, a number of new telephone service features have been provided by advanced intelligent communications networks such as an Advanced Intelligent Network (AIN). The AIN evolved out of a need to increase the capabilities of the telephone network architecture to meet the growing needs of telephone service customers. The AIN architecture generally comprises two networks, a data messaging network and a trunked communications network. The trunked communications network handles voice and data communications between dispersed network locations, whereas the data messaging network is provided for controlling operations of the trunked communications network.
An illustration of the basic components of an AIN architecture is shown in FIG. 1 . As shown in FIG. 1 , Central Offices (CO) 10 - 16 are provided for sending and receiving data messages from an Integrated Service Control Point (ISCP) 20 via a Signaling Transfer Point (STP) 30 - 34 . The data messages are communicated to and from the COs 10 - 16 and the ISCP 20 along a Common Channel Inter-Office Signaling (CCIS) network 22 . Each CO 10 - 16 serves as a network Service Switching Point (SSP) to route telephone calls between a calling station (e.g., station 40 ) and a called station (e.g., station 48 ) through the trunked communications network 24 - 26 . For more information regarding AIN, see Berman, Roger K., and Brewster, John H., “Perspectives on the AIN Architecture,” IEEE Communications Magazine, February 1992, pp. 27-32, the disclosure of which is expressly incorporated herein by reference in its entirety.
While prior AIN or AIN-type intelligent network applications may have provided various features to subscribers and users, these prior applications do not allow users to dial one telephone number and reach a single point of contact for multiple services provided by a subscriber. Current systems and methods require users to identify one of many possible numbers to call depending on the specific information or service desired from the subscriber. This requires users to know the telephone number of all departments or service groups of the subscriber that they need information from.
Moreover, none of the current systems and methods allow a user to dial an abbreviated telephone number to access services from a subscriber. Currently, the user must lookup, write down, or memorize a full seven or more digit number for each department or service group that they may need information from.
Therefore, a system and method is needed that allows users to dial one telephone number and reach a single point of contact for Information and services provided by a subscriber, and that provides an abbreviated telephone number that is easy to remember for accessing the single point of contact for services from the subscriber.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a system and method for geographical call routing for a non-emergency calling service that substantially obviates one or more of the problems arising from the limitations and disadvantages of the related art.
It is an object of the present invention to provide an AIN system and method that routs calls to a non-emergency service based on the geographical location of the caller.
It is also an object of the present invention to provide an AIN system and method that allows users to dial one telephone number and reach a single point of contact for services provided by a subscriber.
It is a further object of the present invention to provide an AIN system and method that allows users to dial an abbreviated telephone number that is easy to remember for accessing a single point of contact for services from a subscriber.
Accordingly, one aspect of the present invention is directed to an advanced intelligent communications system for routing telephone calls based on the location of a calling party, The system includes: a plurality of call origination telephones; at least one switching device operatively connected to at least one of the plurality of call origination telephones, the at least one switching device servicing calls placed by at least one calling party using one of the plurality of call origination telephones; a processor operatively connected to the at least one switching device, the processor determining routing of the calls placed by the at least one calling party; a storage device operatively connected to the processor, the storage device containing location information related to the at least one calling party; and at least one destination telephone operatively connected to at least one of the at least one switching device, wherein the processor sends routing information to the at least one switching device for routing calls to one of the at least one destination telephone and a terminating announcement, based on the location of the at least one calling party.
According to another aspect of the present invention, each at least one switching device has an associated signaling point code that is used by the processor to determine the location of the at least one calling party relative to a defined service area.
According to yet another aspect of the present invention, the signaling point code indicates whether the at least one switching device services only calls within the defined service area.
According to a further aspect of the present invention, the signaling point code indicates whether the at least one switching device services calls both within the defined service area and outside of the defined area.
According to another aspect of the present invention, each signaling point code that indicates whether the at least one switching device services only calls within the defined service area, has an associated call routing telephone number.
According to yet another aspect of the present invention, the storage device contains information mapping the signaling point codes to the associated call routing telephone number for the at least one switching device that services only calls within the defined service area.
According to a further aspect of the present invention, for the signaling point codes that indicate the at least one switching device does not service any calls within the defined service area, the processor sends routing information to the at least one switching device to route the call to the terminating announcement.
According to another aspect of the present invention, the storage device contains information indicating whether the signaling point codes represent switching devices that service telephones within the service area.
According to yet another aspect of the present invention, the storage device contains information indicating whether the signaling point codes represent switching devices that service telephones both in the service area and outside the service area.
According to a further aspect of the present invention, the storage device contains information mapping telephone numbers of the at least one calling party to associated zip codes.
According to another aspect of the present invention, the storage device contains information mapping the associated zip codes to call routing telephone numbers.
According to yet another aspect of the present invention, information regarding the processing of the calls placed by the at least one calling party is recorded.
According to a further aspect of the present invention, a report generator generates reports based on the information recorded.
According to another aspect of the present invention, the calls placed by the at least one calling party are to an abbreviated telephone number comprising three digits.
According to yet another aspect of the present invention, the calls placed by the at least one calling party are to “1” plus an abbreviated telephone number comprising three digits.
According to a further aspect of the present invention, the calls placed by the at least one calling party are to “0” plus an abbreviated telephone number comprising three digits.
According to another aspect of the present invention, the defined service area comprises multiple service areas.
According to yet another aspect of the present invention, the at least one switch device comprises at least one of a 5ESS switch, a AXE10 switch, a 1AESS switch, and a DMS100 switch.
According to a further aspect of the present invention, the at least one switching device comprises an AIN switch.
According to another aspect of the present invention, the at least one switching device comprises a non-AIN switch.
According to yet another aspect of the present invention, the at least one switching device is a host switching device that services at least one remote terminal.
According to a further aspect of the present invention, the present invention includes a method for routing a call based on the location of the calling party number in an advanced intelligent communications system that includes: receiving a telephone call at a switching point, the telephone call being from a calling party number to an abbreviated dialed number, determining if the abbreviated dialed number is a triggering number; notifying a service control point of receipt of the telephone call by the switching point if the abbreviated dialed number is a triggering number; classifying the switching point; determining the location of the calling party number; determining the appropriate routing of the telephone call based on the location of the calling party number; sending call routing information regarding the telephone call to the switching point; and routing the telephone call to one of a destination number and a default announcement.
According to another aspect of the present invention, the abbreviated dialed number comprises three digits.
According to yet another aspect of the present invention, the abbreviated dialed number comprises ‘1’ plus three digits.
According to a further aspect of the present invention, the abbreviated dialed number comprises ‘0’ plus three digits.
According to another aspect of the present invention, the classifying includes determining whether the switching point receives telephone calls only from within a defined service area.
According to yet another aspect of the present invention, the classifying includes determining whether the switching point receives telephone calls from both within a defined service area and outside the defined service area.
According to a further aspect of the present invention, the notifying further comprises sending information related to the switching point to the service control point.
According to another aspect of the present invention, the determining if the abbreviated dialed number is a triggering number includes comparing the information related to the switching point to location information.
According to yet another aspect of the present invention, the notifying includes sending information related to the calling party number to the service control point.
According to a further aspect of the present invention, the determining of the location comprises comparing a zip code of the calling party number to location information.
According to another aspect of the present invention, the determining of the location comprises determining the location of the service switching point.
According to yet another aspect of the present invention, the determining of the appropriate routing comprises determining the zip code of the location of the calling party number.
According to a further aspect of the present invention, the routing comprises routing the telephone call to the destination number closest to the calling party number.
According to another aspect of the present invention, the default announcement recites a message and terminates the call.
According to yet another aspect of the present invention, the present invention includes an advanced intelligent communications system for routing telephone calls based on the location of a calling party that includes: calling means for originating a telephone call; switching means operatively connected to the calling means, the switching means servicing calls placed by a calling party using the calling means; processor means operatively connected to the switching means, the processor means determining routing of the calls placed by the calling party; storage means operatively connected to the processor means, the storage means containing location information related to the calling party; and at least one destination site operatively connected to at least one of the switching means, wherein the processor means sends routing information to the switching means for routing calls to one of the at least one destination site and a terminating announcement, based on the location of the calling party.
According to a further aspect of the present invention, the switching means has an associated signaling point code that is used by the processor means to determine the location of the calling party.
According to another aspect of the present invention, the signaling point code indicates whether the switching means services only calls from within a defined service area.
According to yet another aspect of the present invention, the signaling point code indicates whether the switching means services calls from both within the defined service area and from outside of the defined area.
According to a further aspect of the present invention, each signaling point code that indicates whether the switching means services only calls from within a defined service areas has an associated call routing telephone number.
According to another aspect of the present invention, the storage means contains information mapping the signaling point codes to the associated call routing telephone number for the switching means that services only calls from within the defined service area.
According to yet another aspect of the present invention, for the signaling point codes that indicate the switching means does not service any calls from within the defined service area, the processor means sends routing information to the switching means to route the call to the terminating announcement.
According to a further aspect of the present invention, the storage means contains information indicating whether the signaling point codes represent switching means that service calls from within the service area.
According to another aspect of the present invention, the storage means contains information indicating whether the signaling point codes represent switching means that service calls from both within the service area and outside the service area.
According to yet another aspect of the present invention, the storage means contains information mapping telephone numbers of the calling party to associated zip codes.
According to a further aspect of the present invention, the storage means contains information mapping the associated zip codes to call routing telephone numbers.
According to another aspect of the present invention, information regarding the processing of the calls placed by the at least one calling party is recorded.
According to yet another aspect of the present invention, the invention includes means for generating reports based on the information recorded.
According to a further aspect of the present invention, the calls placed by the calling party are to an abbreviated telephone number comprising three digits.
According to another aspect of the present invention, the calls placed by the calling party are to an abbreviated telephone number comprising “1” plus three additional digits.
According to yet another aspect of the present invention, the calls placed by the calling party are to an abbreviated telephone number comprising “0”, plus three additional digits.
According to a further aspect of the present invention, the present invention includes an advanced intelligent communications system for routing a call based on the location of the calling party number that includes: receiving means for receiving a telephone call at a switching point, the telephone call being from a calling party number to an abbreviated dialed number; determining means for determining if the abbreviated dialed number is a triggering number; notifying means for notifying a service control point of receipt of the telephone call by the switching point if the abbreviated dialed number is a triggering number; classifying means for classifying the switching point; second determining means for determining the location of the calling party number, third determining means for determining the appropriate routing of the telephone call based on the location of the calling party number; sending means for sending call routing information regarding the telephone call to the switching point; and routing means for routing the telephone call to one of a destination number and a default announcement.
According to another aspect of the present invention, the abbreviated dialed number includes a telephone number that comprises three digits.
According to yet another aspect of the present invention, the abbreviated dialed number comprises a telephone number that comprises ‘1’ plus three additional digits.
According to a further aspect of the present invention, the abbreviated dialed number includes a telephone number that comprises to plus three additional digits.
According to another aspect of the present invention, the classifying means determines whether the switching point receives telephone calls only from within a defined service area.
According to yet another aspect of the present invention, the classifying means determines whether the switching point receives telephone calls from both within a defined service area and outside the defined service area.
According to a further aspect of the present invention, the notifying means further sends information related to the switching point to the service control point.
According to another aspect of the present invention, the first determining means further compares the information related to the switching point to location information.
According to yet another aspect of the present invention, the notifying means further sends information related to the calling party number to the service control point.
According to a further aspect of the present invention, the second determining means compares a zip code of the calling party number to location information.
According to another aspect of the present invention, the second determining means determines the location of the service switching point.
According to yet another aspect of the present invention, the third determining means determines the zip code of the location of the calling party number.
According to a further aspect of the present invention, the routing means routes the telephone call to the destination number closest to the calling party number.
According to another aspect of the present invention, the default announcement recites a message and terminates the call.
Additional features and advantages of the present invention will be set forth in the description to follow, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the methods particularly pointed out in the written description and claims hereof together with the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory, and are intended to provide further examples and an explanation of the invention as claimed.
The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrating one embodiment of the invention. The drawings, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example, and not by way of limitation, by the figures of the accompanying drawings in which like reference numerals refer to similar elements, and in which:
FIG. 1 shows a block diagram of an exemplary prior art AIN system;
FIG. 2 is a block diagram showing an AIN geographical call routing for a non-emergency calling service according to the present invention;
FIG. 3 is a block diagram of an Integrated Service Control Point according to the present invention;
FIG. 4 is a flow diagram of geographical call routing for a non-emergency calling service according to the present invention;
FIG. 5 is an exemplary Single Point Code Table according to the present invention;
FIG. 6 is an exemplary Zip Code to Routing Telephone Number table according to the present invention;
FIG. 7 is a block diagram of an AIN geographical call routing for a non-emergency calling service with multiple service areas according to the present invention;
FIG. 8 shows an exemplary multiple service area SPC table according to the present invention;
FIG. 9 is an exemplary table showing switch specific default announcement translations;
FIG. 10 is an exemplary table showing POTS and coin call disposition according to the present invention.
FIG. 11 shows an exemplary AMA record;
FIG. 12 is a flow diagram of the geographical call routing for a non-emergency calling service with DRS according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.
Many telephone services may be provided using an AIN or AIN-type network for centralized control of telephone services offered to subscribers, as opposed to localized control of services at the Central Office (CO). An AIN system is provided through interaction between switching points and other systems supporting AIN logic.
1. AIN Network
The geographical call routing for a non-emergency call service according to the present invention may be implemented using AIN Release 0.1 protocols and advanced intelligent network capabilities which are provided by a telephone company, i.e., programmable service control points (SCPs), central offices equipped with AIN service switching point (SSP) features, and existing Common Channel Interoffice Signaling (CCIS) networks. The Signaling System 7 (SS7) network is a widely used CCIS network that provides two-way communication of Transaction Capabilities Application Protocol (TCAP) formatted data messages between the SCP and the STP. The telephone network essentially employs an upper-level software network through the STPs and the SCP. The software resides over the hardware to check the call route and the availability of connection prior to hardware connection.
FIG. 2 illustrates a general block diagram of an Advanced Intelligent Network (AIN) in which a system and method for geographical call routing for a non-emergency calling service is embodied in accordance with the present invention. In FIG. 2 , local telephone lines 114 connect a plurality of individual locations 72 - 94 in each geographic area to the closest Central Office (CO), or End Office (EO) which contains Service Switching Points 60 - 70 . An End Office is a Central Office that is connected to the telephone equipment of a user. In FIG. 2 , each CO is shown as a Service Switching Point (SSP) 60 - 70 .
The SSPs may include, but are not limited to, 5ESS, AXE10, 1AESS, and DMS-100 switches. If 5ESS switches are utilized, then these switches should be equipped with generic 5E9 (or higher) and provided with the necessary trigger requirements (discussed below) in order to serve subscribers. Any 1AESS switches should be equipped with generic 1AE12.06 (or higher) and provided the necessary trigger requirements in order to serve subscribers. For DMS switches, DMS release (NA008), and the necessary trigger features should be provided. The corresponding software release for the ISCP is Release (5.0). For AXE10 switches, AXE 10 8.0 and the necessary trigger features should be provided. Future software releases on these network elements should not impact the service.
For purposes of illustration, only six SSPs are shown in FIG. 2 . However, more (or less) than six SSPs may be utilized. The SSPs 60 - 70 are programmable switches which: recognize AIN-type calls; launch queries to an Integrated Service Control Point (ISCP) 110 ; and, receive commands and data from the ISCP 110 to further process and route AIN-type calls. The SSPs 60 - 70 are connected by trunked communication lines 120 which are used to connect and carry telecommunication signals, e.g., voice and/or data, from a calling party to a called party. When one of the SSPs 60 - 70 is triggered by an AIN-type call, the SSP formulates an AIN service request and responds to call processing instructions from the network element in which the AIN service logic resides. A trigger event is the combination of the occurrence of receipt of a call, and the called telephone number satisfying the trigger criteria administered in the SSP, which invokes AIN or switch-based feature involvement in an originating or terminating call. A trigger occurs when the SSP determines that it must query the ISCP to continue processing a call. Triggers can occur from both the originating and terminating telephone numbers. The AIN service logic may reside in a database at ISCP 110 . A Call Processing Record (CPR) is a graphical representation of service logic. The CPR shows the flow of decisions and actions that are made as a call is processed.
In FIG. 2 , the SSPs 60 - 70 are equipped with Common Channel Inter-Office Signaling (CCIS) capabilities (or, alternatively, Common Channel Signaling (CCS)), e.g., Signaling System 7 (SS7), which provides for two-way communications of data messages between each SSP 60 - 70 and the ISCP 110 via SS7 links 116 . The data messages are formatted in accordance with the Transaction Capabilities Applications Protocol (TCAP). As shown in FIG. 2 , SSPs 60 - 70 are connected to Signaling Transfer Points (STPs) 100 - 104 by SS7 links 116 . The connections by links 116 to the STPs are for signaling purposes, and allow the SSPs to send and receive messages to and from the ISCP 110 . Each of the STPs can be connected to a number of other STPs. For purposes of illustration in FIG. 2 , SS7 links 116 are shown as connecting STPs 100 and 102 to a regional STP 104 and connecting the regional STP 104 to ISCP 110 .
FIG. 3 shows an ISCP 110 that may include a Service Management System (SMS) 118 , a Data and Reports System (DRS) 120 , a programmable Service Control Point (SCP) 122 , and a Service Creation Environment (SCE) 124 . The SCE 124 is a terminal that may be implemented to work with SMS 118 to create, modify, and load services into a database in the SCP 122 . The SCP 122 executes software-based service logic and returns call routing instructions to the SSPs. The SMS 118 and DRS 120 may be provided for compiling calling information to be used for billing and administrative purposes. By way of example, ISCP 110 may be implemented with the Bellcore Integrated Service Control Point (ISCP), loaded with ISCP software Version 3.4, available from Bell Telephone Laboratories, Inc., Murray Hill, N.J.
In a typical AIN-type system, when a non-AIN telephone call is initiated from, for example, party A at location 88 in FIG. 2 , the call is directed to the end office 68 serving the calling location 88 . While each of the end offices 60 - 70 may not be AIN-type SSPs, they are SS7 SSPs, and, therefore, part of the software data network. When the end office 68 receives the originating call, the call is suspended and the software network takes over the routing and connecting of the call. Normal call processing begins when an originating station 88 is off-hook and the end office 68 receives dialed digits (the telephone number of the party at station 88 ) from the originating station. End office 68 analyzes the digits and determines the call type, i.e., intraswitch or interswitch. An intraswitch call, i.e., a local call, directly connects calling station 88 with called station 90 without any querying outside of end office 68 , that serves both stations.
When the called station, for example, a party at station 82 , is not served by the same end office as originating station 88 , further processing may be necessary. In this situation, and assuming an entire SS7 network, the originating call from station 88 is suspended at the end office 68 , which further sends a query message through one or more of the STPs 100 and 102 , and/or regional STP 104 to ISCP 110 to offer termination of the call. The query message is routed to terminating end office 64 , the end office serving called station 82 . If station 82 is off-hook, i.e., busy, terminating end office 64 responds to the query from end office 68 that the call cannot be connected, and a busy signal is transmitted to calling station 88 . If station 82 is on-hook, end office 64 responds to the query of originating end office 68 by transmitting a ringback signal to calling station 88 , which is then serially connected through the trunked communication lines 120 to end office 64 and from end office 64 to called station 82 .
Advanced Intelligent Network (AIN) call processing differs from standard telephone call processing in that a query to a centralized database or service logic, e.g., ISCP 110 , is triggered by an AIN application. In AIN-type call processing, an SSP is responsible for identifying calls associated with AIN services, detecting when conditions for AIN service involvement are met, formulating service requests for call processing instructions, and responding to the instructions received. As with normal call processing, when the call is suspended at the calling party's end office, this end office may send a data message, via the SS7 links 116 , to the STPs to establish the call route. AIN services are created by assigning appropriate SSP call suspension points, known as AIN “triggers”, accessed via customer lines or telephone numbers, and accessing customer or service-specific logic in the ISCP 110 . A Dialed Number (DN) Trigger is an AIN 0, office-based, originating trigger which invokes AIN features when the trigger criteria are met. Trigger criteria are met when a call is placed to the designated NPA codes, NPA-NXX codes or NPA-NXX-XXXX codes. Ideally, AIN service should be triggered at the earliest possible point in the call, i.e., at the originating CO, however, service providers may only be able to provision the network with AIN triggers residing in the COs serving the subscribing customer or at an intermediate point on one of the connecting trunks. The SSPs launching the AIN queries are SSPs 60 - 66 , because SSPs 68 and 70 do not service any telephones within the service area, Thus, if an originating call through SSP 60 encounters an AIN trigger, i.e., a call requiring AIN service involvement, the SSP 60 suspends call processing, then queries the ISCP 110 through the STPs 100 and 104 over the SS7 links 116 .
The ISCP 110 executes software based service logic programs stored in the SCP 122 to perform subscriber functions, and returns a response to the originating end office with call routing instructions. The AIN service application may be stored in SCP 122 , or another element containing or consisting of an ISCP database. New services may be created by assigning appropriate SSP AIN triggers to customer lines or telephone numbers to access customer and/or service-specific logic in ISCP 110 . The SS7 message routing should be devised to minimize the need for data administration at the local and regional STPs.
When ISCP 110 receives a query, the intelligent network screening service logic will be executed. Call data may be collected and recorded in DRS 120 . For example, the ISCP 110 may contain resident service software that collects the calling (originating) telephone number, called (terminating) telephone number, the date, and the time of each query to the ISCP 110 A call processing record (CPR) that is stored within SCP 122 , may also be provided. The CPR may contain the service logic for network screening and call routing.
The ISCP service logic must have detailed knowledge of trunk group identifiers, route index numbers, and individual SSPs in order to service a customer. This information may be obtained during a service order process and may require that translation groups be consulted to complete such service order/provisioning information.
2. Geographical Call Routing For A Non-Emergency Calling Service System
An embodiment of the geographical call routing for a non-emergency calling service system according to the present invention that will be used for illustration is a geographical call routing for a non-emergency calling service system provided by a city to its residents. In the system, a caller may place a call to a nonemergency abbreviated telephone number to get information regarding city resources, activities, or services, etc. The abbreviated number may be three digits, such as 311, or “1” or “0” plus three digits; e.g. 1 311 or 0 311. The caller, or user, dials the 311 number to get answers to questions regarding information or services. Normally, the user would have to dial the number for the specific service, or the number for the office handling questions related to the information desired.
The non-emergency call routing system service is provided by a telephone service provider. The telephone service provider may or may not be the local telephone service provider of the subscriber to the service. In the above example, the city is a subscriber to the AIN-based geographical call routing system. A resident of the city is a user of the subscriber services provided by the system. If a user desired information regarding a city service, the user would normally call the telephone number associated with the department or agency that has information for that service. The present invention provides the user with the ability to dial only a single abbreviated telephone number to access information for all services provided by the subscriber.
Since only a single telephone number is used for information regarding all services, the frequency of calls to this number will be greater than if several telephone numbers, one for each department, is used. The present invention takes calls made to the abbreviated number and routes them to one of one or more destinations based on the location of the calling party. The location of the calling party is determined relative to a defined service area where the subscriber provides the abbreviated non-emergency call routing services. Only calls from users within this service area will be routed to one of the destinations that answer calls made to the non-emergency number. The location of the SSP that services the originating call from the calling party is used to determine routing of the call. The calling party number (CPN) is also used to determine how to route the call when the SSP location is not sufficient.
FIG. 4 is a flowchart of the geographical non-emergency call routing system according to the present invention. A telephone call to the 311 number is received at a SSP (S 2 ) that services calls for the CPN that placed the call. An AIN trigger is generated (S 4 ) for calls placed to telephone numbers having digits 311, 1+311, or 0+311. Information related to the call is sent to ISCP 110 from the SSP. The SSP will send information related to both the calling party, and the SSP. This information will include the CPN, as well as a Signaling Point Code (SPC). A SPC is associated with each SSP that services telephone numbers in the service area. The SPC relates to the location of the SSP. The SPC also identifies whether the SSP services only telephone numbers within the service area, or whether the SSP services telephone numbers both in the service area, and outside of the service area. ISCP 110 uses the SPC in determining the routing of the call.
ISCP 110 will determine if the SPC is contained in a SPC table contained in ISCP 110 (S 6 ). The SPC table maps each SPC to a Routing Telephone Number (RTN). The subscriber to the non-emergency call routing system may provide this mapping to the service provider. FIG. 5 is an exemplary SPC Table according to the present invention. The first column of FIG. 5 contains the SPC values identifying the SSPs. Column two of FIG. 5 shows a descriptive field designating what municipality, region, or area the SSP services based on the SPC. In the exemplary table in FIG. 5 , the region represents a city where the last character in the region field represents the state that the city is located in. The third column has a SPLIT variable that indicates whether the associated SSP services only telephone numbers that are within the service area, or services both telephone numbers within the service area and telephone numbers outside of the service area. If the SSP only services telephone numbers that are within the service area, the SPLIT variable will be “N”. If the SSP services both telephone numbers within the service area and telephone numbers outside of the service area, the SPLIT variable will be “Y”.
If the SPC, of the SSP that received the call, is not contained in the SPC table, the call is routed to a default announcement and terminated. Generally, the SPC of the SSP will not be in the SPC table if the SSP only services telephones located outside of the defined service area. SSP 68 and SSP 70 in FIG. 2 are examples of SSPs that do not service any telephone numbers within the defined service area. The service area is defined in FIG. 2 by thick solid lines forming a square. Therefore, a calling party from outside of the service area, for example outside of the city limits, would not have access to the services provided by the subscriber city or municipality.
If the SPC is in the SPC table, and indicates that the telephones serviced by the SSP are all within the service area, service logic in ISCP 110 will identify the routing telephone number (RTN) associated with the SPC of the SSP as shown in FIG. 5 . The service logic will send this routing information to the SSP, and the SSP will route the call accordingly. Column 5 of FIG. 5 shows an associated customer billing number for each RTN. The billing number is a telephone number related to the subscriber of the geographical non-emergency call routing service. This number is printed on billing information sent to the subscriber.
If the SPC indicates that the SSP is divided, or split (S 8 ), i.e. the SSP services telephones both in the service area, and telephones outside of the service area, the ISCP service logic performs additional processing to determine the appropriate routing of the call. The service logic verifies that a ten digit CPN has been received from the SSP (S 12 ). If a ten digit CPN has not been received, the ISCP will send routing information to the SSP to route the call to a default announcement and terminate the call (S 24 ).
However, if a ten digit CPN has been received, the service logic will attempt to identify a zip code associated with the CPN (S 14 ). This can be accomplished many ways. For example, a list of CPNs and associated zip codes may be contained in a database. The service logic would then send the CPN to the database to retrieve the associated zip code. The service logic may also, however, use a lookup table that contains a list of CPNs and their associated zip codes. Zip codes may vary in length from 5 digit zip codes to more than five digits.
If no zip code is found for the CPN (S 16 ), the service logic will cause the ISCP to send routing information to the SSP (S 27 ) directing the SSP to route the call to a default announcement and disconnect the call (S 24 ). If a zip code match is found for the CPN (S 16 ), the service logic then determines the associated RTN for the zip code (S 18 ). ISCP 110 will contain information such as that shown in FIG. 6 . FIG. 6 is an exemplary Zip Code Routing table that lists zip codes and their associated routing telephone numbers. If an associated routing telephone number is not found, the service logic will cause the ISCP to send routing information to the SSP (S 27 ) directing the SSP to route the call to a default announcement and disconnect the call (S 24 ). If an associated routing telephone number is found, ISCP 110 would send routing information to the SSP that contains the associated RTN (S 26 ).
Therefore, as shown in FIG. 4 , once the SSP receives the routing directions from ISCP 110 , the SSP will either route the call to the appropriate routing telephone number for the calling party number (S 28 ), or route the call to a default announcement and disconnect the call (S 24 ).
The geographical call routing for a non-emergency call service system according to the present invention may also be implemented for multiple service areas. For example, it is possible for several different areas to provide the non-emergency calling service for their residents.
FIG. 7 is a diagram showing an embodiment of the present invention where the non-emergency call routing system has multiple service areas (denoted by the thick black rectangles). In this embodiment, the geographical call routing for a non-emergency call service according to the present invention still determines the appropriate routing of the call based on the geographical location of the calling party. A 311 call from a calling party will be routed to the appropriate destination or routing telephone number based on which service area the calling party number is located in or serviced by, and by the location of the calling party relative to the service area. The SPC of each SSP defines the location of the SSP, and which service area the SSP services. If the SSP services telephones both within one service area, and telephones within another service area or no service area, then the associated zip code of the calling party number will be used to determine the routing of the call. If the zip code is not in the zip code routing table, then the call will be routed to a default announcement.
Four separate geographical areas, each one denoted by the thick box-shaped outlines, and the labels DALLAST, TULSAO, STLOUISM, and KANSASCM are shown in FIG. 7 . STPs 202 - 208 are connected to ISCP 220 through STP 210 . Connections between SSPs and STPs (e.g. SS7 links 116 ), and SSPs and calling party telephones (e.g. local telephone lines 114 ) are the same as shown in FIG. 2 discussed previously. In FIG. 7 , only one STP is shown in each geographical area, however, there may be multiple STPs in each area, and more SSPs and calling party telephones than shown, and still be within the spirit and scope of the present invention. ISCP 220 contains the SPC values for all SSPs that service calls from all service areas that subscribe to the geographical non-emergency calling service system. The ISCP also contains all call routing telephone numbers associated with each service area.
For example, calls placed by a calling party at stations 260 , 262 , or 270 to the non-emergency number calling service would be routed to a default announcement and terminated because these stations are not within the STLOUISM service area, or any other service area. The SPC of SSP 242 will not have an associated call routing telephone number.
Calls placed by a calling party at stations 264 or 266 will cause a trigger in SSP 244 . Since SSP 244 services calls only from stations within the STLOUISM service area, the SPC of SSP 244 will likely have an associated routing telephone number for the STLOUISM service area. The routing telephone number for the SPC of SSP 244 will be sent to SSP 244 , and the calls routed accordingly.
Calls placed by stations 268 and 270 will cause a trigger in SSP 246 . The SPC of SSP 246 will be SPLIT since SSP 246 services stations both within the STLOUISM service area and stations outside of the STLOUISM service area. For calls to the non-emergency number placed at stations 268 and 270 , the calling party number will be sent to the ISCP to find an associated zip code. If the zip code is not found, the call will be routed to a default announcement and terminated. If a zip code is found, the associated routing telephone number will be sent to SSP 246 , and the call routed accordingly. Since station 268 is within the STLOUISM service area, the SPC of station 268 will likely have an associated zip code in ISCP 220 with an associated routing telephone number. Conversely, since station 270 is not within the STLOUISM service area, the SPC of station 270 will likely not have an associated routing telephone number.
An exemplary routing table with SPCs and associated routing telephone numbers for multiple service areas is shown in FIG. 8 . In this example, call routing numbers for the four different service areas, denoted by DALLAST, STLOUISM, TULSAO, and KANSASCM, are shown. This table is similar to that shown in FIG. 5 discussed previously, except FIG. 5 only related to a single service area. The SPC Table in FIG. 8 is for a system that services multiple service areas, as shown by the different regions that represent different cities. The last character in the region field represents the state that the city is located. As shown in FIG. 8 , there can be different SPCs for the same service area, and also different routing telephone numbers for calls from the same service area. The term “BLANK” means that there is no information for this entry.
3. Trigger Requirements
The present invention may be implemented with, for example: 5ESS, AXE10, 1AESS, and/or DMS-100 switches. A trigger will be set against the digits 311, 1+311, and 0+311 in the SSP switches. The 311 trigger should be activated only in those SSPs that serve telephone numbers located within the service area. If a trigger is generated, a query is launched to the ISCP 110 . The 311 digits will be translated into ten-digit numbers in each of these switches.
The non-emergency 311 service may be used by telephones that are serviced by non-AIN equipped switches. In these cases, in order to provide the 311 service, it will be necessary to route 311 calls to a nearby compatible 5ESS, AXE10, 1AESS, or DMS-100 SSP. Once the 311 number is received by one of these SSPs, a trigger will be generated, and the call processed accordingly.
For the terminating announcement, AIN Announcement ID # 99 is translated in each 311 participating SSP according to the switch specific features as shown in FIG. 9 . The announcement may be recorded and installed in any SSP that is part of the non-emergency calling service system. The terminating announcement is not limited to AIN Announcement ID # 99 , but may be any message desired, recorded, and installed for the terminating announcement.
a. 5ESS Switch Types
For a non-emergency 311 number served by a 5ESS switch, a N11 trigger is encountered and an Info_Analyzed query message is generated with a trigger criteria type of N11. The trigger on the 5ESS switch is a 10-digit trigger. The trigger may be based upon AIN Release 0.1 protocol and may preferably require that AIN Release 0.1 query call variables be converted into common call variables by a CPR (Calling Party Record) in the ISCP 110 . If the 5ESS switch is utilized, then these switches should be equipped with Generic 5E9.1 (or higher) and provided with the necessary trigger requirements in order to serve subscribers.
b. 1AESS Switch Types
For a non-emergency 311 number served by a 1AESS switch, a NPA (3/6/10) trigger is encountered and an Info_Analyzed query message is generated with a trigger criteria type of NPA. The trigger on the LAESS switch may be a dialed line number (DN) trigger based upon a 10 digit virtual number. The trigger may be based upon the AIN Release 0.1 protocol and may preferably require AIN Release 0.1 query call variables to be converted into common call variables by a CPR in the ISCP 110 . Further, if 1AESS switches are employed, they should preferably be equipped with Generic 1AE12.03 (or higher) and provided with the necessary trigger requirements in order to serve subscribers.
c. DMS-100 Switch Types
For a non-emergency 311 number served by a DMS switch, a NPA (3/6/10) trigger is encountered and an Info_Analyzed query message is generated with a trigger criteria type of NPA. The trigger of the DMS-100 switch may utilize a termination attempt trigger (TAT) based upon the AIN Release 0.1 protocol and may preferably require AIN Release 0.1 query call variables to be converted into common call variables by a CPR in the ISCP 110 . A TAT is a subscribed trigger that is assigned to a telephone number. AIN features are invoked because of an attempt to terminate a call on the dialed number which subscribes to this trigger. These were first available in AIN 0.1. If DMS-100 switches are used, DMS release NA008 (or higher) should preferably be provided.
d. AXE 10 Switch Types
For a non-emergency 311 number served by a AXE 10 switch, a N11 trigger is encountered and an Info_Analyzed query message is generated with a trigger criteria type of N11. If AXE 10 switches are used, AXE 10 8.0 (or higher) should preferably be provided.
4. Non-AIN Switches
In the non-emergency call routing system according to the present invention, switches that are not equipped for AIN can be used. The non-AIN switch is assigned an SSP (Hub SSP) that is AIN equipped, and part of the non-emergency call routing system. If a call to the non-emergency call routing service is received by the non-AIN switch, and the non-AIN switch services telephones that the non-emergency call routing system is providing service for, the call will be routed from the non-AIN switch to the Hub SSP. A trigger will then be generated, and the call processed the same as calls placed to AIN SSPs used in the non-emergency call routing system. The non-AIN switch should be assigned to an AIN Hub SSP with the same type non-emergency number routing table information in the ISCP.
The call processing of 311 calls to a non-AIN switch is determined based on the locations of both the non-AIN switch, and the Hub SSP. If both the non-AIN switch and the Hub SSP are entirely within the service area, the SPLIT variable will be “N”, and only the SPC Table will be accessed to determine the appropriate routing of the call. However, if either the non-AIN switch or the Hub SSP are outside of the service area, the SPLIT variable will be “Y”, and the ZIP Code Routing table will be used to determine the appropriate routing of the call.
5. Hosts/Remotes
The non-emergency call routing system according to the present invention can have host SSPs that service remote terminals. Remote terminals are line termination points that service one or more telephones. The remote terminals, however, are “dumb” terminals with no programming or processing means. Interoffice calls placed from telephones serviced by remote terminals are always routed to a host SSP. The host SSP then processes the call to determine the appropriate routing of the call. Remote terminals are not connected to trunk lines, and cannot route interoffice calls. Interoffice calls placed by a telephone number to another telephone number serviced by a remote terminal are always routed to the host SSP that services the remote terminal, and then from the host SSP to the destination end office.
Calls from telephones serviced by remote terminals to the 311 non-emergency number are processed similar to the way calls are processed for 311 calls to non-AIN SSPs. The call processing of 311 calls from a remote terminal is determined based-on the locations of both the remote terminal, and the host SSP. If both the remote terminal and the host SSP are entirely within the service area, the SPLIT variable will be “N”, and only the SPC Table will be accessed to determine the appropriate routing of the call. If, however, either the remote terminal or the host SSP are outside of the service area, the SPLIT variable will be “Y”, and the ZIP Code Routing table will be used to determine the appropriate routing of the call.
6. Local Service Providers
A subscriber who subscribes to the non-emergency call routing system, provided by a service provider, may desire to provide the non-emergency call routing service to users in an area that has telephone service provided by a telephone service provider (such as a local service provider) that is different from the provider that provides the non-emergency call routing system services. In this case, the local service provider (LSP) may provide service to some portion of the service area where the nonemergency call routing service is provided.
The local service provider may handle the non-emergency call by routing the call from a calling party to a routing telephone number, or the local service provider may route the non-emergency call to an SSP of the non-emergency call routing service provider where a trigger will be generated. If the LSP handles the non-emergency call, the LSP will have a database or some other means for mapping the calling party number to an associated telephone number for routing of the call, defined by the subscriber. If the calling party number does not have an associated call routing number, the LSP will route the call to a default announcement and terminate the call. If the LSP does not choose to handle calls placed to the non-emergency call routing service, all calls received by the LSP that have been placed to the non-emergency telephone number will be routed to an SSP that is part of the system of the service provider providing the non-emergency call routing services. In this case, a trigger will be generated and the call routed like other non-emergency calls received by the system.
7. POTS and Coin Call Dispositions
FIG. 10 shows the call disposition based oh the type of switch, the number dialed, and whether the call is placed from a Plain Old Telephone System (POTS), or from a coin telephone. The left most column lists the types of switches. The two columns to the right of this show whether a coin deposit is required, and whether the coin will be returned after it has been deposited. The next three columns represent the telephone number digits dialed that may initiate a trigger according to the non-emergency calling system of the present invention.
8. Usage Monitoring and Billing
The geographical call routing for a non-emergency calling service system according to the present invention monitors usage of the non-emergency calling service network. A distributed network function (in the SSPs) measures usage of the network and produces Automatic Message Accounting (AMA) records containing usage information. This information is used to obtain a count of completed calls to each 311 subscriber. This allows each subscriber to be billed on a number of completed calls basis. However, this information may be used for other purposes, and/or the subscriber billed based on different criteria related to the service, and still be within the spirit and scope of the present invention.
An AMA record is created in the SSP for each call made to the non-emergency number. The ISCP sends, to each SSP, information informing the SSP whether to create an AMA record for the call, and if so, the appropriate AMA parameters needed for the SSP to create the AMA record. This may include, among other items, a slip id (SLPID), as shown in Table 1 below, that tells the switch type, and the AMA originating number. The SLPID is then made part of the AMA record. An exemplary AMA record is shown in FIG. 11 . The first column in the AMA record shown in FIG. 11 is the title of the information collected. The second column is used to refer to tables that may reside in the ISCP if a table structure is used to collect this information. The third column is the information collected, and the fourth column contains any comments or additional information related to the information in column three. This information may be used for a variety of purposes, such as identifying high usage SSPs, or for billing the subscriber for the service.
TABLE 1
AMA Originating Number
Switch Type
NPA
Number
1AESS & AXE
311
0000000
5ESS
000
3110000
DMS
000
0000311
In accordance with the present invention and as discussed previously, a billing telephone number may be associated with each routing telephone number. For each routing number associated with a SPC of an SSP, there may be an associated billing number. Also, when the SPC indicates SPLIT, for each zip code that has an associated call routing telephone number, an associated billing telephone number may exist. Therefore, when the ISCP receives the SPC and the CPN from the SSP to determine routing of the call, both the routing telephone number and the billing telephone number may be obtained simultaneously.
9. Data and Reports System
The ISCP in the geographical call routing for a non-emergency calling system according to the present invention passes call information to a Data and Reports System (DRS). The DRS stores call information related to calls to the non-emergency calling service system. For example, the DRS may store information related to: an occurrence of an event, the flow of decisions and actions that are made as a call is processed, the time of a call, the date of a call, and the calling party number. This information may be used to generate reports or billing information for the service provider. The information in these reports may also be useful, for example, if a call cannot be routed, or if an error condition arises.
FIG. 12 is a diagram of the AIN geographical call routing for a non-emergency calling service that includes the DRS for recording information related to the handling of the call. Reference step numbers in FIG. 12 that are the same as those in FIG. 4 represent the same activity as in FIG. 4 . FIG. 12 shows additional steps S 20 and S 22 representing the DRS function. As shown in FIG. 12 , whenever a call to the non-emergency number cannot be routed to a routing telephone number, i.e. the call is routed to a default announcement and terminated, information related to the call is gathered and recorded by the DRS in step S 22 . Also, when the call can be routed to a routing telephone number, call related information is recorded by the DRS in step S 20 .
A call disposition will be determined by the ISCP based on the handling of each call to the non-emergency number. The call disposition will be sent to the DRS. Some exemplary call dispositions are shown in Table 2.
TABLE 2
NUM-
BER
DISPOSITION
1
Call routed to the 311 answer point without accessing Zip Code
Table
2
No CPN delivered
3
CPN delivered, but not in Zip Code Table
4
CPN delivered, CPN in Zip Code Table, but an associated Zip
code is not in Zip Code Table
5
Time-out condition
6
Return Error message
7
SCCP routing error
8
SPC not in SPC Table - Call originating from a subscriber that
is not in the customer's defined service area, or error in SPC
Table
9
No RTN in SPC Table
10
No RTN in Zip Code Table - Call originating from a subscriber
that is not in the customer's defined service area, or error
in Zip Code Table
11
Call routed to the RTN answer point after accessing Zip Code
Table
Call disposition 1 occurs after the “Yes” branch of step S 10 . Call disposition 2 occurs after the “No” branch of step S 12 . Call disposition 3 occurs after exiting step S 14 if the CPN is not found in the Zip Code Table. Call disposition 4 occurs after the “No” branch of step S 16 . Call dispositions 5, 6, or 7 may occur after exiting step S 14 . The SCCP is part of the SS7 protocol that provides communication between signaling nodes by adding circuit and routing information to the signaling message. Call disposition 8 occurs after the “No” branch of step S 6 . Call disposition 9 occurs after the “No” branch of step S 10 . Call disposition 10 occurs after the “No” branch of step S 19 . Call disposition 11 occurs after the “Yes” branch of step S 19 .
The disposition of each call will be sent to the DRS and recorded. The recorded dispositions will be monitored by the service provider to identify any problems with the system and for service assurance to subscribers.
10. Interactions with Other AIN Type Services
The service provider may provide the geographical non-emergency call routing service system to a subscriber in area that is serviced by another AIN type service. This AIN type service may be provided by a LSP and consist of, for example, the LSP receiving operator, directory assistance, and local calls on their own network. The LSP may elect to receive some or all of these type calls on the network provided by the non-emergency call routing service system provided by the service provider.
If the LSP elects to receive not to receive local calls, i.e. these calls are processed by the non-emergency call routing service system, calls to the 311 number would generate a trigger, and the calls would be processed and routed by the non-emergency call routing service system as usual, If, however, the LSP elects to receive and process local calls itself, calls to the 311 number would be received by the non-emergency call routing service system and routed to the LSP via the LSP's own network. For this situation, no trigger would be generated, and R is the responsibility of the LSP to properly route the 311 call.
The non-emergency call routing service system according to the present invention also supports Disaster Routing Service. This is an intelligent call forwarding type of service. For example, if a police station had no one available to answer calls to its numbers because of some disaster or other situation, the police station could activate the Disaster Routing Service and then all calls made to the normal telephone number of the police station would be forwarded to another location. A service such as this can be supported for the 311 non-emergency number. If a call is placed to the 311 number, processing occurs as normal, and call routing information is sent back to the SSP. At the SSP, the received RTN would cause another trigger in the SSP, and cause the SSP to forward the call to another number accordingly.
The non-emergency call routing service system according to the present invention also supports Local Number Portability (LNP). This AIN based service, mandated by the FCC, provides the ability of users of telecommunications services to retain, at the same location, existing telephone numbers when switching from one service provider to another. If a call is placed to the 311 number, a trigger would be generated and the call processed normally. After the RTN is sent to the originating SSP, normal LNP service call processing would occur.
It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to a preferred embodiment, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the spirit and scope of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.
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A method for location-based communicating includes identifying a service provider based on information received from a requesting party at a networked communications apparatus. The method also includes determining whether a plurality of predefined service areas have been defined for the identified service provider. When the plurality of the at least one predefined service areas have been defined for the service provider, determinations are made as whether the requesting party is in one of the predefined service areas. When the requesting party is in a predefined service areas, information specified for a service location for the predefined service area is forwarded to the requesting party.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser. No. 13/366,419, filed Feb. 6, 2012, which claims priority to U.S. Provisional Application No. 61/593,083, filed Jan. 31, 2012.
BACKGROUND OF THE INVENTION
[0002] This application relates to a gas turbine engine, wherein the size and number of core inlet stator vanes at an upstream end of a compressor section are positioned to minimize icing concerns.
[0003] Gas turbine engines are known, and typically include a fan delivering air into a compressor section as core flow, and also to a bypass path. The air entering the compressor section typically passes across inlet stator vanes, and towards a compressor rotor. The air is compressed in the compressor section, delivered into a combustion section, mixed with fuel and ignited. Products of this combustion pass downstream over turbine rotors, driving the rotors to rotate, and in turn drive the compressor and fan sections.
[0004] In one traditional type of gas turbine engine, a low pressure turbine drives a low pressure compressor, and a high pressure turbine drives a high pressure compressor. The low pressure turbine typically also drives the fan blade through a low spool. In such engines, the fan blade and low pressure compressor were constrained to rotate at the same speed as the low pressure turbine.
[0005] More recently, it has been proposed to incorporate a gear reduction between the low spool and the fan blade such that the fan blade may rotate at a distinct speed relative to the low pressure turbine. Such engines have a gear reduction typically positioned inwardly of a core engine gas flow.
[0006] One concern with gas turbine engines when utilized on airplanes is that ice may be passed downstream into the core flow. The ice may accumulate on an outer housing, known as a splitter, which defines an outer periphery of the core flow, and on the stator vanes. When the ice builds up, this is undesirable. The problem becomes particularly acute with a geared turbofan, as the core flow tends to be across a smaller cross-sectional area then in the prior systems.
SUMMARY
[0007] In a featured embodiment, a gas turbine engine has a fan, a turbine operatively connected to the fan, an inner core housing having an inner periphery, and a splitter housing having an outer periphery. The inner periphery of the inner core housing and the outer periphery of the splitter housing define a core path. A plurality of inlet stator vanes is located in the core path and each has a leading edge and a trailing edge. The inner periphery of the inner core housing, the outer periphery of the splitter housing and the leading edge of adjacent ones of the plurality of inlet stator vanes define a flow area having a hydraulic diameter. The hydraulic diameter of the flow area is greater than or equal to about 1.5 inches (3.8 centimeters).
[0008] In another embodiment according to the previous embodiment, the hydraulic diameter is greater than or equal to about 1.7 inches (4.3 centimeters).
[0009] In another embodiment according to the previous embodiment, the turbine is a low pressure turbine which also drives a low pressure compressor, and the fan as a low spool.
[0010] In another embodiment according to the previous embodiment, the low spool drives the fan through a gear reduction.
[0011] In another embodiment according to the previous embodiment, the gear reduction is positioned inwardly of the inner core housing.
[0012] In another embodiment according to the previous embodiment, the gear reduction has a gear reduction ratio greater than 2.3.
[0013] In another embodiment according to the previous embodiment, the gear reduction has a gear ratio of greater than 2.5.
[0014] In another embodiment according to the previous embodiment, the fan also delivers air into a bypass duct.
[0015] In another embodiment according to the previous embodiment, a bypass ratio of the amount of air delivered into the bypass duct compared to the amount of air delivered into the core path is greater than about 6.
[0016] In another embodiment according to the previous embodiment, the bypass ratio is greater than 10.
[0017] In another embodiment according to the previous embodiment, the fan has an outer diameter that is larger than an outer diameter of the rotors in the low pressure compressor.
[0018] In another embodiment according to the previous embodiment, the low pressure turbine has a pressure ratio that is greater than about 5:1.
[0019] In another featured embodiment, a gas turbine engine has a fan that delivers air into a core path and into a bypass duct as bypass air. The air in the core path reaches a low pressure compressor, and then a high pressure compressor. The air that is compressed by the high pressure compressor is delivered into a combustion section where it is mixed with fuel and ignited. Products of the combustion pass downstream over a high pressure turbine and then a low pressure turbine. The low pressure turbine drives the low pressure compressor as a low spool. A gear reduction is driven by the low spool to in turn drive the fan at a rate of speed lower than that of the low spool. An inner core housing defines an inner periphery of the core path. A splitter housing defines an outer periphery of the core path. A plurality of inlet stator vanes extend between the splitter and the inner core housing. There is a flow area between adjacent stator vanes, wherein a hydraulic diameter is defined as: Hydraulic diameter=(4×A)/(O+L+I+L), where A is the area between the leading edge of one vane, the leading edge of an adjacent vane, the inner periphery of the splitter, and the outer periphery of the inner core housing. L is the length of the leading edge of each vane. O is the length of the inner periphery of the vanes and I is the length of the outer periphery between adjacent vanes. The hydraulic diameter is greater than or equal to about 1.5 inches (3.8 centimeters).
[0020] In another embodiment according to the previous embodiment, the hydraulic diameter is greater than or equal to about 1.7 inches (4.3 centimeters).
[0021] In another embodiment according to the previous embodiment, the gear reduction is positioned inwardly of the inner core housing.
[0022] In another embodiment according to the previous embodiment, a bypass ratio of the amount of air delivered into the bypass duct compared to the amount of air delivered into the core path is greater than about 6.
[0023] In another embodiment according to the previous embodiment, the bypass ratio is greater than 10.
[0024] In another embodiment according to the previous embodiment, the gear reduction has a gear reduction ratio greater than 2.3.
[0025] In another embodiment according to the previous embodiment, the low pressure turbine has a pressure ratio that is greater than about 5:1.
[0026] In another embodiment according to the previous embodiment, the gear reduction has a gear reduction ratio greater than 2.3.
[0027] In another featured embodiment, a compressor module has a compressor rotor, a plurality of inlet stator vanes adjacent the rotor, a flow area defined between leading edges of two adjacent stator vanes, and an outer boundary and an inner boundary. The hydraulic diameter is greater than or equal to about 1.5 inches (3.8 centimeters).
[0028] In another embodiment according to the previous embodiment, the hydraulic diameter is greater than or equal to about 1.7 inches (4.3 centimeters).
[0029] These and other features may be best understood from the following drawings and specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 shows a gas turbine engine somewhat schematically.
[0031] FIG. 2 is a cross-sectional view through an upstream end of a gas turbine engine.
[0032] FIG. 3 is a forward view of a portion of the FIG. 2 gas turbine engine.
[0033] FIG. 4 is a schematic view.
DETAILED DESCRIPTION
[0034] FIG. 1 schematically illustrates a gas turbine engine 20 . The gas turbine engine 20 is disclosed herein as a two-spool turbofan that generally incorporates a fan section 22 , a compressor section 24 , a combustor section 26 and a turbine section 28 . Alternative engines might include an augmentor section (not shown) among other systems or features. The fan section 22 drives air along a bypass flow path while the compressor section 24 drives air along a core flow path for compression and communication into the combustor section 26 then expansion through the turbine section 28 . Although depicted as a turbofan gas turbine engine in the disclosed non-limiting embodiment, it should be understood that the concepts described herein are not limited to use with turbofans as the teachings may be applied to other types of turbine engines including three-spool architectures.
[0035] The engine 20 generally includes a low speed spool 30 and a high speed spool 32 mounted for rotation about an engine central longitudinal axis A relative to an engine static structure 36 via several bearing systems 38 . It should be understood that various bearing systems 38 at various locations may alternatively or additionally be provided.
[0036] The low speed spool 30 generally includes an inner shaft 40 that interconnects a fan 42 , a low pressure compressor 44 and a low pressure turbine 46 . The inner shaft 40 is connected to the fan 42 through a geared architecture 48 to drive the fan 42 at a lower speed than the low speed spool 30 . The high speed spool 32 includes an outer shaft 50 that interconnects a high pressure compressor 52 and high pressure turbine 54 . A combustor 56 is arranged between the high pressure compressor 52 and the high pressure turbine 54 . A mid-turbine frame 57 of the engine static structure 36 is arranged generally between the high pressure turbine 54 and the low pressure turbine 46 . The mid-turbine frame 57 further supports bearing systems 38 in the turbine section 28 . The inner shaft 40 and the outer shaft 50 are concentric and rotate via bearing systems 38 about the engine central longitudinal axis A which is collinear with their longitudinal axes.
[0037] The core airflow is compressed by the low pressure compressor 44 then the high pressure compressor 52 , mixed and burned with fuel in the combustor 56 , then expanded over the high pressure turbine 54 and low pressure turbine 46 . The mid-turbine frame 57 includes airfoils 59 which are in the core airflow path. The turbines 46 , 54 rotationally drive the respective low speed spool 30 and high speed spool 32 in response to the expansion.
[0038] The engine 20 in one example is a high-bypass geared aircraft engine. In a further example, the engine 20 bypass ratio is greater than about six (6), with an example embodiment being greater than ten (10), the geared architecture 48 is an epicyclic gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3 and the low pressure turbine 46 has a pressure ratio that is greater than about 5. In one disclosed embodiment, the engine 20 bypass ratio is greater than about ten (10:1), the fan diameter is significantly larger than that of the low pressure compressor 44 , and the low pressure turbine 46 has a pressure ratio that is greater than about 5:1. Low pressure turbine 46 pressure ratio is pressure measured prior to inlet of low pressure turbine 46 as related to the pressure at the outlet of the low pressure turbine 46 prior to an exhaust nozzle. The geared architecture 48 may be an epicycle gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.5:1. It should be understood, however, that the above parameters are only exemplary of one embodiment of a geared architecture engine and that the present invention is applicable to other gas turbine engines including direct drive turbofans.
[0039] A significant amount of thrust is provided by the bypass flow B due to the high bypass ratio. The fan section 22 of the engine 20 is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet. The flight condition of 0.8 Mach and 35,000 ft, with the engine at its best fuel consumption—also known as “bucket cruise Thrust Specific Fuel Consumption (‘TSFC’)”—is the industry standard parameter of 1 bm of fuel being burned divided by 1 bf of thrust the engine produces at that minimum point. “Low fan pressure ratio” is the pressure ratio across the fan blade alone, without a Fan Exit Guide Vane (“FEGV”) system. The low fan pressure ratio as disclosed herein according to one non-limiting embodiment is less than about 1.45. “Low corrected fan tip speed” is the actual fan tip speed in ft/sec divided by an industry standard temperature correction of [(Tambient deg R)/518.7)̂0.5]. The “Low corrected fan tip speed” as disclosed herein according to one non-limiting embodiment is less than about 1150 ft/second.
[0040] FIG. 2 shows a portion of the gas turbine engine 20 . In particular, an outer housing, known as a splitter 80 defines an outer periphery for the core flow path C. A row of stator vanes 82 is positioned at a forward end. Air from the fan blade is divided into the bypass flow path B, and into the core flow path C, as mentioned above. The gear reduction 48 is positioned inwardly of an inner housing 83 .
[0041] As shown in FIGS. 3 and 4 , the spacing and number of stator vanes 82 is selected such that the total flow area A between the vanes 82 is selected to reduce the likelihood of icing. As shown, a pair of spaced vanes 82 are circumferentially spaced by area A. The area A is defined by a leading edge L of one vane 82 , a leading edge L of an adjacent vane 82 , the inner periphery O of the splitter 80 , and the outer periphery I of the inner housing 83 . A perimeter is defined by the sum of L, O, L and I. The hydraulic diameter may be defined as 4 times the area A divided by the perimeter. This would be equation 1 as follows:
[0000] Hydraulic diameter=(4 ×A )/( O+L+I+L ) Equation 1
[0042] The hydraulic diameter is desirably greater than or equal to about 1.5 inches (3.8 centimeters). In preferred embodiments, it would be greater than or equal to about 1.7 inches (4.3 centimeters).
[0043] The hydraulic diameter can be calculated for a compressor module in a similar manner by measuring the leading edges and measuring the distances along the outer and inner boundaries of the flow area, even though the module is not mounted in a splitter or outward of an inner housing.
[0044] Of course, FIG. 3 shows a small circumferential segment, and it should be understood that the spacing would typically be equal across the entire circumference.
[0045] Although an embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
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A gas turbine engine is defined wherein the inlet guide vanes leading into a core engine flow path are sized and positioned such that flow paths positioned circumferentially intermediate the vane are sufficiently large that a hydraulic diameter of greater than or equal to about 1.5 is achieved. This will likely reduce the detrimental effect of icing.
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BACKGROUND
[0001] 1. Field
[0002] One or more embodiments described herein relate to compressors.
[0003] 2. Background
[0004] Scroll compressors have been used in air conditioners, refrigerators, and other appliances. In a scroll compressor, two scrolls rotate relative to one another to form a plurality of pressure chambers. As the pressure chambers continuously move in a central direction, suction is created to discharge refrigerant gas. However, in related-art scroll compressors, foam builds up inside the compressor to degrade performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The embodiments will be described in detail with reference to the following drawings, in which like reference numerals refer to like elements:
[0006] FIG. 1 is a diagram showing a sectional view of one type of scroll compressor;
[0007] FIG. 2 is a diagram showing a cut away of the compressor of FIG. 1 ;
[0008] FIG. 3 is a diagram showing a sectional view of another type of scroll compressor;
[0009] FIG. 4 is a diagram showing a cut away of the scroll compressor of FIG. 3 ;
[0010] FIG. 5 is a diagram showing an example of a foam reduction device that may be included in the scroll compressor of FIG. 3 ;
[0011] FIGS. 6 and 7 are diagrams showing sectional views of an interval maintaining member that be included in the foam reduction device of FIG. 5 ;
[0012] FIG. 8 is a diagram showing a sectional view of another embodiment of a foam shut-off plate that may be included in the scroll compressor of FIG. 3 ; and
[0013] FIGS. 9, 10 , and 11 are diagrams showing exemplary installations of a compressor which may include any of the embodiments of the foam reduction device embodied and broadly described herein.
DETAILED DESCRIPTION
[0014] FIG. 1 shows one type of scroll compressor which includes a casing 1 , a main frame 2 , a sub-frame 3 , a motor (M), a shaft 4 , a rotating scroll 5 , a fixing scroll 6 , a high/low pressure partition plate 7 , and a check valve 8 . An airtight internal space of the casing is divided into a suction area (S 1 ) and a discharge area (S 2 ). A gas suction pipe (SP) is installed in the suction area and a gas discharge pipe (DP) is installed in the discharge area.
[0015] The main frame 2 and sub-frame 3 are fixed to upper and lower circumferential surfaces of the casing. The motor is mounted between the main frame and sub-frame and shaft 4 transmits rotational force to the rotor of the motor.
[0016] The rotating scroll is mounted on the main frame and is fastened to the shaft. The fixing scroll has a fixing lap 6 a of a spiral shape fixed to an upper surface of the main frame, such that the fixing lap engages rotating lap 5 a of the rotating scroll to form a plurality of pressure chambers (P). The high/low pressure partition plate 7 is fastened to a rear surface of the fixing scroll to partition an internal space of the casing into the suction area and discharge area. The check valve 8 is connected to a rear surface of a light plate configured in fixing scroll 6 to prevent gas discharged into outlet space (S 2 ) from back flowing.
[0017] The sub-frame 3 is welded to an inner circumferential surface of the casing in a circular plate shape. The sub-frame has a hole 3 a to support a lower portion of the shaft in a radial direction, or to support an oil inlet pipe 4 b inserted in an oil path 4 a of the shaft in a radial direction.
[0018] Also, a plurality of oil through-holes 3 b are formed on the sub-frame in a circular arc shape with respect to oil drawn through oil path 4 a of the shaft. The through-holes drop the oil drawn through oil path 4 a of the shaft to a bottom reservoir of the casing.
[0019] In operation, once power is applied to the motor, shaft 4 rotates with the rotor of the motor to transmit rotational force to the rotating scroll 5 . The rotating scroll rotates to form pressure chambers (P), which continuously move, between rotating lap 5 a and fixing lap 6 a . The pressure chambers are moved to a center by the continuous rotational movement of the rotating scroll to thereby reduce volume and compress refrigerant gas.
[0020] An oil feeder (not shown) or oil suction pipe 4 b may be provided at a lower end of shaft 4 , and the oil remaining in the lower end of the casing is drawn through the oil feeder or oil suction pipe 4 b to lubricate each sliding part before returning to the casing through the oil through-hole 3 b . During that process, the oil feeder or oil suction pipe 4 b may stir the oil within the casing to generate foam.
[0021] FIG. 3 shows another type of scroll compressor, FIG. 4 shows a sub-bearing and foam shut-off plate that may be included in the scroll compressor of FIG. 3 , and FIG. 5 shows an example of a foam reduction device that may be included in the scroll compressor of FIG. 3 .
[0022] As shown in FIGS. 3 to 5 , a scroll compressor having a foam reduction device includes a casing 10 , a motor 20 , a compression part 30 and an oil supply part 40 . The casing is formed airtight to hold a predetermined amount of oil. The motor is mounted within the casing to generate rotational force. The compression part receives the rotational force from the motor to form one or more pressure chambers (P) between two scrolls. And, oil supply part 40 pumps the oil from a reservoir of the casing to supply it to the compression part.
[0023] The airtight internal space of the casing is divided into a suction area (S 1 ) and a discharge area (S 2 ) by a high/low pressure partition plate 34 . A refrigerant suction pipe (SP) is installed in the suction space (S 1 ) and a refrigerant discharge pipe (DP) is installed in the discharge space (S 2 ). Main frame 11 and sub-frame 12 are fixed to opposite sides of the motor mounted within the suction area of the casing.
[0024] The motor includes a stator 21 and a rotor 22 , the latter of which is coupled to a shaft 23 . The stator is fixed within the casing and the rotor is provided within the stator in a predetermined air gap to rotate due to mutual action with the stator. The shaft is fastened to the rotor to transmit rotational force of the motor to the compression part.
[0025] The compression part includes a fixing scroll 31 , a rotating scroll 32 , an Oldham's ring 33 , high/low pressure partition plate 34 , and a check valve 35 . The fixing scroll is fixed to an upper surface of main frame 11 and forms a fixing lap 31 a of a spiral shape on a down surface of its light plate. The rotating scroll is rotatably mounted on an upper surface of the main frame to form a rotating lap 32 a of a spiral shape and the rotating scroll engages the fixing scroll to form a plurality of pressure chambers (P). The Oldham's ring is installed between the rotating scroll and main frame to rotate the rotating scroll, to thereby prevent the rotating scroll from rotating on its own axis. The high/low pressure partition plate 34 is installed on a rear surface of the light plate provided in the fixing scroll 31 . The check valve closes an outlet 31 c of the fixing scroll 31 to prevent the discharged gas from back flowing.
[0026] The oil supply part 40 includes an oil feeder 41 , a foam shut-off plate 42 , and an interval maintenance member 43 . The oil feeder is installed at a low end of the shaft 23 to rotate together with the shaft so that the oil feeder pumps the oil of the casing. The foam shut-off plate is fixed to a side of the sub-frame 12 to shut-off oil of the casing from foamingly rising to the surface of oil. The interval maintenance member 43 is disposed between the sub-frame and foam shut-off plate 42 to vary the height of the foam shut-off plate based on the variation of the oil amount collected within the casing, and/or one or more environmental conditions, and/or a type of oil or refrigerant in the compressor.
[0027] The foam shut-off plate may be formed in a circular shape having a through-hole 42 a through which shaft 23 of the motor passes. Oil through-holes 42 b are formed adjacent through-hole 42 a so that the lubricated oil or the oil drawn/separated through the gas suction pipe (SP) may flow through oil through-holes 42 b . Also, a plurality of fastening holes 42 c , corresponding to fastening recesses 12 b of sub-frame 12 , are formed near oil through-holes 42 b to be fastened by bolts (B).
[0028] As shown in FIG. 4 , the foam shut-off plate may be installed on an upper surface of the sub-frame 12 because the amount of oil can vary, for example, based on the type of oil or kind of refrigerant drawn into the casing or based on environmental changes of an air conditioner having the scroll compressor. Although not shown in the drawings, foam shut-off plate 42 may alternatively be installed on a lower surface of the sub-frame.
[0029] Interval maintenance member 43 may be formed in one piece as shown in FIG. 5 , or may be formed from a plurality of layered metal sheets as shown in FIG. 6 to adjust the height of the foam shut-off plate more precisely. In the latter case, each metal sheet of the interval maintenance member may be separately arranged or formed in a circular shape.
[0030] Further, as shown in FIG. 7 , the interval maintenance member may be an elastic member, e.g., a compression coil spring. If so, fastening protrusions 12 a and 42 d may be formed between and in contact with sub-frame 12 and foam shut-off plate 42 to allow for insertion of the compression coil spring.
[0031] Also, the interval maintenance member may be made of metal to be welded or fixed by a bolt. Alternatively, the interval maintenance member may be made from molded plastic to be fixed to the sub-frame by a bolt. Considering production costs, it may be preferable in some instances to make the interval maintenance member from plastic.
[0032] As shown in FIG. 8 , the appropriate height of the foam shut-off plate may be adjusted and the foam shut-off plate may be fastened to an inner circumferential surface of casing 10 , separate from sub-frame 12 . In this case, the foam shut-off plate may be made of metal so that it can be welded to the casing. Alternatively, an auxiliary fixing member 44 may be welded to the casing and the foam shut-off plate may be made of non-metal material such as plastic to be fastened to fixing member 44 .
[0033] In the case where the foam shut-off plate is assembled to fixing member 44 , interval maintenance member 43 may be formed in one piece (e.g., to have a unitary construction) and a plurality of metal sheets or an elastic member may be provided between the foam shut-off plate and the fixing member. In addition to these features, it is noted that reference numeral 12 a corresponds to a bearing hole, reference numeral 23 a identifies an oil path, and reference numeral 31 b identifies an inlet.
[0034] The scroll compressor described herein may therefore include a foam reduction device which can vary the height of a foam shut-off plate based on the variable amount of oil within a casing according, for example, to surrounding changes of air conditions and/or the type of oil or refrigerant used. Structurally, in accordance with one embodiment, the foam reduction device may include a casing that holds a predetermined amount of oil, a plurality of frames fixed to opposite sides of the casing, a shaft supported by the frame in a radial direction to transmit rotational force of a motor to a rotating scroll such that the rotating scroll is engaged with a fixing scroll to form one or more pressure chambers, and with the shaft suctioning oil to be supplied to sliding parts, and a foam shut-off plate installed on an upper or lower portion one frame installed in a lower half portion of the casing to shut-off foams generated when the shaft rotates.
[0035] Descriptions of scroll compressors and the operation thereof may be found, for example, in U.S. Pat. Nos. 6,695,600, 6,685,441, 6,659,735, and 6,287,099, the contents of which are incorporated herein by reference and which are subject to an obligation of assignment to the same entity.
[0036] Although the embodiments described herein relate to scroll compressors for ease of discussion, it is understood that an oil pump as embodied and broadly described herein may be applied to other types of compressors and/or other applications which require fluid pumping. These other types of compressors include but are not limited to different types of scroll compressors, reciprocating compressors, centrifugal compressors, and vane-type compressors.
[0037] Moreover, a compressor containing the foam reduction device described herein may have numerous applications in which compression of fluids is required. Such applications may include, for example, air conditioning or refrigeration applications. One such exemplary application is shown in FIG. 9 , in which a compressor 710 having an oil pump as described herein is installed in a refrigerator/freezer 700 . The installation and functionality of a compressor when embodied within a refrigerator is discussed in detail in U.S. Pat. Nos. 7,082,776, 6,955,064, 7,114,345, 7,055,338, and 6,772,601, the entirety of which are incorporated herein by reference.
[0038] Another exemplary application is shown in FIG. 10 , in which a compressor 810 having an oil pumping assembly as described herein is installed in an outdoor unit of an air conditioner 800 . The installation and functionality of a compressor when embodied within an outdoor unit of air conditioner is discussed in detail in U.S. Pat. Nos. 7,121,106, 6,868,681, 5,775,120, 6,374,492, 6,962,058, 6,951,628, and 5,947,373, the entirety of which are incorporated herein by reference.
[0039] Another application of the compressor containing an oil pump as described herein relates to an integrated air conditioning unit. As shown in FIG. 11 , this application includes a compressor 910 having an oil pump as described herein is installed in a single, integrated air conditioning unit 900 . The installation and functionality of a compressor when embodied within an outdoor unit of air conditioner is discussed in detail in U.S. Pat. Nos. 7,036,331, 7,032,404, 6,588,228, 6,412,298, 6,182,460, and 5,775,123, the entirety of which are incorporated herein by reference.
[0040] The foam reduction device of the compressor described herein may therefore have one or more of the following advantageous effects.
[0041] First, as shaft 23 rotates by power applied to motor 20 , rotating scroll 32 rotates an eccentric distance. Hence, pressure chambers (P) formed between rotating lap 32 a of rotating scroll 32 and fixing lap 31 a of fixing scroll 31 continuously move. The pressure chambers (P) move to a center position by the continuous rotation of rotating scroll 32 . As a result, the volumes of the pressure chambers (P) are reduced to compress refrigerant gas.
[0042] When shaft 23 sunk into the oil rotates, the oil held in a lower portion of the casing 10 is sucked up along oil path 23 a of the shaft to lubricate one or more moving or sliding parts. Hence, the oil passing through the oil through-holes 42 b is dropped to a bottom (reservoir) of the casing. The shaft, or alternatively an oil feeder or an oil suction pipe, stirs the oil to generate foam. The foam tries to rise up toward compression parts 30 but is stopped from rising by the foam shut-off plate 42 .
[0043] Thus, safety of an oil surface is enhanced and oil is prevented from being sucked into the pressure chambers and being mixed with refrigerant. Also, since the surface of oil remains calm to thereby maintain the amount of oil suction and to prevent alternation with the rotor, the efficiency of the compressor may be enhanced.
[0044] Next, when the scroll compressor is adapted to an air conditioner or other appliance, the surroundings of the air conditioner may be changed or the amount of oil may be changed by the kind of refrigerant or oil. Thus, although the sub-frame is installed in an optimal position to support the shaft, the position of the foam shut-off plate may be adjustable according to the oil suction amount. Thus, there is another advantageous effect of foam shut-off.
[0045] Also, the foam shut-off plate is fixed to the casing, separate from the sub-frame and the foam shut-off plate is installed at an optimal position based on the oil amount of the sub-frame. This results in another advantageous effect of shutting off the foam completely.
[0046] Also, since the foam shut-off plate can be made of various materials, the foam shut-off plate is not difficult to fabricate and production costs can therefore be lowered. Since the elastic member is installed between the foam shut-off plate and the sub-frame, or alternatively the auxiliary fixing member, noise generated by vibration transmitted from foam can be reduced.
[0047] Any reference in this specification to “one embodiment,” “an exemplary,” “example embodiment,” “certain embodiment,” “alternative embodiment,” and the like means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment as broadly described herein. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to affect such feature, structure, or characteristic in connection with other ones of the embodiments.
[0048] Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, numerous variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
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A foam control device includes a first member coupled to an oil reservoir of a compressor and a second member to prevent foam from flowing into an interior section of the compressor. when a shaft of the compressor rotates. The second member controls a position of the first member based on at least one condition which, for example, may include an amount of oil in the reservoir, an environmental condition, or the type of oil or refrigerant used. According to one embodiment, the first member includes a plate containing one or more apertures that allow oil, suctioned from the reservoir, to pass back into the reservoir when the compressor shaft rotates.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation application of International Application No. PCT/JP2008/059281 filed on May 20, 2008, the entire contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to honeycomb structures.
[0004] 2. Discussion of Background
[0005] Conventionally, as a system for converting exhaust gases from automobiles, a SCR (Selective Catalytic Reduction) system in which NOx is reduced to nitrogen and water using ammonia has been known (see below).
[0000] 4NO+4NH 3 +O 2 →4N 2 +6H 2 O
[0000] 6NO 2 +8NH 3 →7N 2 +12H 2 O
[0000] NO+NO 2 +2NH 3 →2N 2 +3H 2 O
[0006] In the SCR system, zeolite is known as a material for absorbing ammonia.
[0007] JP-A-9-103653 discloses a method for converting NOx into innocuous products which involves providing an iron-ZSM-5 monolithic structure zeolite having a silica to alumina mole ratio of at least about 10, wherein the content of the iron is about 1 through 5% by weight, and contacting the zeolite with a NOx-containing process stream in the presence of ammonia at a temperature of at least about 200° C.
[0008] Furthermore, International Publication No. 06/137149 discloses a honeycomb structure having a honeycomb unit that contains inorganic particles, inorganic fibers, and/or whiskers, wherein the inorganic particles include one or more kinds selected from the group consisting of alumina, silica, zirconia, titania, ceria, mullite, and zeolite.
[0009] However, the honeycomb structure, which is obtained by extrusion-molding a material using zeolite ion-exchanged with Fe as a main raw material, is low in strength. When fine zeolite is used, or when inorganic particles other than zeolite and inorganic fibers are added to a material for extrusion molding so as to improve the strength of such a honeycomb structure, the honeycomb structure contains a bunch of fine particles, which in turn causes many grain boundaries and reduced thermal conductivity. Therefore, when such a honeycomb structure is applied to the SCR system in which NOx is reduced to nitrogen and water using ammonia, a temperature difference between the central part and the peripheral part of the honeycomb structure caused when exhaust gas flows becomes large as compared with a cordierite substrate. As a result, a region whose temperature is insufficient for the NOx conversion performance of the zeolite ion-exchanged with Fe is caused in the honeycomb structure, so that the NOx conversion ratio of the honeycomb structure becomes insufficient.
[0010] The contents of JP-A-9-103653 and International Publication No. 06/137149 are incorporated by reference herein.
SUMMARY OF THE INVENTION
[0011] According to an aspect of the present invention, a honeycomb structure includes at least one honeycomb unit having a longitudinal direction and including walls extending along the longitudinal direction to define through-holes. The honeycomb structure includes a center region, a peripheral region, an inorganic binder, zeolite ion-exchanged with at least one of Cu, Mn, Ag, and V, and zeolite ion-exchanged with at least one of Fe, Ti, and Co. The center region has a smaller similarity shape in relation to a peripheral shape of the honeycomb structure in a cross section perpendicular to the longitudinal direction. The smaller similarity shape is defined by including a center of the honeycomb structure and substantially a half of a length from the center to the peripheral shape of the honeycomb structure. The peripheral region is located outside the smaller similarity shape. The zeolite ion-exchanged with at least one of Cu, Mn, Ag, and V is present at a first weight ratio and at a second weight ratio in the center region and in the peripheral region, respectively, relative to a total weight of the zeolite. The second weight ratio is larger than the first weight ratio. The zeolite ion-exchanged with at least one of Fe, Ti, and Co is present at a third weight ratio and at a fourth weight ratio in the center region and in the peripheral region, respectively, relative to a total weight of the zeolite. The third weight ratio is larger than the fourth weight ratio.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] 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:
[0013] FIG. 1A is a perspective view showing an example of a honeycomb structure according to an embodiment of the present invention;
[0014] FIG. 1B is the enlarged view of a cross section orthogonal to the longitudinal direction of the honeycomb structure shown in FIG. 1A ;
[0015] FIG. 1C is a schematic view showing the cross section orthogonal to the longitudinal direction of the honeycomb structure shown in FIG. 1A ;
[0016] FIG. 2A is a schematic view showing other example of the cross section orthogonal to the longitudinal direction of the honeycomb structure according to the embodiment of the present invention;
[0017] FIG. 2B is a schematic view showing still other example of the cross section orthogonal to the longitudinal direction of the honeycomb structure according to the embodiment of the present invention;
[0018] FIG. 3A is a perspective view showing other example of the honeycomb structure according to the embodiment of the present invention;
[0019] FIG. 3B is a perspective view showing a honeycomb unit shown in FIG. 3A ; and
[0020] FIG. 4 is a diagram for explaining a method for measuring a NOx conversion ratio.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0021] Embodiments will now be described with reference to the accompanying drawings, wherein like reference numerals designate corresponding or identical elements throughout the various drawings.
[0022] FIGS. 1A , 1 B, and 1 C show an example of a honeycomb structure according to the embodiment of the present invention. Note that FIGS. 1A , 1 B, and 1 C are a perspective view showing a honeycomb structure 10 , an enlarged view showing a cross section orthogonal to the longitudinal direction of the honeycomb structure 10 , and a schematic view showing the cross section orthogonal to the longitudinal direction of the honeycomb structure 10 , respectively. The honeycomb structure 10 has a single honeycomb unit 11 containing zeolite and an inorganic binder and in which plural through-holes 12 are arranged side by side in the longitudinal direction through partition walls 12 . In addition, a peripheral coating layer 14 is formed on the peripheral surface of the honeycomb unit 11 . Here, the zeolite may include zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V and zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co. In addition, the zeolite may further include zeolite not ion-exchanged and zeolite ion-exchanged with metals other than the above substances. When the honeycomb structure 10 excluding the peripheral coating layer 14 , i.e., the cross section orthogonal to the longitudinal direction of the honeycomb unit 11 is divided into two equal parts at even intervals between the periphery and the center O of the cross section, a region B on the peripheral side is larger than a region A on the central side in the weight ratio of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V relative to the total weight of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V and the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co. Moreover, the region A on the central side is larger than the region B on the peripheral side in the weight ratio of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co relative to the total weight of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V and the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co. Note that a boundary between the region A on the central side and the region B on the peripheral side is represented as a boundary line C.
[0023] Note that the honeycomb structure according to the embodiment of the present invention may have the peripheral coating layer formed at its peripheral surface. The region on the central side and the region on the peripheral side of the honeycomb structure are defined by a region other than the peripheral coating layer when the honeycomb structure has the peripheral coating layer, and they are defined by the honeycomb structure when the honeycomb structure does not have the peripheral coating layer.
[0024] A conventional honeycomb structure, which is obtained by extrusion-molding a material using zeolite ion-exchanged with Fe as a main raw material, tends to be low in strength. When fine zeolite is used, or when inorganic particles other than zeolite and inorganic fibers are added to a material for extrusion molding so as to improve the strength of such a conventional honeycomb structure, the honeycomb structure contains a bunch of fine particles, which in turn easily causes many grain boundaries and reduced thermal conductivity. Therefore, when such a honeycomb structure is applied to the SCR system in which NOx is reduced to nitrogen and water using ammonia, a temperature difference between the central part and the peripheral part of the honeycomb structure caused when exhaust gas flows easily becomes large as compared with a cordierite substrate. As a result, a region whose temperature is insufficient for the NOx conversion performance of the zeolite ion-exchanged with Fe is easily caused in the honeycomb structure, so that the NOx conversion ratio of the honeycomb structure easily becomes insufficient.
[0025] The embodiment of the present invention may provide a honeycomb structure capable of improving a NOx conversion ratio in a wide temperature range in a SCR system.
[0026] The present inventors have found that high NOx conversion performance is obtained in a wide temperature range when the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V is arranged at the peripheral part of the honeycomb structure 10 and the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co is arranged at the central part of the honeycomb structure 10 . This is because the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V has a higher NOx conversion performance in a low temperature range (e.g., between 150° C. and 200° C.) than the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co. Therefore, when the honeycomb structure 10 is applied to a SCR system (in which NOx is reduced to nitrogen and water using ammonia), the zeolite in the honeycomb unit 11 can be easily effectively used for the conversion of NOx, and an NOx conversion ratio can be easily improved in a wide temperature range (e.g., between about 200° C. and about 500° C.).
[0027] Hereinafter, the honeycomb structure 10 is described in detail. The honeycomb unit 11 has the region A on the central side and the region B on the peripheral side via the boundary line C. The boundary line C is the line obtained by connecting the dots generated when line segments connecting the center O and the periphery of the cross section are divided into two equal parts at the cross section orthogonal to the longitudinal direction of the honeycomb unit 11 . Therefore, the boundary line C is similar in shape to the periphery of the honeycomb unit 11 .
[0028] Note that provided that the region B on the peripheral side is larger than the region A on the central side in the weight ratio of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V relative to the total weight of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V and the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, Co, the weight ratio of the zeolite ion-exchanged of the region A on the central side to the region B on the peripheral side may be constant or continuously or discontinuously changed. When this weight ratio of the zeolite ion-exchanged is changed in the region A on the central side, the ratio of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co is preferably larger toward the center O. Furthermore, when this weight ratio of the zeolite ion-exchanged is changed in the region B on the peripheral side, the ratio of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co is preferably larger toward the periphery.
[0029] Note that this weight ratio of the zeolite ion-exchanged of the region A on the central side to the region B on the peripheral side can be obtained from the regions excluding the partition walls intersecting with the boundary line C in the regions A and B. This is because the zeolite may penetrate into the partition walls intersecting with the boundary line C.
[0030] In the region A on the central side, the weight ratio of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co relative to the total weight of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V and the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co is preferably in the range of about 0.80 through about 1.00 and more preferably in the range of about 0.90 through about 1.00. When this weight ratio is about 0.80 or greater, the zeolite in the region A on the central side is easily effectively used for the conversion of NOx.
[0031] In the region B on the peripheral side, the weight ratio of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V relative to the total weight of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V and the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co is preferably in the range of about 0.80 through about 1.00 and more preferably in the range of about 0.90 through about 1.00. When this weight ratio is about 0.80 or greater, the zeolite in the region B on the peripheral side is easily effectively used for the conversion of NOx.
[0032] In the honeycomb unit 11 , the content of zeolite per apparent volume is preferably in the range of about 230 through about 270 g/L. When the content of zeolite per apparent volume of the honeycomb unit 11 is about 230 g/L or greater, it is not necessary to increase the apparent volume of the honeycomb unit 11 so as to obtain a sufficient NOx conversion ratio. When the content of zeolite per apparent volume of the honeycomb unit 11 is about 270 g/L or less, the strength of the honeycomb unit 11 hardly becomes insufficient. Note that the zeolite represents the whole zeolite, i.e., the zeolite ion-exchanged and the zeolite not ion-exchanged.
[0033] Note that the apparent volume of the honeycomb unit represents a volume including the through-holes.
[0034] The ion-exchange amounts of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V and the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co are independently preferably in the range of about 1.0 through about 10.0% by weight and more preferably in the range of about 1.0 through about 5.0% by weight. When the ion-exchange amount is about 1.0% by weight or greater, variation in the adsorption performance of ammonia hardly becomes insufficient. When the ion-exchange amount is about 10.0% by weight or less, the honeycomb unit 11 hardly becomes structurally unstable where it is heated. Note that when the zeolite is ion-exchanged, it is impregnated with an aqueous solution containing a cation.
[0035] The zeolite is not particularly limited, but examples thereof include β zeolite, ZSM5 zeolite, mordenite, faujasite, zeolite A, zeolite L, and the like. Two or more of these substances may be used in combination. Note that the zeolite represents the whole zeolite.
[0036] In addition, the zeolite has a molar ratio of silica to alumina in the range of about 30 through about 50. Note that the zeolite represents the whole zeolite.
[0037] Furthermore, the zeolite preferably contains secondary particles, and the average particle diameter of the secondary particles of the zeolite is preferably in the range of about 0.5 through about 10 μm. When the average particle diameter of the secondary particles of the zeolite is about 0.5 μm or greater, it is not necessary to add a large amount of inorganic binders. As a result, extrusion molding of the honeycomb unit becomes easy. When the average particle diameter of the secondary particles of the zeolite is about 10 μm or less, the specific surface area of the zeolite in the honeycomb unit is hardly reduced. As a result, reduction in a NOx conversion ratio hardly occurs. Note that the zeolite represents the whole zeolite.
[0038] Moreover, in order to improve its strength, the honeycomb unit 11 may further contain inorganic particles other than the zeolite. The inorganic particles other than the zeolite are not particularly limited, but examples thereof include alumina, silica, titania, zirconia, ceria, mullite, precursors thereof, and the like. Two or more of these substances may be used in combination. Among these substances, alumina and zirconia are particularly preferable. Note that the zeolite represents the whole zeolite.
[0039] The average particle diameter of the inorganic particles other than the zeolite is preferably in the range of about 0.5 through about 10 μm. When this average particle diameter is about 0.5 μm or greater, it is not necessary to add a bunch of inorganic binders. As a result, extrusion molding of the honeycomb unit becomes easy. When this average particle diameter is about 10 μm or less, the effect of improving the strength of the honeycomb unit 11 hardly becomes insufficient. Note that the inorganic particles other than the zeolite may contain secondary particles.
[0040] Furthermore, the ratio of the average particle diameter of the secondary particles of inorganic particles other than the zeolite to the average particle diameter of the secondary particles of the zeolite is preferably about 1 or less and more preferably in the range of about 0.1 through about 1. When this ratio about 1 or less, the effect of improving the strength of the honeycomb unit 11 hardly becomes insufficient. Note that the zeolite represents the whole zeolite.
[0041] The content of the inorganic particles other than the zeolite in the honeycomb unit 11 is preferably in the range of about 3 through about 30% by weight and more preferably in the range of about 5 through about 20% by weight. When this content is about 3% by weight or greater, the effect of improving the strength of the honeycomb unit 11 hardly becomes insufficient. When this content is about 30% by weight or less, the content of the zeolite in the honeycomb unit 11 is hardly reduced. As a result, reduction in a NOx conversion ratio hardly occurs.
[0042] The inorganic binder is not particularly limited, but examples thereof include solid contents included in alumina sol, silica sol, titania sol, water glass, sepiolite, attapulgite, and the like. Two or more of these substances may be used in combination.
[0043] The content of the inorganic binder in the honeycomb unit 11 is preferably in the range of about 5 through about 30% by weight and more preferably in the range of about 10 through about 20% by weight. When the content of the inorganic binder is about 5% by weight or greater, the strength of the honeycomb unit 11 is hardly reduced. When the content of the inorganic binder is about 30% by weight or less, the molding of the honeycomb unit 11 hardly becomes difficult.
[0044] In order to improve its strength, the honeycomb unit 11 preferably contains inorganic fibers.
[0045] The inorganic fibers are not particularly limited so long as they are capable of improving the strength of the honeycomb unit 11 , but examples thereof include alumina, silica, silicon carbide, silica alumina, glass, potassium titanate, aluminum borate, and the like. Two or more of these substances may be used in combination.
[0046] The aspect ratio of the inorganic fibers is preferably in the range of about 2 through about 1000, more preferably in the range of about 5 through about 800, and still more preferably in the range of about 10 through about 500. When the aspect ratio of the inorganic fibers is about 2 or greater, the effect of improving the strength of the honeycomb structure 11 is hardly reduced. When the aspect ratio of the inorganic fibers is about 1000 or less, clogging, etc., hardly occurs in a molding die at the molding of the honeycomb structure 11 . In addition, when the honeycomb structure 11 is molded through extrusion molding, the inorganic fibers are broken, which hardly reduces the effect of improving the strength of the honeycomb unit 11 .
[0047] The content of the inorganic fibers in the honeycomb unit 11 is preferably in the range of about 3 through about 50% by weight, more preferably in the range of about 3 through about 30% by weight, and still more preferably in the range of about 5 through about 20% by weight. When the content of the inorganic fibers is about 3% by weight or greater, the effect of improving the strength of the honeycomb unit 11 is hardly reduced. When the content of the inorganic fibers is about 50% or less, the content of the zeolite of the honeycomb unit 11 is hardly reduced. As a result, a NOx conversion ratio is hardly reduced.
[0048] The porosity of the honeycomb unit 11 is preferably in the range of about 25% through about 40%. When the porosity of the honeycomb unit is about 25% or greater, exhaust gases are easily likely to penetrate into the partition walls. As a result, the zeolite in the honeycomb unit 11 may be easily effectively used for the conversion of NOx. When the porosity of the honeycomb unit is about 40% or less, the strength of the honeycomb unit 11 hardly becomes insufficient.
[0049] The opening ratio of the cross section orthogonal to the longitudinal direction of the honeycomb unit 11 is preferably in the range of about 50 through about 65%. When the opening ratio of the honeycomb unit is about 50% or greater, the zeolite in the honeycomb unit 11 may be easily effectively used for the conversion of NOx. When the opening ratio of the honeycomb unit is about 65% or less, the strength of the honeycomb unit 11 hardly becomes insufficient.
[0050] The density of the through-holes 12 of the cross section orthogonal to the longitudinal direction of the honeycomb unit 11 is preferably in the range of about 31 through about 124 pieces/cm 2 . When the density of the through-holes 12 of the honeycomb unit is about 31 pieces/cm 2 or greater, exhaust gases are easily likely to contact the zeolite. As a result, the NOx conversion performance of the honeycomb unit 11 is hardly reduced. When the density of the through-holes 12 of the honeycomb unit is about 124 pieces/cm 2 or less, the pressure loss of the honeycomb unit 11 is hardly increased.
[0051] The thickness of the partition walls partitioning the through-holes 12 of the honeycomb unit 11 is preferably in the range of about 0.10 through about 0.50 mm and more preferably in the range of about 0.15 through about 0.35 mm. When the thickness of the partition walls of the honeycomb unit is about 0.10 mm or greater, the strength of the honeycomb unit 11 is hardly reduced. When the thickness of the partition walls of the honeycomb unit is about 0.50 mm or less, exhaust gases are easily likely to penetrate into the partition walls. As a result, the zeolite is easily effectively used for the conversion of NOx.
[0052] The thickness of the peripheral coating layer 14 is preferably in the range of about 0.1 through about 2 mm. When the thickness of the peripheral coating layer 14 is about 0.1 mm or greater, the effect of improving the strength of the honeycomb structure 10 hardly becomes insufficient. When the thickness of the peripheral coating layer 14 is about 2 mm or less, the content of the zeolite per unit volume of the honeycomb structure 10 is hardly reduced. As a result, the NOx conversion performance of the honeycomb structure 10 is hardly reduced.
[0053] The honeycomb structure 10 is of a cylindrical shape. However, the shape of the honeycomb structure according to the embodiment of the present invention is not particularly limited, and examples thereof include a substantially triangular pillar shape (see FIG. 2A ), a substantially cylindroid shape (see FIG. 2B ), and the like.
[0054] Furthermore, the through-holes 12 are of a quadrangular pillar shape. However, the shape of the through-holes according to the embodiment of the present invention is not particularly limited, and examples thereof include a substantially triangular pillar shape, a substantially hexagonal pillar shape, and the like.
[0055] Next, an example of a method for manufacturing the honeycomb structure 10 is described. First, raw material pastes for the region A on the central side and the region B on the peripheral side, which contain the zeolite and the inorganic binder and further, as occasion demands, the inorganic particles other than the zeolite, the inorganic fibers, and the like, are subjected to double extrusion molding, thereby manufacturing a cylindrical-shaped raw honeycomb molded body in which the plural through-holes are arranged side by side through the partition walls. Accordingly, the cylindrical-shaped honeycomb unit 11 having sufficient strength can be obtained even at low firing temperature. Here, the paste for the region B on the peripheral side is larger than the paste for the region A on the central side in the weight ratio of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V relative to the total weight of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V and the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co.
[0056] Note that the inorganic binder is added to the raw material pastes as alumina sol, silica sol, titania sol, water glass, sepiolite, attapulgite, and the like. Two or more of these substances may be used in combination.
[0057] Furthermore, an organic binder, a dispersion medium, a molding auxiliary agent, and the like may be added to the raw material pastes as occasion demands.
[0058] The organic binder is not particularly limited, but examples thereof include methyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, polyethylene glycol, phenol resin, epoxy resin, and the like. Two or more of these substances may be used in combination. Note that the addition amount of the organic binder is preferably in the range of about 1 through about 10% relative to the total weight of the zeolite, the inorganic particles other than the zeolite, the inorganic fibers, and the inorganic binder. Note that the zeolite represents the whole zeolite.
[0059] The dispersion medium is not particularly limited, but examples thereof include water, organic solvents such as benzene, and alcohols such as methanol, and the like. Two or more of these substances may be used in combination.
[0060] The molding auxiliary agent is not particularly limited, but examples thereof include ethylene glycol, dextrin, fatty acid, fatty acid soap, polyalcohol, and the like. Two or more of these substances may be used in combination.
[0061] When the raw material pastes are prepared, they are preferably mixed and kneaded together. The raw material pastes may be mixed by a mixer, an attritor, and the like, and kneaded by a kneader, and the like.
[0062] Next, the honeycomb molded body thus obtained is dried with a drying apparatus such as a microwave drying apparatus, a hot-air drying apparatus, a dielectric drying apparatus, a pressures reduction drying apparatus, a vacuum drying apparatus, and a freeze drying apparatus.
[0063] Then, the obtained honeycomb molded body is degreased. Degreasing conditions are not particularly limited, but they can appropriately be selected according to the kinds and amounts of the organic matters contained in the molded body. However, the honeycomb molded body is preferably degreased at about 400° C. for about two hours.
[0064] Next, the honeycomb molded body is fired to obtain the cylindrical-shaped honeycomb unit 11 . A firing temperature is preferably in the range of about 600 through about 1200° C. and more preferably in the range of about 600 through about 1000° C. When the firing temperature is about 600° C. or greater, sintering easily progresses. As a result, the strength of the honeycomb unit 11 is hardly reduced. When the firing temperature is about 1200° C. or less, the sintering does not excessively progress. As a result, the reaction sites of the zeolite in the honeycomb unit 11 is hardly reduced.
[0065] Then, the paste for the peripheral coating layer is coated on the peripheral surface of the cylindrical-shaped honeycomb unit 11 . The paste for the peripheral coating layer is not particularly limited, but examples thereof include a mixture of the inorganic binder and the inorganic particles, a mixture of the inorganic binder and the inorganic fibers, a mixture of the inorganic binder, the inorganic particles, and the inorganic fibers, and the like.
[0066] Furthermore, the paste for the peripheral coating layer may contain the organic binder. The organic binder is not particularly limited, but examples thereof include polyvinyl alcohol, methyl cellulose, ethyl cellulose, carboxymethyl cellulose, and the like. Two or more of these substances may be used in combination.
[0067] Next, the honeycomb unit 11 after being coated with the paste for the peripheral coating layer is dried and solidified, thereby obtaining the cylindrical-shaped honeycomb structure 10 . When the organic binder is contained in the paste for the peripheral coating layer, the honeycomb structure 10 is preferably degreased. The degreasing conditions may appropriately be determined according to the kinds and amounts of the organic matters contained in the peripheral coating layer, but the organic structure 10 is preferably degreased at about 700° C. for about 20 minutes.
[0068] FIGS. 3A and 3B show other example of the honeycomb structure according to the embodiment of the present invention. Note that a honeycomb structure 20 is similar to the honeycomb structure 10 except that it has plural of the honeycomb units 11 , in which the plural through-holes 12 are arranged side by side in the longitudinal direction through the partition walls, are bonded together by interposing an adhesive layer 13 .
[0069] The cross section area of the cross section orthogonal to the longitudinal direction of the honeycomb unit 11 is preferably in the range of about 5 through about 50 cm 2 . When the cross section area of the honeycomb unit is about 5 cm 2 or greater, the specific surface area of the honeycomb structure 10 is hardly reduced and the pressure loss thereof is hardly increased. When the cross section area of the honeycomb unit is 50 cm 2 or less, strength for the thermal stress caused in the honeycomb unit 11 hardly becomes insufficient.
[0070] The thickness of the adhesive layer 13 for bonding the honeycomb units 11 together is preferably in the range of about 0.5 through about 2 mm. When the thickness of the adhesive layer 13 is about 0.5 mm or greater, adhesive strength hardly becomes insufficient. On the other hand, when the thickness of the adhesive layer 13 is about 2 mm or less, the specific surface area of the honeycomb structure 10 is hardly reduced and the pressure loss thereof is hardly increased.
[0071] Furthermore, the honeycomb unit 11 is of a quadrangular pillar shape. Here, the shape of the honeycomb unit according to the embodiment of the present invention is not particularly limited, but it is preferably one such as a substantially hexagonal pillar that makes it easy to bond the honeycomb units together.
[0072] Next, an example of a method for manufacturing the honeycomb structure 20 is described. First, the quadrangular-pillar-shaped honeycomb units 11 are manufactured in the same manner as the honeycomb structure 10 . At this time, the manufactured honeycomb units 11 include honeycomb units for the region A on the central side, honeycomb units for the region B on the peripheral side, and honeycomb units for the region including the boundary line C. The honeycomb units 11 for the region including the boundary line C can be manufactured by double extrusion molding using the material pastes for the regions A and B on the central and the peripheral sides. However, in the embodiment of the present invention, the honeycomb units 11 for the region A on the central side and/or the honeycomb units 11 for the region B on the peripheral side may be used for the region including the boundary line C.
[0073] Then, the paste for the adhesive layer is coated on the peripheral surfaces of the honeycomb units 11 , and the honeycomb units 11 are bonded together one by one. The bonded honeycomb units 11 are dried and solidified to manufacture the aggregate of the honeycomb units 11 . At this time, the aggregate of the honeycomb units 11 after being manufactured may be cut into a cylindrical shape and polished. Furthermore, the honeycomb units having a substantially sector-shaped or a substantially square-shaped cross sections may be bonded together to manufacture the aggregate of the cylindrical-shaped honeycomb units 11 .
[0074] The paste for the adhesive layer is not particularly limited, but examples thereof include a mixture of the inorganic binder and the inorganic particles, a mixture of the inorganic binder and the inorganic fibers, a mixture of the inorganic binder, the inorganic particles, and the inorganic fibers, and the like.
[0075] Furthermore, the paste for the adhesive layer may contain an organic binder. The organic binder is not particularly limited, but examples thereof include polyvinyl alcohol, methyl cellulose, ethyl cellulose, carboxymethyl cellulose, and the like. Two or more of these substances may be used in combination.
[0076] Next, the paste for the peripheral coating layer is coated on the peripheral surface of the aggregate of the cylindrical-shaped honeycomb units 11 . The paste for the peripheral coating layer is not particularly limited, but it may contain a material the same as or different from the material of the paste for the adhesive layer. Furthermore, the paste for the peripheral coating layer may have the same composition as the paste for the adhesive layer.
[0077] Then, the aggregate of the honeycomb units 11 on which the paste for the peripheral coating layer is coated is dried and solidified to obtain the cylindrical shaped honeycomb structure 20 . When the organic binder is contained in the paste for the adhesive layer and/or the paste for the peripheral coating layer, the honeycomb structure 20 is preferably degreased. Degreasing conditions are not particularly limited, but they can appropriately be selected according to the kinds and amounts of the organic matters contained in the honeycomb structure 20 . However, the honeycomb structure 20 is preferably degreased for about 20 minutes at about 700° C.
[0078] Note that the honeycomb structures 10 and 20 are manufactured in such a manner that a honeycomb structure using a material paste containing zeolite not ion-exchanged is first manufactured and then an aqueous solution containing a cation is applied in the central part and the peripheral part of the honeycomb structure to exchange the ion of the zeolite.
EXAMPLES
Example 1
[0079] First, 2250 g of β zeolite having an average particle diameter of 2 μm, a silica/alumina ratio of 40, and a specific surface area of 110 m 2 /g, 2600 g of alumina sol as an inorganic-binder-containing component having a solid content of 20% by weight, 550 g of γ-alumina as inorganic particles having an average particle diameter of 2 μm, 780 g of alumina fibers as inorganic fibers having an average fiber diameter of 6 μm and an average fiber length of 100 μm, and 410 g of methyl cellulose as an organic binder were mixed and kneaded together to obtain a raw material paste. Next, the raw material paste was extrusion-molded by an extrusion molding machine to obtain a cylindrical-shaped raw honeycomb molded body. Then, the honeycomb molded body was dried by a microwave drying apparatus and a hot-air drying apparatus and degreased at 400° C. for five hours. Next, the honeycomb molded body was fired at 700° C. for five hours to manufacture a cylindrical-shaped honeycomb unit having a diameter of 143 mm and a length of 150 mm. After that, an iron nitrate aqueous solution and a copper nitrate aqueous solution were applied in the central part and the peripheral part of the honeycomb unit separately several times to exchange the ions of the central part and the peripheral part of the honeycomb unit. The ion-exchange kinds of the zeolite in the region A on the central side and the zeolite in the region B on the peripheral side of the obtained honeycomb unit 11 were Fe and Cu, respectively, and the ion-exchange amount thereof was 3% by weight (see Table 1). Note that the ion-exchange amount was obtained through an IPC emission spectrometry using the ICPS-8100 (manufactured by Shimadzu Corporation). Furthermore, the boundary line C as the boundary between the region A on the central side and the region B on the peripheral side represents the circle positioned 71.5 mm away from the center O on the cross section orthogonal to the longitudinal direction of the honeycomb unit 11 , and the ion-exchange amount was obtained from the partition walls that do not intersect with the boundary line C.
[0080] Furthermore, the obtained honeycomb unit 11 showed an opening ratio of 60%, a through-hole density of 78 pieces/cm 2 , a partition wall thickness of 0.25 mm, a zeolite content of 250 g/L per apparent volume, and a porosity of 30% at the cross section orthogonal to the longitudinal direction.
[0081] Here, the opening ratio was obtained by calculating the areas of the through-holes in the region of a 10 cm square of the honeycomb structure with an optical microscope. Furthermore, the density of the through-holes was obtained by measuring the number of through-holes in the region of the 10 cm square of the honeycomb structure with the optical microscope. Moreover, the partition wall thickness was the average value obtained by measuring the thicknesses of the partition walls (at five areas) of the honeycomb structure with the optical microscope. Furthermore, the porosity was obtained by a mercury penetration method.
[0082] Next, 29 parts by weight of γ alumina as inorganic particles having an average particle diameter of 2 μm, 7 parts by weight of alumina fibers as inorganic fiber having an average fiber diameter of 6 μm and an average fiber length of 100 μm, 34 parts by weight of alumina sol as an inorganic-binder-containing component having a solid content of 20% by weight, 5 parts by weight of methyl cellulose as an organic binder, and 25 parts by weight of water were mixed and kneaded together to obtain a paste for the peripheral coating layer.
[0083] Moreover, the paste for the peripheral coating layer was coated on the peripheral surface of the honeycomb unit 11 so that the thickness of the peripheral coating layer 14 becomes 0.4 mm. After that, the honeycomb unit 11 was dried and solidified at 120° C. and degreased at 400° C. for two hours with a microwave drying apparatus and a hot-air drying apparatus to obtain the cylindrical-shaped honeycomb structure 10 having a diameter of 143.8 mm and a length of 150 mm.
Example 2
[0084] The honeycomb structure 10 was manufactured in the same manner as Example 1 except that the ion-exchange kinds in the region A on the central side and the region B on the peripheral side were changed by the use of an aqueous solution containing iron nitrate and copper nitrate (see Table 1).
Example 3
[0085] The honeycomb structure 10 was manufactured in the same manner as Example 1 except that the ion-exchange kinds in the region A on the central side and the region B on the peripheral side were changed by the use of an aqueous solution containing iron nitrate and silver nitrate (see Table 1).
Example 4
[0086] The honeycomb structure 10 was manufactured in the same manner as Example 1 except that the ion-exchange kinds in the region A on the central side and the region B on the peripheral side were changed by the use of an aqueous solution containing iron nitrate and manganese nitrate (see Table 1).
Example 5
[0087] The honeycomb structure 10 was manufactured in the same manner as Example 1 except that the ion-exchange kinds in the region A on the central side and the region B on the peripheral side were changed by the use of an aqueous solution containing iron nitrate and vanadium nitrate (see Table 1).
Example 6
[0088] The honeycomb structure 10 was manufactured in the same manner as Example 1 except that the ion-exchange kinds in the region A on the central side and the region B on the peripheral side were changed by the use of an aqueous solution containing cobalt nitrate and copper nitrate (see Table 1).
Example 7
[0089] The honeycomb structure 10 was manufactured in the same manner as Example 1 except that the ion-exchange kinds in the region A on the central side and the region B on the peripheral side were changed by the use of an aqueous solution containing titanium nitrate and copper nitrate (see Table 1).
Example 8
[0090] The honeycomb structure 10 was manufactured in the same manner as Example 1 except that the ion-exchange kinds in the region A on the central side and the region B on the peripheral side were changed by the use of an aqueous solution containing iron nitrate and copper nitrate (see Table 1).
Comparative Example 1
[0091] 2250 g of β zeolite ion-exchanged with Fe by 3% by weight having an average particle diameter of 2 μm, a silica/alumina ratio of 40, and a specific surface area of 110 m 2 /g, 2600 g of alumina sol having a solid content of 20% by weight, 550 g of γ-alumina having an average particle diameter of 2 μm, 780 g of alumina fibers having an average fiber diameter of 6 μm and an average fiber length of 100 μm, and 410 g of methyl cellulose were mixed and kneaded together to obtain a raw material paste.
[0092] The honeycomb structure 10 was manufactured in the same manner as Example 1 using the obtained raw material paste except that the honeycomb unit was not ion-exchanged (see Table 1).
Comparative Example 2
[0093] The honeycomb structure 10 was manufactured in the same manner as Comparative Example 1 except that the ion-exchange kind of zeolite was changed from Fe to Cu (see Table 1).
[0000]
TABLE 1
REGION A ON
REGION B ON
NO x CONVERSION
CENTRAL SIDE
PERIPHERAL SIDE
RATIO (%)
ION-EXCHANGE KIND
ION-EXCHANGE KIND
1500 rpm/
3000 rpm/
(WEIGHT RATIO)
(WEIGHT RATIO)
40 N · m
170 N · m
EXAMPLE 1
Fe (100)
Cu(100)
71
95
EXAMPLE 2
Fe/Cu(90/10)
Fe/Cu(10/90)
71
95
EXAMPLE 3
Fe/Ag(90/10)
Fe/Ag(10/90)
72
90
EXAMPLE 4
Fe/Mn(90/10)
Fe/Mn(10/90)
70
90
EXAMPLE 5
Fe/V(90/10)
Fe/V(10/90)
70
92
EXAMPLE 6
Co/Cu(90/10)
Co/Cu(10/90)
70
92
EXAMPLE 7
Ti/Cu(90/10)
Ti/Cu(10/90)
70
90
EXAMPLE 8
Fe/Cu(80/20)
Fe/Cu(20/80)
69
92
COMPARATIVE
Fe(100)
Fe(100)
46
97
EXAMPLE 1
COMPARATIVE
Cu(100)
Cu(100)
72
85
EXAMPLE 2
Note that A/B (X/Y) of the ion-exchange kind (weight ratio) in the table represents that the weight ratio of A to B is X/Y.
[0094] (Measurement of NOx Conversion Ratio)
[0095] As shown in FIG. 4 , a diesel engine (1.6 L direct-injection engine) 100 was operated under conditions that it had a rotation number of 1500 rpm and a torque of 40 N·m or a rotation number of 3000 rpm and a torque of 170 N·m while being connected in series to a diesel oxidation catalyst (DOC) 200 , a diesel particulate filter (DPF) 300 , a SCR 400 , and a diesel oxidation catalyst (DOC) 500 via exhaust pipes. Urea water was injected to the exhaust pipe right before the SCR 400 . At this time, the inflow and outflow amounts of nitrogen monoxide (NO) and nitrogen dioxide (NO 2 ) to and from the SCR 400 were measured by the MEXA-7500DEGR (manufactured by HORIBA, Ltd.), and the NOx conversion ratio (%) represented by the formula “(NOx inflow amount−NOx outflow amount)/(NOx inflow amount)×100” was measured (detection limit: 0.1 ppm). Note that as the DOC 200 , the DPC 300 , the SCR 400 , and the DOC 500 , a honeycomb structure having a diameter of 143.8 mm and a length of 7.35 mm (commercialized product), a honeycomb structure having a diameter of 143.8 mm and a length of 152.4 mm (commercialized product), the honeycomb structures described in Examples 1 through 8 or Comparative Example 1 and 2, and a honeycomb structure having a diameter of 143.8 mm and a length of 50.8 mm (commercialized product), each of which is accommodated in a metal container (shell) and has a holding sealing member (mat) at its periphery, are used, respectively. Measurement results are shown in Table 1. It is clear from Table 1 that the honeycomb structures shown in Examples 1 through 8 are superior to the honeycomb structures shown in Comparative Examples 1 and 2 in a NOx conversion ratio in a wide temperature range.
[0096] As described above, the NOx conversion ratio of the honeycomb structure 10 can be improved in a wide temperature range, provided that, when the cross section orthogonal to the longitudinal direction of the honeycomb structure 10 is divided into two equal parts at even intervals between the periphery and the center O of the cross section, the region B on the peripheral side is larger than the region A on the central side in the weight ratio of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V relative to the total weight of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V and the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co, and the region A on the central side is larger than the region B on the peripheral side in the weight ratio of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co relative to the total weight of the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Cu, Mn, Ag, and V and the zeolite ion-exchanged with one or more kinds of metal selected from the group consisting of Fe, Ti, and Co.
[0097] The present invention is not limited to the specifically disclosed embodiment, but variations and modifications may be made without departing from the scope of the present invention.
[0098] Obviously, numerous 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 herein.
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A honeycomb structure includes center and peripheral regions. The center region has a smaller similarity shape in relation to a peripheral shape of the honeycomb structure in a cross section perpendicular to the longitudinal direction. The peripheral region is located outside the smaller similarity shape. Zeolite ion-exchanged with at least one of Cu, Mn, Ag, and V is present at a first weight ratio and a second weight ratio in the center region and the peripheral region, respectively, relative to a total weight of the zeolite. The second weight ratio is larger than the first weight ratio. Zeolite ion-exchanged with at least one of Fe, Ti, and Co is present at a third weight ratio and a fourth weight ratio in the center region and the peripheral region, respectively, relative to a total weight of the zeolite. The third weight ratio is larger than the fourth weight ratio.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from U.S. Provisional Application 60/989,405, filed Nov. 20, 2007; U.S. Provisional Application No. 61/058,876 filed Jun. 4, 2008, and U.S. Provisional Application No. 61/080,110, filed Jul. 11, 2008, the contents of which are incorporated hereby reference.
FIELD OF THE INVENTION
[0002] The embodiments of the present invention in one aspect relates to removal of selected gases from air. The embodiments of the invention have particular utility for the extraction of carbon dioxide (CO 2 ) from air and will be described in connection with such utilities, although other utilities are contemplated, including the sequestration of other gases including NO x and SO 2 .
BACKGROUND OF THE INVENTION
[0003] There is compelling evidence to suggest that there is a strong correlation between the sharply increasing levels of atmospheric CO 2 with a commensurate increase in global surface temperatures. This effect is commonly known as Global Warming. Of the various sources of the CO 2 emissions, there are a vast number of small, widely distributed emitters that are impractical to mitigate at the source. Additionally, large scale emitters such as hydrocarbon-fueled power plants are not fully protected from exhausting CO 2 into the atmosphere. Combined, these major sources, as well as others, have lead to the creation of a sharply increasing rate of atmospheric CO 2 concentration. Until all emitters are corrected at their source, other technologies are required to capture the increasing, albeit relatively low, background levels of atmospheric CO 2 . Efforts are underway to augment existing emissions reducing technologies as well as the development of new and novel techniques for the direct capture of ambient CO 2 . These efforts require methodologies to manage the resulting concentrated waste streams of CO 2 in such a manner as to prevent its reintroduction to the atmosphere.
[0004] The production of CO 2 occurs in a variety of industrial applications such as the generation of electricity power plants from coal and in the use of hydrocarbons that are typically the main components of fuels that are combusted in combustion devices, such as engines. Exhaust gas discharged from such combustion devices contains CO 2 gas, which at present is simply released to the atmosphere. However, as greenhouse gas concerns mount, CO 2 emissions from all sources will have to be curtailed. For mobile sources the best option is likely to be the collection of CO 2 directly from the air rather than from the mobile combustion device in a car or an airplane. The advantage of removing CO 2 from air is that it eliminates the need for storing CO 2 on the mobile device.
[0005] Extracting carbon dioxide (CO 2 ) from ambient air would make it possible to use carbon-based fuels and deal with the associated greenhouse gas emissions after the fact. Since CO 2 is neither poisonous nor harmful in parts per million quantities, but creates environmental problems simply by accumulating in the atmosphere, it is possible to remove CO 2 from air in order to compensate for equally sized emissions elsewhere and at different times.
[0006] Various methods and apparatus have been developed for removing CO 2 from air. In one prior art method, air is washed with a sorbent such as an alkaline solution in tanks filled with what are referred to as Raschig rings that maximize the mixing of the gas and liquid. The CO 2 interacts with and is captured by the sorbent. For the elimination of small amounts of CO 2 , gel absorbers also have been used. Although these methods are effective in removing CO 2 , they have a serious disadvantage in that for them to efficiently remove carbon dioxide from the air; the air must be driven past the sorbent at fairly high pressures.
[0007] The most daunting challenge for any technology to scrub significant amounts of low concentration CO 2 from the air involves processing vast amounts of air and concentrating the CO 2 with an energy consumption less than that that originally generated the CO 2 . Relatively high pressure losses occur during the scrubbing process resulting in a large expense of energy necessary to compress the air. This additional energy used in compressing the air can have an unfavorable effect with regard to the overall carbon dioxide balance of the process, as the energy required for increasing the air pressure may produce its own CO 2 that may exceed the amount captured negating the value of the process.
[0008] Prior art methods result in the inefficient capture of CO 2 from air because these prior art methods heat or cool the air, or change the pressure of the air by substantial amounts. As a result, the net reduction in CO 2 is negligible as the capture process may introduce CO 2 into the atmosphere as a byproduct of the generation of electricity used to power the process.
[0009] In co-pending U.S. application Ser. No. 11/683,824, filed Mar. 8, 2007, U.S. Publication No. U.S.-2007-0217982-A1, assigned to a common assignee, there is described an air capture device that utilizes a solid functionalized anion exchange material that is formed to provide a relatively large surface area which allows for air flow. The solid anion exchange material may be formed from membranes of anion exchange material such as functionalized polystyrene or the like, or comprise membranes of inert substrate material coated with anion exchange material. In a preferred embodiment of our prior invention, the anion exchange material comprises “noodle-like” 1 mm thick by 1 mm wide strands formed by slitting commercially available anion exchange membrane material available from Snowpure, LLC, San Clemente, Calif. The manufacturer describes this membrane material as comprising crushed anionic exchange resin mixed in a polypropylene matrix and extruded as a membrane according to the teachings of U.S. Pat. Nos. 6,503,957 and 6,716,888. The solid anion exchange polymer also maybe formed into cells or the like.
SUMMARY OF THE INVENTION
[0010] The present invention explores alternative solid ion exchange materials for currently utilized ion exchange materials as above described as solid sorbent materials for CO 2 air-capture. More particularly, there is provided a process for forming solid sorbent materials for CO 2 air capture by immobilizing solid CO 2 sorbent materials in or on a support. In a preferred embodiment of the invention the solid CO 2 sorbent materials comprise solid particulate sorbent materials held together in a porous matrix. Alternatively, the solid CO 2 sorbent materials may comprise solid particulate sorbent materials supported on a surface of a support matrix. The support matrix may take a form of a membrane, which may be cut or slit into elongate elements, fiber strands which may be ordered or unordered, various geometric shapes such as tubes or bundles of tubes, honeycombs, discs or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Further features and advantages of the present invention will be seen from the following detailed description taken in conjunction with the accompanying drawings, wherein like numerals depict like parts, and wherein:
[0012] FIG. 1 is a three-dimensional depiction of a polymer matrix of the prior art Snowpure membrane showing resin beads interspersed throughout the matrix.
[0013] FIG. 2 is a schematic depiction of the CO 2 /H 2 O vapor measurement device apparatus used in this investigation.
[0014] FIG. 3 shows the PSU-resin membrane before gelling.
[0015] FIG. 4 shows the PSU-resin membrane after the final membrane formation.
[0016] FIG. 5 is a graph showing the CO 2 adsorption capacity or desorption kinetics of a 0.78 gram sample of a PSU-resin composite membrane. Adsorption capacity of a sample in the chamber can be estimated from the area between the horizontal dashed line representing the atmospheric concentration of CO 2 (˜400 ppm), and the adsorption curve, which shows the amount of CO 2 being adsorbed by the membranes as the 400 ppm CO 2 air goes through the chamber.
[0017] FIG. 6 is another graph of CO 2 versus time showing a CO 2 adsorption of the reference membrane Snowpure, 1.13 g.
[0018] FIG. 7 is a graph of CO 2 versus time showing the CO 2 adsorption capacity of two membranes, the Snowpure 1.13 g reference membrane, and a PSU PVP 1.03 g membrane.
[0019] FIG. 8 is a graph of CO 2 versus time showing the CO 2 adsorption capacity of two membranes, the same Snowpure reference membrane plotted with a PVDF-HFP 0.88 g membrane.
[0020] FIG. 9 is a graph of CO 2 versus time showing the CO 2 desorption pattern that occurs when air saturated with water vapor is purged through the chamber.
[0021] FIG. 10 is a graph of CO 2 versus time showing the VBC/styrene ratio equal to one as air is purged through it to dry the membrane.
[0022] FIG. 11 is a graph of CO 2 versus time for the membrane and VBC\styrene equal to one with a water vapor purge through the chamber.
[0023] FIG. 12 is a graph of CO 2 versus time for the VBC/styrene ratio equal to one air purge of the membrane in the chamber.
[0024] FIG. 13 is a graph of CO 2 versus time showing the behavior of the sample VBC/styrene ratio equal to two when air is purged through the chamber containing the sample membrane.
[0025] FIG. 14 is a graph of CO 2 versus time for the VBC/styrene ratio equal to two sample membrane with a high humidity air purge.
[0026] FIG. 15 is a graph of CO 2 versus time for her the membranes and VBC only, 2.7 g, and the snow pure 2.9 Graeme membrane.
[0027] FIG. 16 is a graph of CO 2 concentration versus time for the sample polyester/cotton thread VBC only, 2.0 g, with a dry air purge.
DETAILED DESCRIPTION OF THE INVENTION
[0028] In order to develop alternative methods for forming solid CO 2 sorbent materials we first needed to better understand the structure of the currently utilized commercially available materials and the reasons why such materials are capable of absorbing CO 2 . As best understood from the aforesaid U.S. Pat. Nos. 6,503,957 and 6,716,888, the Snowpure materials are made by a thermal extrusion method using polypropylene as the support matrix and ground anion exchange resin powder as an active filler. The polypropylene polymer is hydrophobic so it can afford physical support and not be soluble in aqueous solutions. The polypropylene polymer matrix has a narrow molecular weight distribution and low melting point (125˜130° C., although usually polypropylene melts at around 160° C.). The low melting temperature helps avoid thermal decomposition of the resin powders during the extrusion process. Also the polypropylene matrix is stable under chemical conditions such as high basicity or acidity.
[0029] According to the aforesaid U.S. patents of Snowpure, in the manufacturing process described by Snowpure, the polypropylene is melted in an extruder, and the resin powders are added into the melted polymer together with glycerin. The resin particles are hydrophilic and have exchangeable ions when wet. Glycerin is believed to help disperse the resin particles in the polymer matrix and form a barrier layer between resin and polymer. After extrusion, the membrane is soaked in an 80° C. water bath to remove the glycerin and to fully expand the resin. The structure is called a “composite” membrane because it consists of two phases, the polypropylene polymer matrix and the agglomeration of resin powders which it is believed forms continuous channels in the polymer. FIG. 1 is a simplified representation of the basic structure of the material obtained from Snowpure, except that the volume fill of the resin is much larger than depicted below.
[0030] The continuous channel shown by the continuous resin beads is believed to be important for membrane function in the Snowpure material. If the resin agglomerations are discontinuous or separated from each other and surrounded by polymer, the final membrane would be hydrophobic and would not be able to conduct ions in water or adsorb CO 2 at all.
[0031] The following examples describe alternative methods for forming solid sorbent materials for CO 2 air capture:
[0032] A first method of fabrication is based on solvent casting techniques.
[0033] This process starts with a polymerizable monomer or polymer in a liquid carrier having dispersed therein particles of a solid CO 2 sorbent material. There are two major properties for the polymerizable monomers used in this method. First, the polymerizable monomer or monomer blend or polymer should be soluble in the liquid carrier; second, the polymerizable monomer or monomer blend or polymer should be able to form a polymer sheet or film. Amongst preferred polymers are mentioned polybisphenol-A-carbonate, poly(ethylene terephthalate), polystyrene, poly(methyl methacrylate), poly(vinyl acetate), poly(vinyl chloride), polytetrafluoroethylene, polysulfone, poly(vinylidene fluoride), styrene/butyl acrylate/methacrylic acid terpolymer, and poly(vinylidene fluoride-co-hexafluoropropylene).
[0034] The solid CO 2 sorbent materials are materials capable of absorbing and releasing gaseous CO 2 under controlled conditions. The solid CO 2 sorbent materials may comprise solid ion exchange resins such as described in U.S. Pat. Nos. 6,503,957 and 6,716,888, as well as solid CO 2 sorbents or “getters” such as strong base Type 1 and Type 2 functionality ion exchange materials as are available commercially from a variety of vendors including Dow, Dupont and Rohm and Haas.
[0035] A mixture of the polymerizable monomer or monomer blend or polymer and the solid CO 2 sorbent material is mixed with the solid sorbent materials and liquid carrier, and applied in a solvent casting method. The monomer or monomer blend or polymer is dissolved and the solid CO 2 sorbent materials particles are homogeneously dispersed in the liquid carrier. When the mixture is poured on a flat surface, e.g., a stainless steel block on a hot plate, and the liquid carrier evaporated, a sheet or film having the particles dispersed throughout is left on the surface. However in this method the structure of the sheet is determined by the interactions among the liquid carrier, the monomer or monomer blend and the particles.
[0036] In one experiment we made a sheet by mixing poly(vinylidene fluoride) and resin particles in dimethylformamid (DMF). The ion-exchange resin is ground or chopped to particle size of 100 to 1000 microns, preferably 200 to 500 microns. The resin particles should comprise 10 to 90 volume percent of the cast film, preferably 20 to 80 volume percent. The finished sheet preferably has a thickness of 0.1 to 2.0 mm, preferably 0.2 to 1.0 mm. Experiments showed that without glycerin addition the sheet with even 50% resin content is still hydrophobic, which indicates the particle agglomerations are separated by polymer. When glycerin or phenolphthalene is added into the monomer, filler and liquid carrier mixture, the sheets formed are hydrophilic and ion-conductive. FIG. 2 is an CO 2 absorption curve of both membranes under similar conditions.
[0037] A second method of fabrication of polymer membranes is the phase inversion/immersion precipitation method. Phase inversion methods are described generally in U.S. Pat. Nos. 3,876,738, 4,340,480, 4,770,777, and 5,215,662, all of which are incorporated herein by reference. Generally, the process is to immerse a polymer solution made by a polymer dissolved in a solvent or mixture of solvents into a miscible non-solvent such as water (i.e., a liquid in which the polymer is not soluble, but the non-solvent is miscible with the solvent). In a non-solvent such as a water bath, the polymer starts to solidify because of the penetration of water molecules whereas the solvent component diffuses into the water, leaving spaces throughout the polymer where the solvent formerly was. Thus the formed membrane is asymmetric. The surface of the membrane has a relatively dense gel surface, while the bulk interior of the membrane is relatively porous. Spaces formed by this method are interconnecting, however. The phase inversion technique has been established for about twenty years. Reverse osmosis and nanofiltration membranes are also made using this technique. It is also applied in hollow fiber membranes for pervaporation separation of ethanol/water solutions or gas separations. In our application the porous structure enables the easy access of air to the resins embedded in the polymer matrix.
[0038] A third method of fabrication of polymer membranes is the sorption method in which a mixture of liquid monomers and initiators are absorbed in a woven or non-woven fiber matrix of polypropylene, PVC, polyester, cellulose etc. The monomers polymerize under thermal or radiation conditions forming a thin layer on the matrix surface. Mizutani, Y., Journal of Membrane Science, 1990, 49, 121-144 reported the preparation of an ion exchange membrane using the paste method, in which the paste, consisting of monomers and finely powdered PVC was coated onto PVC cloth and the cloth was exposed to heat. Later Choi et. al. published papers describing the making of ion exchange membranes by the sorption method, in which monomers were absorbed in non-porous reinforcing materials such as polypropylene, or PVC films. Choi, Y., et al., Desalination, 2002, 146, 287-291; Choi, Y. et al., Journal of Membrane Science, 2003, 221, 219-231; Choi, Y., et al., Journal of Membrane Science, 2003, 223, 201-215. The non-porous reinforcing material was swollen while monomers were absorbed in non-porous reinforcing materials. The swollen reinforcing material permitted enlarged free volume for the adsorbed monomers. The membrane was treated with UV radiation for monomer polymerization (anion exchange membranes). In our experiments solutions of monomers such as vinylbenzyl chloride, styrene, divinylbenzene and the initiator benzoyl peroxide were absorbed into non porous or porous fabrics such as filter paper, polyester/cellulose paper, cloth etc, or porous film such as porous alumina, polycarbonate etc. through capillary action. The solution-saturated fabrics were then exposed to heat or radiation to polymerize the monomers. The resulting membranes in carbonate form showed moisture swing effects in absorbing CO 2 from the atmosphere.
Materials and Methods.
[0039] The following protocols or material preparation processes recur throughout the Examples, and so they are presented here for purposes of streamlining the disclosure of the various embodiments.
[0040] 1) Amination protocol. Synthetic membranes were soaked in a 40% aqueous solution of trimethylamine for 10 hours at 50° C. They were then rinsed with tap water, and placed twice in 100 ml 0.1M HCl solution to neutralize any residual unbound trimethylamine. At this point the counterion on the membrane is chloride, and the chloride was exchanged with carbonate via the carbonation process (see below).
[0041] Carbonation protocol. Samples in the chloride form are exchanged with carbonate counterion by immersing them in 0.5 M Na 2 CO 3 with stirring for 30 minutes twice at room temperature, and then rinsing with DI water until neutral.
[0042] Polymer loading capacity. A supporting matrix should be chemically and mechanically stable through all polymerization and derivatization processes and should be loaded with the highest amount of coated polymers. We define “loading capacity of a matrix” as (weight of net polymers coated on matrix)/(weight of net matrix).
[0043] Ion exchange capacity measurement process. Sample membranes made hereunder had their Ion Exchange Capacity (“IEC”) measured to test their efficiency of CO 2 adsorption. IEC is defined as the total amount of ion groups per unit mass of dry material (mmol/g). The higher the IEC number the higher the corresponding CO 2 absorption capacity. Generally, samples were heated in an oven at about 60° C. until dry (no more weight loss). About 1.0 g of dried sample was weighed and soaked in 20 ml 0.5M NaNO 3 solution for 30 minutes with stirring. The sample was filtered and soaked in another fresh 20 ml 0.5M NaNO 3 solution for another 30 min. with stirring. All filtered solutions were collected and were titrated to pH 7 with 0.1M standard HCl solution. The total ionic numbers could be deduced from the titration results and IEC could be calculated as a ratio: total ionic number (mmols)/dried sample weight (grams).
[0044] CO 2 /H 2 O measurement process. FIG. 2 is a schematic of the CO 2 /H 2 O vapor measurement device used in this investigation. In order to compare samples created hereunder against the Snowpure® standard material accurately in terms of their CO 2 adsorption ability, the same or similar weight of samples or Snowpure® were sealed in a container (glass jar, 0.25 liter) with two vents. In order to dry or hydrate the membranes, air (absolute humidity ˜5 ppt) or air saturated with moisture vapor (absolute humidity ˜30 ppt) was pumped into and through the container at a fixed flow rate (usually 0.1 L/min) at 75° F. and was passed through the glass jar containing the sample material. The exiting air is then directed through an IRGA (IR Gas Analyzer, Model LI-840, LI-COR, Inc.), which detects CO 2 and H 2 O vapor content at selected intervals, usually every 10 seconds. The air is then vented to atmosphere.
[0045] Phase inversion method. Materials: DMF (dimethyl formamide) solvent (95%); PSU (polysulfone) pellets (Aldrich, P/N 428302, Mw˜35,000); PVDF powder (poly(vinylidene fluoride), Aldrich, P/N 182702, Mw˜534,000); PVP (Polyvinylpyrrolidone, Sigma-Aldrich, Mw˜10,000); PVDF-HFP (poly(vinylidene fluoride-co-hexafluoropropylene) and Dowex® Marathon A anion exchange resin C1 form (SigmaAldrich, P/N 433942). Resin beads were ball milled to 40˜100 microns at room temperature before use. Polymer matrix materials that may be used herein include but are not limited to polybisphenol-A-carbonate, poly(ethylene terephthalate), polystyrene, poly(methyl methacrylate), poly(vinyl acetate), poly(vinyl chloride), polytetrafluoroethylene, polysulfone, polyether sulfone, poly(vinylidene fluoride), styrene/butyl acrylate/methacrylic acid terpolymer, and poly(vinylidene fluoride-co-hexafluoropropylene). Preferred organic solvents for the polymers may be selected from dimethylformamide or tetrahydrofuran, or N-methylpyrrolidone (NMP). Glycerin, polyvinyl pyrolidone (PVP), dibutylphthalate (DBP), phenolphthalene or other plasticizers may be added to the mixture. For the phase inversion procedure, the aqueous-based solution may be water or methanol, ethanol, isopropanol or mixtures thereof. The resin particles used in the composite membranes may vary in diameter from 10˜100 micrometer and the resin content may vary from 20˜80% of polymer matrix by weight, preferably 30˜60%. The final heterogeneous membrane thickness may vary from 0.1˜1.0 mm, preferably 0.5 mm.
EXAMPLE I
Phase Immersion of PSU-Resin Membrane
[0046] PSU-resin membrane: 0.5 g of PSU pellets were weighed in a 20 ml vial, 2.5 ml of DMF was added into the vial and the mixture was stirred until the polymer dissolved in the DMF. In another vial 0.5 g of ground ion-exchange resin powders were weighed and 2.0 ml of DMF was added. The mixture was stirred until homogeneous. The two vial contents were combined and stirred for another half hour. The mixture was cast on a rectangular 6×4 inch stainless steel block surface on a hot plate maintained at 50° C. In about 10 minutes the membrane completely gelled (the membrane looked transparent at this time and there was no liquid solvent on the surface). The block was removed from the hot plate, allowed to cool to room temperature and then soaked in a deionized water bath (2 liters). After several minutes, the membrane was peeled from the block. The membrane was left in the water bath with stirring for two days (the water in the bath was changed after one day) and boiled in hot water for 1 hour to get rid of any residual solvent inside the membrane. The membranes are then carbonated by the general carbonation protocol.
[0047] FIGS. 3 and 4 show the PSU-resin membrane before gelling and after the final membrane formation, respectively. The IRGA measures the air that has contacted the membrane, and thus reflects the membrane's CO 2 adsorption capacity in real time. Snowpure® membranes are used as the standard CO 2 absorbent material against which the inventive membranes described herein are compared against.
Results:
[0048] With respect to FIG. 5 and FIG. 6 , the CO 2 adsorption capacity of a given membrane in the chamber can be estimated from the area between the horizontal dashed line representing the atmospheric concentration of CO 2 (˜400 ppm), and the adsorption curves, which show the amount of CO 2 being adsorbed by the membranes as the 400 ppm CO 2 air goes through the chamber. Simply, we can cut the areas and measure paper weight. The ratio of paper weights between the membranes being compared is directly proportional to CO 2 capacity if the sample weights are similar. This is also known as the integral of the area under the 400 ppm curve and above the CO 2 adsorption curve.
[0049] From FIGS. 5 and 6 , the CO2 capacity of the PSU membrane is smaller than that of the Snowpure sample (absorption area per unit weight of PSU is smaller than that of Snowpure). Theoretically with the same amount of resin the membranes should absorb the same quantity of CO 2 . One possible reason for the lower CO 2 absorption by the PVDF- and the PSU-resin-CO 3 membranes compared to the Snowpure® membranes is that the resin particles are more tightly surrounded by polypropylene polymer. One way to resolve this is to make the membranes more porous. In the following experiment we added PVP (polyvinylpyrrolidone) into the mixture before casting. PVP is soluble in both polar aprotic solvent and water. After the membrane is cast and later soaked in water, the PVP mixed with the water and left pores inside the membrane.
EXAMPLE II
Phase Inversion Aided by PVP
[0050] Membrane (PSUPVP) preparation: 0.5 g of PSU was weighed in a 20 ml vial and 2.5 ml DMF was added and the mixture stirred until all polymers were dissolved. 0.5 g of resin and 0.2 g of PVP was weighed in another vial and 2.5 ml DMF was added. The mixture was stirred until homogeneous. The two vial contents were combined and stirred for another 0.5 hour at room temperature. The mixture was cast on the same rectangular stainless steel block surface, 6×4 inches on a hot plate at 50° C. After about 10 minutes, the membrane completely gelled (the whole membrane appears transparent at this time and there was no flowing solvent on the surface). The block was removed from the hot plate, allowed to cool to room temperature, and then soaked in a deionized water bath. After several minutes, the membrane was peeled from the block. The membrane then was left in the water bath with stirring for two days (the water in bath was changed after one day) and boiled in hot water for 1 hour to eliminate the solvent and any PVP inside the membrane. The membrane was then carbonated according to the standard protocol.
Results:
[0051] From FIG. 7 the CO2 adsorption capacity of PSUPVP membrane is much bigger than that of the PSU membrane in Experiment I, which indicates that the addition of PVP increases membrane porosity. The IEC value is 1.90 mmol/g. A comparison was made of the CO 2 adsorption for this PSUPVP membrane to the membrane material from Snowpure® ( FIG. 7 ) which also has an IEC value of 1.9. Numerical estimates of the CO 2 uptake for the Snowpure material and PSUPVP membrane based on the integral of the CO 2 deficit in the exhaust stream suggest that the total uptake capacities are quite similar. We conclude that the PSUPVP membrane has comparable CO 2 absorption capacity to the Snowpure®.
[0052] Except for PSU polymer, other thermal plastic polymers could also be used as matrix via phase immersion process.
EXAMPLE III
Phase Immersion of PVDF-HFP Membrane
[0053] Membrane (PVDF-HFP) preparation: 0.5 g of PVDF-HFP were weighed in a 20 ml vial and 3.0 ml DMF was added and the mixture stirred until all polymers were dissolved. 0.5 g of resin was weighed in another vial and 2.0 ml DMF was added. The mixture was stirred until homogeneous. The two vial contents were combined and stirred for another 0.5 hour at room temperature. The mixture was cast on the same rectangular stainless steel block surface, 6×4 inches, on a hot plate at 50° C. After about 10 minutes, the membrane completely gelled (the whole membrane appears transparent at this time and there was no flowing solvent on the surface). The block was removed from the hot plate, allowed to cool to room temperature, and then soaked in a deionized water bath. After several minutes, the membrane was peeled from the block. The membrane then was left in the water bath with stirring for two days (the water in bath was changed after one day) and boiled in hot water for 1 hour to eliminate the solvent and any remaining PVP inside the membrane. The membrane was then carbonated according to the standard protocol.
[0054] Results: PVDF-HFP membrane shows comparable CO2 absorption ability of Snowpure in FIG. 8 with no addition of PVP. This membrane has a IEC of 1.85.
B. Sorption Method
[0055] In the following embodiments solutions of monomers such as vinylbenzyl chloride, styrene, divinylbenzene and the polymerization initiator benzoyl peroxide were absorbed into non-porous fabrics such as filter paper, polyester/cellulose paper, cloth, etc, or porous film such as porous alumina, polycarbonate film, etc. through capillary action. The solution-saturated fabrics were then exposed to heat or radiation to polymerize the monomers. The resulting membranes in carbonated form showed moisture swing effects in absorbing and de-sorbing CO 2 from the atmosphere.
Reagents:
[0056] Vinyl benzyl chloride (VBC, Aldrich, 97%), Styrene (Sigma-Aldrich, 99%), Divinyl benzene (Aldrich, 80%) and Benzoic acid (Fltika, 99%) were all dried by passing them through an Al 2 O 3 column and stored at 0° C. and purified by recrystalization. Benzoyl peroxide (powder) in a beaker was dissolved in a minimum amount of chloroform. The solution was transferred into a separation funnel. The solution was separated into two layers. The water layer was on top and bottom layer was BP-chloroform solution. The bottom layer was collected in a clean beaker and methanol was added until no more precipitation occurred. The solvent was decanted and white precipitate was purged under N 2 and stored in a desiccator.
EXAMPLE IV
Membranes Synthesized from Polyester/Cellulose Matrixes
[0057] 1.5 ml VBC, 1.5 ml styrene, 0.3 ml divinylbenzene and 0.02 g BP were added into a 20 ml vial and were stirred until all BP was dissolved at room temperature. The mixed solution was poured onto Durx® 670 polyester/cellulose papers and was spread on the paper under capillary effect. The wet papers were put in a closed glass container and were purged with N 2 to eliminate residual O 2 in the container. The container was placed in an oil bath and heated to about 68˜70° C. for 10 hours. After reaction completion, the container was cooled to room temperature and was left open for 2˜3 hours to evaporate excess reagents. The membranes were soaked in 40% trimethylamine aqueous solution for 3 hours at 30° C. to aminate them and then were rinsed with tap water. The aminated membranes were soaked in 2×100 ml 0.1M HCl solution to wash off any excess trimethylamine, and then rinsed with tap water. Finally the membrane was carbonated by soaking in 0.5 M Na 2 CO 3 2×100 ml. The final product was rinsed with water until neutral before use.
[0058] VBC was the reagent utilized to enable the subsequent addition of functional amine groups via amination to the final product. Para- or ortho-VBC, or mixtures of both, function adequately. Styrene was the non-functional matrix polymer that increased hydrophobicity of the membrane. Divinyl benzene was the cross-linking reagent, and BP was the initiator for the polymerization reaction. The VBC and styrene ratio could be changed from 100% VBC to 10% VBC, according to product requirements. The cross-linking percentage could be changed from 2% to 20% of total VBC and styrene weight. Reaction vessels can be made from glass, stainless steel or ceramic.
Membrane CO 2 Binding Performance:
[0059] For membrane measurements of CO 2 adsorption capacity, samples were sealed in the 250 ml glass jar mentioned previously and were purged with air at 0.1 L/min flow rate. The measurement protocol was described previously. FIGS. 9-12 are measured from a single sample weighing 3.5 g having an IEC of 0.55 mmol/g.
[0060] In FIGS. 9-12 , the 3.4 g sample was purged by dry air ( FIG. 9 ) followed by moisture saturated air ( FIG. 10 ). The process was repeated once ( FIGS. 11-12 ). With atmospheric CO 2 levels at about the 390 ppm level, the sample showed a repeatable “moisture swing” CO2 adsorption/desorption effect: when the membrane sample was purged by relatively dry air (absolute humidity ˜5 ppt), the membrane adsorbed CO 2 ; when the sample was purged with moisturized air (absolute humidity 30 ppt), it gave off or desorbed CO 2 .
[0061] In FIGS. 9-12 , during sample preparation the VBC to styrene ratio was 1. Under the same reaction conditions but varying the VBC to styrene ratio, it is expected to help increase the membrane's CO 2 absorption capacity, as shown by the following example.
EXAMPLE V
Membranes Synthesized from Polyester/Cellulose Matrixes-Effect of Increase in VBC Content
[0062] In this experiment samples were made under the same conditions as in experiment IV except that VBC and styrene were present at a 2:1 ratio respectively. The sample weights in FIGS. 13-14 are 4.1 g. IEC is 1.35 mmol/g, which is significantly higher than the 1:1 ratio's 0.55 mmol/g.
[0063] In experiment V the samples were made with a higher VBC to styrene ratio (VBC/styrene=2) compared with samples made in experiment IV (VBC/styrene=1). FIGS. 13 and 14 demonstrate that the increased amount of VBC may have provided more ionic sites on the membrane thereby increasing the membrane's CO2 adsorption capacity. The resulting membranes show retention of the moisture swing effect.
[0064] When the amount of VBC was increased to 100%, the resulting samples did not show enhanced performance. IEC titration of the sample with VBC only and the sample with VBC/styrene=1 both resulted in an IEC of 1.0 mmol/g of dry sample, much lower than the IEC of Snowpure® (1.9 mmol/g). The following method is to conduct amination at elevated temperature (from 30° C. to 50° C.) and extended reaction time (from 3 hrs to 10 hrs).
EXAMPLE VI
Membranes Synthesized From Polyester/Cellulose Matrixes-Improved Amination Condition
[0065] 3.0 ml ml VBC, 0.45 ml divinylbenzene and 0.02 g BP were added into a 20 ml vial and were stirred until all BP was dissolved at room temperature. The mixed solution was poured onto Durx® 670 polyester/cellulose papers and was distributed through the paper by the capillary effect. The wet papers were put in a closed glass container and were purged with N 2 to eliminate residual O 2 in the container. The container was placed in an oil bath and heated to about 68˜70° C. for 10 hours. After reaction completion, the container was cooled to room temperature and was left open for 2˜3 hours to evaporate excess reagents. Instead of aminating at 30° C. for 3 hours, the membranes were soaked in 40% trimethylamine aqueous solution for 10 hours at 50° C. and then were rinsed with tap water. The aminated membranes were soaked 2× in 100 ml 0.1M HCl solution to wash off any excess trimethylamine, and then rinsed with tap water. Finally the membrane was carbonated by soaking in 0.5 M Na 2 CO 3 2×100 ml. The final product was rinsed with water until neutral before use.
[0066] Sample membranes or Snowpure® membranes were sealed in a container (glass jar, 0.25 liter) with two vents. Dry air (atmospheric air passed through dry silica column, absolute humidity ˜0 ppt) was pumped into the container at a fixed flow rate (0.1 L/min) at 75° F. and was purged through the sample. The exiting air is then directed through an IRGA (IR Gas Analyzer, Model LI-840, LI-COR, Inc.), which detects CO 2 and H 2 O vapor content at every 10 seconds. The air is then vented to atmosphere.
[0067] FIG. 15 showed that samples made under improved amination conditions had similar CO2 absorption capacity compared with Snowpure®. IEC titration of samples was 2.2 mmol/g, a bit higher than that of Snowpure® (1.9 mmol/g).
[0068] In the above coating method, the matrix we used was polyester/cellulose fabric. This coating method could also be applied to fibers such as polyester thread, nylon thread, polyester/cotton thread etc.
EXAMPLE VII
Polyester/Cotton Thread Synthesized by Sorption Method
[0069] 3.0 ml VBC, 0.45 ml divinylbenzene and 0.02 g BP were added into a 20 ml vial and were stirred until all BP was dissolved at room temperature. The mixed solution was dropped onto polyester/cotton thread (sewing thread, 37% cotton, 63% polyester) and was spread along thread under capillary effect. The wet threads were put in a closed glass container and were purged with N 2 to eliminate residual O 2 in the container. The container was placed in an oil bath and heated to about 68˜70° C. for 10 hours. After reaction completion, the container was cooled to room temperature and was left open for 2˜3 hours to evaporate excess reagents. The threads were soaked in 40% trimethylamine aqueous solution for 10 hours at 50° C. to aminate them and then were rinsed with tap water. The aminated threads were soaked in 2×100 ml 0.1M HCl solution to wash off any excess trimethylamine, and then rinsed with tap water. Finally the threads were carbonated by soaking in 0.5 M Na 2 CO 3 2×100 ml. The final product was rinsed with water until neutral before use.
[0070] The IEC of the coated polyester/cotton thread shown in FIG. 16 is 1.5 meq/g, which is a relatively lower IEC compared with that of Snowpure® (1.9 meq/g) and is from the thread having a lower polymer loading capacity defined in Protocol 3.
[0071] The loading capacity of sample matrixes were measured according to Protocol 3 and used the following matrices: braided nylon thread: 0.5; polyester/cotton thread: 0.85; polyester thread: 0.89 polyester/cellulose fabric: 2.0. The fabrics or fibers such as polyester/cellulose paper, polyester thread, polyester/cotton thread etc. proved to be good matrices. Light weight and high absorption material is optimal.
[0072] The methods described above, and other conceivable methods, may be used to form various superstructures having active resins embedded therein. For example, it is possible using the solid sorbents and polymers or other matrices discussed above to form films that can be arranged in the configurations described in co-pending application PCT Application Serial No. PCT/US08/60672, which describes several geometries that may be used to form a collapsible collector to optimize the porosity of the collector for alternating liquid and gas streams. The films may be formed in flat membranes, concentric cylinders or tubes, or wound up spirals. Some configurations may require the use of spacers, which may be formed of a polymer material, to form the structure.
[0073] Other examples of superstructures that are possible using the present invention include the formation of flat membranes, tubes, hexagons, or monolithic structures, using porous materials. Porous structures will naturally increase the amount of surface area for CO 2 uptake. Alternatively, the solid sorbent material may be produced in a foam that can be manipulated into complex shapes for a specific application or for optimal performance. In another alternative formation, the material could be spun into thin threads or woven into textile or felt-like materials.
[0074] The sorbent materials of the present disclosure may also be applied as surface coating to an underlying structure formed of a durable and inexpensive material. For example, monoliths made out of inexpensive materials could be soaked in the polymer/resin combination and then harden into a useful filter system. These monoliths may be constructed of paper materials, ceramic materials, textiles, or other appropriate materials. The coatings may be applied similar to a paint, such as by spraying, rolling, dipping, or the like.
[0075] In another aspect of the present invention, the superstructure may be formed as the sorbent materials are polymerized around a fibrous structure, similar to a carbon composite matrix structure.
[0076] The present invention may also be used to create a sorbent superstructure with very rough surfaces, which would then increase the uptake rate of the CO 2 capture process. In particular, solvents may be used to form a dendritic structure. A rough surface could also be accomplished by a method involving a step of etching the solid material to create more surface area.
[0077] In embodiments where a high concentration of uptake sites are present, it may be possible to use turbulent flows through the filter, as this would decrease the air side transport limitations of the system.
[0078] Various changes may be made without departing from the spirit and cope of the invention. For example, CO 2 capture elements may be formed using solid amines as the CO 2 sorbent or getter. The solid amine getters preferably are the amines as described in our co-pending U.S. Provisional Application Ser. No. 60/989,405, filed Nov. 20, 2007. The solid amines may be formed on porous solid supports, membranes or films, e.g. from liquid amines which are dried in place on a support. Also, the membranes and films may be formed by roll casting, or doctor blade casting from a solution containing the monomer or monomer blend or polymer dissolved or a solvent containing the particulate CO 2 sorbent or getter. Also, films, membranes or fibers may be formed by spin coating.
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Disclosed is a process for forming a CO 2 capture element comprises providing a mixture of a monomer or monomer blend or a polymer binder, a miscible liquid carrier for the binder and a CO 2 sorbent or getter in particle form, forming the mixture into a wet film or membrane, evaporating the liquid carrier to form a film or membrane, and treating the wet film or membrane to form pores in the body of the film or membrane. Also disclosed is a process of forming a CO 2 capture element which comprises the steps of applying a mixture including a sorbent material and a polymer to an underlying material; polymerizing the mixture in place on the material; and aminating the polymer-coated material.
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FIELD OF THE INVENTION
[0001] The present invention relates to a hockey stick, which consists of a handle portion, or shaft, and a blade portion, or blade.
BACKGROUND OF THE INVENTION
[0002] Up till now, all hockey stick shafts, either of solid or hollow construction, have been manufactured in a similar standard rectangular configuration. This standard rectangular configuration has been the standard shape, which is preferred by a majority of hockey players. These actual designs of rectangularity have various radiuses placed at the intersecting planes (horizontal and vertical), and some of them include a cross sectional configuration of concaved/sided walls.
[0003] Composite hockey stick shafts, depending on their method and materials of construction, exhibit superior characteristics to hockey stick shafts of wood with respect to tensional resistance, bending moment resistance and shear resistance. However, composite hockey stick shafts have an inherent relative flexibility when submitted to direct impact at the blade, on particular under slap shot condition. A hollow rectangular beam structure, such as a hockey stick shaft, will, under a sudden cantilever type of loading (slap shot), exhibit a non-negligible deflection at mid span between the hockey player's hands localization. Such bending moment forces are transmitted inside the thin wall composite fiber-resin matrix construction and generate compression tension and shear stresses in the fiber-resin laminate.
[0004] The resulting level or amplitude of deflection between the player's hands (known as the buckling phenomenon) will be directly related to the area moment of inertia (dependent on the wall thickness) and the flexural elastic modulus of the fiber-resin laminate. Higher are the wall thickness and the laminate elastic modulus, higher is the overall stiffness and lower is the buckling phenomenon between the player's hands, but higher wall thickness involves higher weight of the shaft.
[0005] In some cases, due to the player's personal interest in added rigidity, higher bending resistance or a judicious combination of “stiffness—flex” in that particular zone will normally generate a quicker energy transfer allowing the player to deliver more dynamic and accurate puck releases.
[0006] Players who choose to play with composite hockey sticks continually seek out sticks having adapted rigidity and low weight. Experience has shown that conventional laminate constructions such as carbon, Kevlar and epoxy are close to attain a limit to maximize shot velocity and control, and increase durability and strength.
OBJECTS AND STATEMENT OF THE INVENTION
[0007] It is an object of the present invention to provide a hockey stick with a quicker energy shaft loading under minimal flexural deformation.
[0008] It is a further object of the present invention to provide a hockey stick with a rapid energy transfer right after the contact between the puck and the blade of the stick.
[0009] It is a further object of the present invention to provide a hockey stick with an energy charge in the shaft, which will be delivered at 100% in a shortest time possible.
[0010] These objects can be obtained with the present invention by providing, at mid span of the handle portion of the hockey stick, means having preformed stresses handle portion, which will induce flexural resistance. This creates induced stresses in the body, which will be later neutralized at impact as further stresses are induced.
[0011] There results a stiffer and more rigid handle portion for the hockey stick.
[0012] Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that this detailed description, while indicating embodiments of the invention, is given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art.
IN THE DRAWINGS
[0013] FIGS. 1-6 show various elements illustrating a first embodiment of the present invention;
[0014] FIGS. 7 and 8 show elements of a second embodiment of the present invention;
[0015] FIGS. 9 , 10 a and 10 b show various arrangements of a third embodiment of the present invention;
[0016] FIG. 11 is a perspective view showing a fourth embodiment of the present invention;
[0017] FIGS. 12 and 13 show a fifth embodiment of the present invention; and
[0018] FIGS. 14 and 15 show a sixth embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
First Embodiment
[0019] As shown in FIGS. 1-6 , the force element may consist of a composite mono or bi-leaf spring that stores potential energy when pre-deformed before installation.
[0020] Depending of its geometry and strength, the composite spring will induce a preferential flexural resistance in the form of a multi point preloading stresses inside the tubular hockey shaft.
[0021] When submitted to an impact load, such as in slap shot, the bending moment induced in the hockey shaft must, first counterbalance the pre-induced flexural stresses by the spring insert localized inside the rectangular shaft before generating a deflection at mid span of the hockey shaft (when referring to the hockey player's hands position).
[0022] By definition, a composite mono-leaf bow spring has a central upwardly curved region introduced between two downwardly curved regions that are introduced between two more upwardly curved regions.
[0023] By varying the curvature, either the upwardly curved regions or downwardly curved regions, or by varying the construction of the leaf spring, the rate of displacement along each portion of the multi linear deflection response curve may be controlled.
[0024] Because of the composite material high specific strain energy storage capability and the possibility to design and fabricate a linear spring having continuously variable width and/or thickness along its length, such design features should lead to a more adapted hockey shaft.
[0025] The mono-leaf bow spring can achieve a multi linear deflection response when compressed under load. Also, it can be symmetrically or asymmetrically designed, depending upon the application requirement.
[0026] In some cases, the composite spring could have a sinusoidal profile with variable cross-section, always depending of the specific function requirements.
[0027] Normally the stiffness of the spring is directly related to the area moment of inertia of the section. The material in the central area of the solid cross-section of the leaf spring does not significantly contribute to the bending stiffness.
[0028] It could then be beneficial to manufacture a composite spring having a hollow cross-section being much lighter and having the same stiffness as for a solid area.
[0029] Hence, the embodiment consists in the prefabrication and installation of a linear spring having the geometry of a sinusoidal wave or a mono-leaf bow contacting in four different points inside the rectangular tubular hockey shaft, wherein two of the contact points are at the player's hand localization or slightly eccentric or displaced and the two other points at each end of the hockey shaft.
[0030] Before installation, the linear leaf spring is pre-deformed to be subsequently slid inside the tubular shaft and released. After releasing, the linear spring still has a deformation resulting (by reaction) in a flexural pre-stressed hockey shaft.
[0031] The induced flexural stresses resulting from the pre-deformed linear spring inside the hockey shaft will be oriented in a way as to resist to the shaft deformation when submitted to impact such as in slap shot conditions.
[0032] When the hockey blade impacts the puck, the stresses induced by the flexural moment (cantilever type) will have first to neutralize the one induced by the pre-stressed spring before to act directly on the shaft itself, resulting in a stiffer and more rigid hockey shaft.
[0033] As a variant of the present embodiment of the invention, the rectangular shaft may be molded with a curved shape and following its straightening, a rectangular profile called <<single blade>>, “D” (shown in FIG. 4 ) may be slid inside the shaft ( FIG. 6 ) to keep it permanently straight and pre-stressed.
Second Embodiment
[0034] As shown in FIGS. 7 and 8 , the hockey shaft is fabricated in two longitudinal halves, each one having a rectangular or trapezoidal profile. When moulded, these two halves are curved (more as a bow) and secured into a permanent assembly side-by-side with the particularity to be back to back in a concave condition.
[0035] After being compressed transversely, the two halves are permanently assembled by bonding, over wrapping or any other way.
[0036] The final hockey shaft assembly will have the same visual aspect as a standard shaft but with the added property to be a pre-stressed hockey shaft (in flexural condition).
[0037] The level of energy storage is directly related to the curvature amplitude, which is particular to each hockey shaft halves, combined to their inherent stiffness and strength.
Third Embodiment
[0038] As shown in FIG. 9 , in a first variant, the rectangular shaft has uneven wall thicknesses and to counterbalance and pre-stress the shaft, wires are embedded inside the thinnest wall after being pre-stressed in tension.
[0039] As shown in FIGS. 10 a and 10 b , in a second variant, the internal profile of the cross section is not rectangular, but more in a parallelogram or trapezoidal shape with the result that the circumferential wall thicknesses is not uniform. As in the first variant, wires would be pre-tensioned before being embedded in the thinnest wall section.
Fourth Embodiment
[0040] As shown in FIG. 11 , the basic hockey shaft having a rectangular profile may be molded and curved (with linear recess) to be straightened and locked in place permanently with the use of two straight grooved molded planks. The result is a pre-stressed shaft permanently assembled with adhesive.
Fifth Embodiment
[0041] As shown in FIGS. 12 and 13 , this embodiment is a variation of the first embodiment with the difference that two spring inserts are used inside the rectangular shaft; these spring inserts are immersed and superposed to generate a counterbalancing pre-stress effect (asymmetric).
Sixth Embodiment
[0042] As shown in FIGS. 14 and 15 , this embodiment is a variation of the first embodiment with the difference that two springs inserts are used end-to-end allowing pre-stressing at asymmetric location and with asymmetric pre-stressing loads. Springs may be inserted in the vertical or in the horizontal plane.
Concepts
[0043] The above-described six embodiments can be regrouped in three basics concepts.
[0044] A first concept consists of a straight molded hockey shaft in which the secondary component (one or two spring-type pieces) is slid therein to generate more stiffness. This concept may be found in the above-described first, fifth and sixth embodiments.
[0045] A second concept consists of a straight molded shaft having a variable wall thickness in cross-section and in which continuous wire reinforcements are admitted in one of the sides. This concept may be found in the third above-described embodiment.
[0046] A third concept consists in a curved molded shaft in one or two molded pieces that are straightened and locked in place. This concept is found in the above first, second and fourth embodiment. In a first variant, the hockey stick consists in a single molded shaft that is locked in place (after straightening) with a secondary component installed inside or outside the tubular shaft and mounted in place. In a second variant, the hockey stick consists in two-molded half-size curved molded shaft that are bound back to back after straightening.
First Concept
[0047] When a straight tubular hockey shaft is molded, it possesses a particular rigidity resulting from its construction (fiber—polymer resin—fiber orientation—fiber/resin ratio—relative thicknesses of each layer of reinforcement—total thickness of shaft wall). The rigidity or stiffness factor being directly dependent of the elastic modulus (E) and surface inertia moment (I), its value may be raised without changing any of the variables list mentioned previously. A device is incorporated inside the shaft with the result that, under impact (slap shot), the shaft will deflect less and return the accumulated energy under deformation faster and quicker. The net result will be that the puck (with a constant energy input) leaves the blades quicker and travels faster.
[0048] The device is basically a leaf spring, which, after a specific deformation, is slid and fixed inside the tubular shaft. Different spring rate can be obtained by varying, in a fixed geometry, the content of fiber and resin.
[0049] A steel leaf spring has a very high modulus of elasticity; but, with carbon fiber embedded in a thermoset resin, it is possible to obtain superior value.
[0050] Also, an additional benefit is obtained by the high elastic strain energy inherent in a composite laminate; it can be more than 10 times that of steel.
[0051] By combining different arc portions of the leaf spring (radius not constant), it is possible to obtain a continuous non-linear variable spring deformation rate. Under deformation, it is possible to create different reactive forces at different locations (ex.: hand positions on a hockey shaft).
Second Concept
[0052] The concept of using an asymmetric wall thickness (thickness variation on some of the four sides of the tubular shaft) has for objective to generate a hockey shaft having a different stiffness when used frontward and backward.
[0053] With the integration of preloaded reinforcing wires on the thin side, it is possible to adjust preferentially the stiffness or rigidity in the hockey shaft.
[0054] By a proper choice of the ratio t 1 /t 2 combined to the right number of reinforcing wires and the level of preloading in tension, it is possible to stiffen preferentially in one direction the hockey shaft with the objective to create a hockey stick which delivers the puck quicker and faster.
Third Concept
[0055] The concept to straighten a pre-molded curved shaft (single or double) offers the largest variety of options to obtain different levels of pre-stressed hockey shafts.
[0056] By defining exactly the curve amplitude of the hockey shaft for a determined construction, it is possible to generate the new flexural elastic modulus, resulting in a higher stiffness factor or higher shaft rigidity (more curved more energy required to straighten it and a stiffer hockey shaft at use).
[0057] The option to use two half-molded shafts bonded back to back has the particularity to simplify the assembly procedure.
[0058] When only one molded shaft is used, an accessory is required to lock it in position; however, it provides a lighter shaft.
[0059] In all these concepts, composite material is used to keep weight at a minimum and stiffness at a maximum. High modulus carbon fibres are part of the solution.
[0060] By carefully designing the shape of the components, the material system and the assembly technique, rigidity and stiffness of the hockey shaft is upgraded generating a quicker and faster puck release from the hockey blade, when compared to a conventional composite hockey shaft with pre-stressing in its tubular walls.
[0061] Although the invention has been described above with respect to various embodiments, it will be evident that it may be modified and refined in various ways. It is therefore wished that the present invention should not be limited in interpretation except by the term of the following claims.
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A hockey stick comprising a shaft portion and a blade portion, the shaft portion including means having preformed stresses to induce a flexural resistance at about mid-span so as to create in the shaft portion induced stresses which are neutralized as stresses are further induced in the shaft portion at impact on the blade portion to thereby provide a stiffer and more rigid shaft portion.
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This invention relates to a Space Train™, and to a System for projecting it into space at a velocity enabling its escape from the gravitational field of the Earth, without the use of combustible fuels, and with an acceleration and deceleration tolerable to humans. An object of this invention is to provide an alternate source of lift-off energy for space vehicles to obviate the need for using large quantities of dangerous combustible fuel in proximity to passengers and cargo; and in particular, to avoid another tragedy such as the explosion and destruction of Flight 51-L of the Space Shuttle "Challenger" and its crew; and many other failures which destroyed unmanned rockets carrying valuable cargo. The System comprises an almost horizontal tube; for example, about 1000 km long and about 5 m inside diameter. To enable the Train to travel in the Tube with little loss of energy to air, the Tube is maintained at an air pressure of less than 1 millibar. The Tube is provided with an electromagnetic drive to accelerate the Train. Electric energy from an external source may be stored over a long period, and quickly discharged to coils along the tube to drive the Space Train™ to exit velocity.
The Space train comprises a hollow cylindrical mass of at least 3,000,000 Kg; for example, 180 m long and 5 m in Diameter. The forward and rear ends of the vehicle are conically shaped with a apex angle of about 10° to minimize air friction. The Train is driven with a constant acceleration of about 8 g's, the maximum acceleration comfortably tolerable to humans. The exit velocity of the Space Train from the Tube into the atmosphere is about 12 km/sec.
A Train of such large mass can carry everything needed to construct a permanent Spaceport, or constitute an Interplanetary Space Train™.
An advantage of the Space train™ System of this invention is that it may be launched without the use of energy from combustible fuel; thus avoiding the danger of explosion, increasing launch reliability, and decreasing launch costs.
A further advantage of this invention is the great mass and size of the Space Train™, enabling the inclusion of much cargo, including solar-electric panels for a large Solar-Electric Power source, expendable mass for a mass-driver, electric powered Thrustor, ample crew and passenger quarters, and facilities and provisions for a long stay in space.
A further advantage of this invention is the provision of acceleration and deceleration phases at less than 8 g's for a small time, which may be comfortably tolerated by humans on board as crew and passengers.
A further advantage of the Space Train™ of this invention is that the walls may be sufficiently thick to protect against Solar Flares or other deleterious Space radiation.
Another advantage of the Space Train™ of this invention is that it may be configured to be separated and reassembled in space for use as a permanent Spaceport, or as a cycling Interplanetary Space Train. It may carry onboard one or more smaller vehicles which may be dispatched to Earth, Mars or other space body.
Still another advantage of the Space train™ is that it will decrease the cost of transportation into space by greater than an order of magnitude, opening up the Space Frontier on a cost-efficient, profitable, reliable and safe basis.
These and other advantages and objects, and various other aspects of this invention, will become apparent from the description which follows.
THE PRIOR ART
An excellent review of the current State of the Art, including a bibliography, and "An Exciting Vision of our next Fifty Years in Space" has been presented in the 1986 REPORT OF THE NATIONAL COMMISSION ON SPACE [1]. Present or proposed Space vehicles are launched into space by rockets using chemical propellants [1.1]. Solar-Electric Panels are required to power space ships, but present photovoltaic devices are too inefficient, too expensive, and require too much area to provide for large power requirements [1.2]. The invention of an efficient solar-electric panel with a 60-80% efficiency is described in a recent patent issued to Alvin M. Marks [2], and in a copending patent application [3]: Ser. No. 06/637,405 filed Aug. 3, 1984, entitled Femto Diode and Applications, issued to Alvin M. Marks as U.S. Pat. No. 4,720,642 on Jan. 19, 1988.
Electric propulsion using mass drivers for space ships has been proposed [1.3]. Electromagnetic mass-drivers to catapult materials from the surface of the Moon into space have been proposed, and laboratory work on Earth has shown high accelerations to be feasible [1.4]. Earlier work by Alvin M. Marks [4], and others [5], described the charging of small particles useful for mass-driver electric propulsion systems for space vehicles. Superconductive Electromagnetic Storage Systems to store and rapidly discharge large quantities of electric energy have been described, built and successfully tested [6].
In about 1865, Jules Verne, in a prescient science fiction novel [7] remarkable for its time, told about a projectile carrying 3 humans to the Moon and return. The projectile was supposed to issue from a vertical cannon in a 270 m deep shaft sunk into the Earth, propelled by an explosive charge of pyroxylin (gun cotton) to an exit velocity of about 12 km/sec. Unfortunately, the acceleration would have been 27,000 g's fatal to a human.
Recently, 116 years later, H. Kolm, et al [8,9] proposed a 7.8 km long tube along the slope of a mountain and an electromagnetic drive to propel a projectile carrying a non-human cargo having a mass of 15,000 kg into space. The projectile was 1.2 m dia. The acceleration phase was at 1000 g's which would be fatal to a human. The propulsion device replaced the first rocket stage only; it was necessary to carry aloft combustible fuel for a second stage rocket to propel the vehicle into orbit. The problem of projecting humans into space safely without a combustible fuel driven rocket was not solved.
Electromagnetic drivers for use on materials and vehicles travelling at large velocities have been proposed and may be adapted for use in this invention [1.4, 10]. Similar drives have been employed at atmospheric pressure for passenger trains travelling on the Earth's surface at 400 km/hr. (0.11 km/s), commercially known as "Maglev" trains [11,12].
Recent studies have shown that the maximum acceleration that is safely tolerated by a human is 12 g [13,14].
BACKGROUND OF THE INVENTION
The first conception of a Space Train™, suitable for humans and cargo, accelerated at low g in a long, almost horizontal vacuum tube on Earth, and directly projected into space without combustible fuel was by Alvin M. Marks. At his request, a mathematical physics analysis was made by Peter H. Diamandis, one of the Inventors hereof. Under the constraint of a maximum acceleration or deceleration of 8 g's, new and unexpected ranges of parameters were discovered, enabling the selection of optimum values of Tube length, Space Train™ mass, dimensions, exit velocity angle and height.
The mass and exit velocity of the Space Train™ from the Tube overcomes the drag of the atmosphere, and enables its escape from the gravitational field of the Earth. The mathematical physics and calculations determine Space Train™ mass, velocity vs. time, acceleration and deceleration vs. time, exit angle, height, trajectory and electric drive power. The requisite mass of the Space Train™ is large: about 3,000,000 kg.
Alvin M. Marks proposed utilizing the large mass of the Space Train™ to carry everything needed for its conversion in space into a Spaceport or an Interplanetary Space Train™. If 10 5 -1 m 2 Lepcon™ light-electric power converting panels are carried as cargo, and assembled in space, 100 Mw Electric Power is available at Earth-Sun distance (1.5×10 11 m). This power may be used for propulsion of the Interplanetary Space Train™; and for other requirements. Propulsion is provided by an electrically powered mass-driver Thrustor which expels electrically accelerated charged submicron particles.
CROSS REFERENCE TO RELATED PATENTS AND PATENT APPLICATIONS
The solar-electric power source proposed utilizing the light-electric power converting panels Lepcon™ described in U.S. Pat. No. 4,445,050 issued to Alvin M. Marks, Apr. 3, 1984, entitled: "DEVICE FOR THE CONVERSION OF LIGHT POWER TO ELECTRIC POWER"; and co-pending application Ser. No. 637,405, filed Aug. 3, 1984, entitled: "FEMTO DIODE AND APPLICATIONS" now issued to Alvin M. Marks as U.S. Pat. No. 4,720,642, Jan. 19, 1988. Methods of charging liquid droplets are described in U.S. Pat. No. 4,206,396 issued to Alvin M. Marks on June 30, 1980 entitled: "CHARGED AEROSOL ELECTRIC GENERATOR WITH UNI-ELECTRODE SOURCE". The present application is related to Ser. No. 886,568, filed July 17, 1986, now abandoned, entitled "Space Train™, invented by Alvin M. Marks and Peter H. Diamandis.
SUMMARY OF THE INVENTION
The Space Train™ and its Launching System according to this invention comprises:
1. A horizontal Tube about 1000 km long and about 5 m inside diameter. The Tube is maintained at a vacuum such that there is little loss of energy from the Train to the residual air. Double door air locks at each end open and close as the Train passes.
2. The Train comprises a cylindrical mass of about 3,000,000 Kg; for example 180 m long and 5 m diameter. To minimize air friction, the forward and rear ends of the Train are conically shaped at an apex angle about 10°. The Train reaches exit velocity by a constant acceleration of about 8 g's; tolerable to humans. The exit velocity of the Train from the tube into the atmosphere is about 12 km/sec. at, for example, 3° and 3 km height. A momentary deceleration is a maximum of 8 g's.
3. The Train is propelled by an electromagnetic drive along the tube.
4. An external electric power source of about 10,000 Mw is maintained on line for about 24 hours for each launch, to supply large quantities of electric energy to a plurality of storage devices located in depots along the Tube. The storage devices may be inductors or capacitors at ambient temperature, or superconducting rings. These are discharged quickly to deliver momentary high power pulses to drive the Train.
5. Electrical devices and controls are provided to transfer the electric power from the storage devices to the electromagnetic drives along the tube; to open and close doors, vacuum and air valves, and to control all devices employed during the launch.
THE FIGURES
FIG. 1 shows a cross-section of the Space Train™ and a proposed compartmentalization for various purposes.
FIG. 2 shows a perspective view of the Space Train™ and Loading Platform at the entrance to the Tube.
FIG. 3 shows a cross-section of the Space Train™ and Tube at a mid-section of the Tube on the Earth's surface.
FIG. 4 shows the exit section of the Tube for launching the Space Train™.
FIG. 5 shows a side view of a passenger in a launch chair located in the Space Train™.
FIG. 6 shows a cross-section of the entire length of the Tube showing the trajectory of the Space Train™ on the Earth's surface.
FIG. 7 shows the geometry of the Final Launch Tube Section.
FIG. 8 shows Space Train™ Orbital Dynamics.
FIG. 9 shows curves of Exit Velocity km/s vs. Mass Kg×10 6 for:
(1) a maximum deceleration less than 8 gravities.
(2) escape
FIG. 10 shows graphs of Height(Km) achieved versus Exit Velocity Km/s, for various constant Ship Masses: 2,3, and 4×10 6 Kg.
FIG. 11 shows Height km versus Exit Velocity Km/s for a constant Ship Mass of 3×10 6 Kg, for Launch Angles of 0°, 1°, 2°, and 3°.
FIG. 12 shows the velocity V vs. time t of the Space Train™ from the start to its exit into the atmosphere.
FIG. 13 shows a graph of the Space Train™ Acceleration vs. time indicating the gradual change from acceleration to deceleration near the Tube Exit.
FIG. 14 shows:
(1) electric power applied to the Space Train™
(2) Time in S×10 -3 (ms) during which the power is applied along each coil length section of the Tube as the Train passes vs. Distance along the Tube KM.
MATHEMATICAL PHYSICS ANALYSIS
There follows the mathematical physics analysis which established the parameters for the projection of a Space Train™ directly from the surface of the Earth at its Escape Velocity, at an acceleration and deceleration safely tolerable by humans:
TABLE OF SYMBOLS
F D =Force due to drag (NEWTONS)
ρ=Density of local atmosphere (kg/m 3 )
ρ 0 =Density of atmosphere at sea level=1.226 (kg/m 3 ) at 288° K. or about 15° C. at 1 atm
ρ s =Space Train average density
K=Gas Constant=0.287 (m 2 / 0 ksec 2 )
V=Velocity (m/s)
V e =Exit Velocity (from launch tube) (m/s)
C d =Coefficient of drag
r=Radius of Space Train (m)
L=Length of Space Train (m)
z c =Length of front and back cones of Space Train (m)
z b =Length of center tubular section of Space Train (m)
δ=Angle of Space Train cone (front and rear)
M=Mass of Space Train
D=Distance traveled (m)
t=time (sec.)
ε=Efficiency
E=Energy (Joules)
P=Power (Joules/sec.)
α=Angle of Velocity vector with the Tangent to the Earth directly below (degrees)
A=Cross-sectional area of Space Train (m 2 )
a=Acceleration or deceleration experienced by Space Train (m/s 2 )
a=Average acceleration or deceleration experienced by Space Train (m/s 2 )
a c =Centripetal Acceleration experienced by Space Train (m/s 2 )
a v =Acceleration normal to the path of the launch tube
R e =Radius of Earth=6,370,000 m
R i =Local radius of curvature (m)
X=Distance from Space Train to the surface of the Earth
H=Final height of launch tube (at exit) (m)
h=Distance of Space Train from the center of the Earth
y=Projected length of final launch tube arc onto the Earth (m)
φ=Downrange angle (relative to launch point) (rad)
g=Local gravity (m/s 2 )
g o =Gravity at sea level =9.82 (m/s 2 )
R c =Instantaneous radius of curvature (m)
θ=φ-α
λ=Lapse rate=0.0065 degrees/meter (for h<10,000 meters)
T o =Temperature at sea level=288.15 deg. kelvin
T s =Temperature in stratosphere=216.65 deg. kelvin
SUBSCRIPTS
a=Build-up phase
b=Boost phase
c=Build-down phase
d=Glide phase
e=Atmospheric Compensation Phase
t=Total
MATHEMATICAL PHYSICS
I. LAUNCH TUBE EQUATIONS OF MOTION
D=V.sub.o t+0.5 at.sup.2 (1)
V=V.sub.o +at (2)
a=(a.sub.i +a.sub.f)/2 (3)
E=0.5M(V.sub.f -V.sub.i).sup.2 /ε (4)
P=E/t (5)
F.sub.d =(0.5)ρV.sup.2 C.sub.d A (6)
EXAMPLE
M=3,250,000 kg
V e =11,800 m/s
H=3,000 m
α=3 degrees
ε=0.7
(A) Build-up phase (Linear increase in acceleration from 0 to 78.6 m/s 2 over 10 seconds).
From (3):
a=-(78.6+0)/2=39.3 m/s 2
From (2):
V c =11,872.7+(-39.3)(3)=11,754.8 m/s
From (1)
D c =11,872.7 (3)+(0.5)(-39.3) 2 =35,400 m=35.4 km
(B) Boost phase (Accelerate to 11,872.7 m/s at a rate of 78.6 m/s 2 ).
From (2):
V b =11,872.7=(393)+(78.6)(t b ) t b =146.05 seconds
From (1):
D b =(393)(146.05)+(0.5)(78.6)(146.05) 2 =895.7 km
(C) Build-down phase (Reduces acceleration from 78.6 m/s 2 to 0 m/s 2 over 3 sec.)
From (3):
a=(78.6+0)/2=39.3 m/s 2
From (2):
V c =(11,872.7)+(39.3)(3) 2 =12,226.4 m/s=12.2 km/s
From (1):
D c =(11,872.7.3)(3)+(0.5)(39.3)(3) 2 =35.8 km
(D) Glide phase (Speed maintained constant at 11.8 km/s for 3 seconds).
From (1):
D d =(11,990.6)(3)=36.0 km
(E) Atmospheric Compensation Phase (final section of tube filled with atmosphere over a 5 second period while Space Train Velocity maintained at 11.8 km/second).
From (6):
Initial F d =(0.5)(0)(11,800)(0.2)(19.64)=0 Newtons
Final F d =(0.5)(0.906)(11,800)(0.2)(19.64)=2.477*10 8 Newtons.
Average F d =(0+2.477*10)/2=1.239*10 8 Newtons
a=F d /M=1,239*10 8 /3,250,000=-38.12 m/s 2
From (2):
V e =11,990.6+(-38.12)(5)=11,800
From (1):
D e =(11,990.6)(5)+0.5(-38.12)(5) 2 =59.5 km
(F) Total Parameters of Acceleration Phase
t t =t a +t b +t c +t d +t e =10+146.05+3+3+5=167.05 sec.
D t =D a +D b +D c +D d +D e =1.965+895.7+35.8+36.0+59.5=1,028.9 km (643 miles)
(G) Estimation of required Energy and Power
From (4):
E t =[(0.5)*3,250,000*(11,990-0) 2 ]/0.7=3.337*10 14 Joules
From (5):
P t =E t /t t =3.337*10 14 Joules/167.05=1.998*10 12 =2,000,000 MW
II. FINAL CURVATURE OF LAUNCH TUBE NEEDED TO ACHIEVE α=3 DEGREES (See FIG. 7)
Radius of curvature limited by centripetal acceleration (a c <39.3 m/s 2 ):
R.sub.i =>V.sup.2/a c (7) ##EQU1##
y=˜SQR{(R.sub.e +H).sup.2 -(R.sub.e).sup.2 } (8)
=˜y/R.sub.i (9)
Example
H=3000 meters
a c =64 m/s 2
From (7):
R i =>(11,800) 2 /64=>2,175 km
From (8):
y=SQR{(2175+3) 2 -(2175) 2 }=114.3 km
From (9):
=114.3/2175=0.053 rad=3.01 degrees
III. SPACE TRAIN MASS-EXIT VELOCITY RELATIONSHIP REQUIRED FOR AN INITIAL ATMOSPHERIC DECELERATION OF LESS THAN 8 GRAVITIES (FIG. 10)
a=F.sub.d /M (10)
From (6):
a=[(0.5)ρV.sup.2 C.sub.d A]/M (11)
Example
ρ=0.905 kg/m 3 (at H=3 km)
C d =0.2
A=19.64 (r=2.5 m)
From (11):
78.6=(0.5)(0.906)(V.sup.2)(0.2)(19.6)/M Vel=SQR[(44.3)(M)] (12)
IV. ACCELERATION NORMAL TO THE PATH OF THE LAUNCH TUBE
a.sub.v =(g-a.sub.c) (13)
a.sub.v =(9.82-(V.sup.2 /R.sub.i)m/s.sup.2 (14)
Example
R i =R e =6370 km (for t<157.05 sec.) (Earth curvature)
R i =2175 km (for 154.63<t<167.05 sec.) (Final tube section curvature)
From (14):
a v =(9.82-V 2 /6,370,000) m/s 2 (for t<157.05 seconds)
a v =(9.82+V 2 /2,175,000) m/s 2 (for 157.05<t<167.05 3 sec.)
V. NET ACCELERATION EXPERIENCE DURING LAUNCH
The vector sum of accelerations normal to the launch tube, and accelerations tangent to the launch tube.
a.sub.t =SQR(a.sup.2 +a.sub.v.sup.2) (15)
VI. ORBITAL TRAJECTORY CALCULATIONS (See FIG. 8) 1/R c =d(a-φ)/dS=-dφ/dt:1/V (Centripetal Accelerations) (16)
-F.sub.d -Mg Sin a=M dV/dt (17)
Mg Cos a=MV.sup.2 /R.sub.c (18)
From (16):
MV.sup.2 /R.sub.c =-MV d(α-φ)/dt=-MV dφ/dt (19)
V Cos α=h dφ/dt (20)
V Sin α=dX/dt (21)
Equations of Motion (differential form) From (17):
dV/dt=-F.sub.d /M-g Sin α (22)
From (19):
dφ/dt=-g/V* Cos α (23)
From (20):
dφ/dt=V/h Cos α (24)
From (21):
dh/dt=V Sin α (25)
VII. MODELING THE DYNAMIC PARAMETERS OF FLIGHT
g=g.sub.o (R.sub.er).sup.2 /(R.sub.e +X).sup.2 (26)
For X<10 km T=T.sub.o -(λ)(X) (27)
For 10<X<20 km T=216 degrees kelvin
For T>20 km T=240 degrees kelvin
For X<10 km
ρ=ρ.sub.o *(1-(λ*X/T.sub.o)).sup.(g/(λ*K)-1) (28)
For 10<X<40 km
ρ=ρ.sub.o *(2.178.sup.(-g*(X-3265)/(K*T))) (29)
______________________________________For 40 < × < 50 ρ = .005 kg/m.sup.3For 50 < × < 60 ρ = .001 kg/m.sup.3For 60 < × < 80 ρ = .0001 kg/m.sup.3For 80 < × < 100 ρ = .00001 kg/m.sup.3______________________________________
VIII. ITERATIVE SOLUTION TO SPACE TRAIN FLIGHT DYNAMICS
Equations 22-29 were solved iteratively using a computer.
From (22):
a.sub.n +1=-F.sub.dn+1 /-g.sub.n+1 Sin (α.sub.n+1) (30)
V.sub.n+1 =V.sub.n +(a.sub.n+1 +a.sub.n)/2*dt (31)
From (23):
.sub.n+1 =.sub.n +[-g.sub.n+1 /V.sub.n+1 * Cos (.sub.n +.sub.n+1)+[-g.sub.n * Cos (.sub.n +.sub.n)]*dt/2 (32)
From (24):
.sub.n+1 =.sub.n +[V.sub.n+1 /h.sub.n+1 * Cos (.sub.n+1 +.sub.n)+V.sub.n /h.sub.n * Cos (.sub.n +.sub.n)]*dt/2 (33)
From (25):
h.sub.n+1 +h.sub.n +[V.sub.n+1 * Sin (.sub.n+1 +.sub.n+1)+V.sub.n * Sin (.sub.n +.sub.n)]*dt/2 (34)
IX. SPACE TRAIN SHAPE AND DENSITY
ρ.sub.s =M/[(2/3)*πr.sup.2 (z.sub.c)+(πr.sup.2 (z.sub.b)](35)
z.sub.c =r/tan (δ/2) (36)
% open room on Space Train=100*(1-ρ.sub.s /(density of building material (37)
Example
M=3,250,000 kg
δ=10 degrees
r=2.5 meters
z b =122.9 meters
Density of building material (iron)=7,874 kg/m 3
From (36):
z c =2.5/tan (5)=28.6 meters
From (35):
ρ s =3,250,000/[(2/3)*π(2.5) 2 (28.6)+( 2 (2.5) 2 )(122.9)]=1,165.9 kg/m 3
From (37):
% open room on Space Train=100*(1-1,165.9/7,874)=85.2% open room
FIGURE KEY
1. Front 10 degree nose cone
2. Front stabilizing gyroscope
3. Passenger compartment/work/sleep area
4. Shuttle de-orbit vehicle
5. Supplies and building materials
6. Solar/Electric Lepcon™ Panel Storage
7. Rear stabilizing gyroscope
8. Propulsion Mass to be ejected
9. Electric Mass driver propulsion system
10. Tip of rear cone, ejects to provide exhaust port
19. Launch Tube
20. Space Train™
21. First Airlock
22. Open-air loading platform
23. Crew compartment
24. Hatch
25. First door of airlock system
26. Second door of airlock system
27. Air evacuation pump
28. Main Vacuum Duct
29. Subsidiary vacuum ducts 29, 29', 29"
30. Electronic Control Module
31. Pull-only Electromagnets (cross-section)
32. Mid-section of launch tube
33. Superconducting Magnetic Storage Ring
34. Power distribution system (bus)
35. Power plants (coal, nuclear, solar)
36. Switching System
39. Upwardly curved end of tube
40. Mountain terrain
41. Second Air Lock System of Launch Tube
42. Main Duct of Air Conduction System
43. Secondary Air Ducts 43, 43', 43", etc.
44. Second Airlock Entrance Door (Third Door)
45. Second Airlock Exit Door (or Thin Membrane) (Fourth Door)
46. Radius vector to Earth's center at start of tube
47. Radius vector to Earth's center at end of tube
48. Radius vector R c of upward curve near end of tube
49. Inlet Air Conduit
50. Passenger.
51. Cushion Gee chair.
52. Z-axis pivot (computer controlled).
53. Y-axis pivot (computer controlled).
54. Counterweight.
55. Seat belt system.
56. Surface of Earth.
57. Tangent to Earth directly below Space Train.
58. Launch point of Space Train.
59. Optimum point of operation. Lowest mass and exit velocity with the constraint of achieving escape from Earth's gravity and not exceeding 8 gravities deceleration.
"a" placed after a number refers to the "actuator" for the device.
"c" placed after a number refers to a control wire to the device.
"v" placed after a number refers to a valve in the pipe or duct.
DISCUSSION
The acceleration of the Space Train™ to an exit velocity of 11.8 km/sec. takes place in five phases designed to provide a physiologically tolerable ride during the three minutes of maximal stress. Research indicates that the average human can withstand accelerations up to 12 times that of gravity when that acceleration is directed perpendicular to the chest (denoted here as Gx). Accelerations of greater than 12 Gx are found to interfere with breathing. Accelerations parallel to the chest (denoted here as Gz) are tolerable only up to three times that of gravity since these alter cerebral blood flow and cause blackouts.
During the Build-up Phase, the ship's acceleration is linearly increased from zero to eight gravities Gx over a period of 10 seconds rather than instantaneously, thus avoiding a sudden jolt to the passenger. The Boost Phase accelerates the Space Train™ to a final velocity of 12 km/sec. over a period of 146 seconds. The Build-down Phase decreases the acceleration from eight gravities to zero Gx over a three second period. Following, a Glide phase (3 seconds), allows a period of zero acceleration in which the passenger's chairs can be rotated 180 degrees to prepare for the deceleration phase. During the final phase, the Atmospheric Compensation period of time, (up to a density of 0.905 kg/m 3 ) produces a linear increase in the deceleration which peaks at -8 Gx's at the end of the tube causing a change in velocity equal to -190 m/s, and an exit velocity of 11.8 km/sec. at the launch tube exit. The velocity profile of the first 200 seconds is shown in FIG. 12. The Tangential acceleration profile is shown in FIG. 13. The Total acceleration experienced by the passenger is actually greater than this; it is the vector sum of the tangential acceleration (Gx) and the acceleration normal to the Earth (the result of gravity and centripetal acceleration--Equation 14). In the examples calculated in section II, a maximum centripetal acceleration of 4 times gravity was assumed. In the final section of tube (according to equation 14) the total normal acceleration (a v ) is 49.1 m/s 2 or 5 gravities while at the maximum tangential deceleration is -8 Gx. According to equation 15, the total acceleration experienced for the last second in the Launch Tube is approximately 9.45 times the force of gravity (the largest acceleration experienced during the entire flight).
FIG. 1 shows a cross-section of the Space Train™ indicating the proposed division of interior space. This 180 meter craft contains sufficient room for crew, living and research quarters, a shuttle vehicle for return of the crew, building materials for construction in space and numerous Lepcon™ light/electric power converting panels needed to provide electric power for all uses. The ship also contains an interplanetary mass-driver propulsion system in the rear cone. Front and rear cones were designed with a 10 degree angle to minimize drag. Since the cross-sectional area and cone angle are the critical parameters in equation (6) for drag, the ship can be elongated without a serious increase in drag forces--thus providing additional room if needed.
The open air loading platform is seen in FIG. 2. Passengers board the Space Train™ without any special suits or training. The ship is next moved into the tube by any suitable conventional means, such as fixed rollers on the ground, and a chain drive into the Launch Tube through the first door 25 of the air lock system 21, in which, the Second Door 26 is closed. The First Door 25 is then closed. The air is evacuated from the air lock 21 by an Air Vacuum Pump 27, through valve 29v, which is controlled by the electronic control module 30 via wire 29c. Only first stage vacuum pumps may be required because a high vacuum is not needed. At 1 millibar residual air pressure, the air friction of the moving vehicle is negligible, 0.1% of atmospheric pressure. At this point, the Second Door 26 of the air lock is opened by its actuator 26a, controlled by wire 26c connected to electronic control module 30, control cable 30c, and the launch is ready to proceed.
FIG. 3 is a cross-section of the Launch Tube and Space Train at some midpoint in the Boost Phase. Here, the "pull only" electromagnets indicate that they do not reverse currents to electromagnetically push the train but only pull it. Referring to FIG. 3, to enable the electromagnets 31 to pull the Space Train™ 20, its hull is made wholly or in part of a magnetic material such as iron; or other known magnetic material. An electric current is applied to the electromagnetic coils 31 just ahead of the center of the vehicle as it advances along the Tube 19. This also provides a self-centering force on the ship. The coils are spaced at predetermined intervals, specified by the ship's speed, required acceleration, and the coils electromagnetic field strength. The electric current is supplied to the coils 31 via the switches 36, which supply power from the inductor 33 via the bus 34. Electric power is provided by conventional sources (coal, nuclear, or solar). The electric power will be pulled off the power grid over a 24 hour period and stored in a series of superconducting storage rings 33, each ring supplying power to one or a group of electromagnets during the course of a launch.
References [8, 9, 10, 11] are incorporated in the specification to teach the known means of carrying out the invention, to describe prior art electromagnetic propulsion devices, and to set forth well known principles which may be employed in the engineering design of the present invention.
FIG. 4 illustrates the final section of the Launch Tube constructed just under the surface of a suitable terrain and opening into the atmosphere at an altitude of 1-6 km and an angle of 1° to 6°; for example 3 km and 3°. The final section of the tube contains a series of conduits comprising a Main Air Duct 42, and distribution Air Ducts 43, 43', 43", etc., which channel air from the atmosphere into the evacuated Launch Tube 19. These conduits are opened by valve 49v once the Space Train™ passes the next to last (third) air lock door 44. The atmospheric flow rate is such that the final tube section is completely filled with air in 5 seconds thus providing a smooth transition from zero to negative eight Gx's. At the end of the tube, the Space Train™ passes through the last (open) door 44; or alternatively, breaks through a thin membrane or passes through the last (fourth) Door 45 of the 2nd Airlock 41, which previously sealed the evacuated tube from atmospheric pressure.
FIG. 6 shows the entire course of the Launch Tube. The door 45 is opened or closed by its actuator 45a, controlled by wire 45c connected to the electronic control module 30 via cable 30c. In this example, the first 914 km follows the curvature of the Earth (R e =6,370 km) while the final 114 km curves upward (R 1 =2175 km) to provide a launch height of 3 km, at an angle of 3°.
FIG. 7 shows an example of the geometry of the final Launch Tube section indicating the curvatures, section lengths and angles. It is hoped that a mountain with the appropriate west face terrain, able to accommodate such a curvature, can be found in some region near the equator.
The angles and geometry describing the flight path and the equations of the orbital trajectory are defined in FIG. 8. The angle "α" is defined as the angle between the velocity vector and the tangent to the surface of the Earth at the launch point.
The Space Train™ mass of 3,250,000 kg and exit velocity of 11.8 km/sec. were chosen using the graphs seen in FIG. 9. The upward sloping curve determines the mass-exit velocity relationship needed to maintain the deceleration of the craft at 8 Gx's. Points below this curve are safe for passengers given the acceleration constraint. The upward sloping curve indicates the exit velocity (for a ship of a particular mass) needed to escape from Earth's gravity well. This curve was generated using the computer simulation of the flight path for vehicles of varying masses and initial velocity. The point of intersection of these two curves represents the minimum mass and minimum velocity needed for the ship to achieve escape velocity without experiencing a deceleration of greater than 8 gravities (Gx's).
The maximum height achieved (apogee) by Space Train is a function which depends primarily on mass, exit velocity and launch angle. FIG. 9 demonstrates that for a given exit velocity, the more massive ship attains a greater apogee. The greater mass allows the ship to store up more kinetic energy and thus loose a smaller percentage of its total energy during it transatmospheric flight. FIG. 10 demonstrates that for a given exit velocity, the greater the launch angle, the greater the apogee reached. In this situation, the greater launch angle decreases the amount of time that the ship spends in the dense atmosphere. Both curves were generated using an iterative computer program. It was assumed during these calculations that the Earth's rotational velocity would contribute approximately 400 m/s additional velocity to the ship.
FIG. 14 shows two functions plotted on the same graph: Power vs. Distance and Switching Time vs. Distance. Power here represents the amount of energy need per second to accelerate the 3,250,000 kg Space Train [P=(M*a)(V)]. The switching time refers to the amount of time needed for the voltage in the electromagnet coils to rise to their full potential, or conversely, the amount of time needed for the voltage in the coils to fall back to zero. It was assumed that the switch must occur within the time taken for the ship to transverse 10 or 100 meters. The maximum switching time found, approximately 0.8 milliseconds for 10 meters, or 8 ms for 100 meters (at 3*10 12 watts) appears to be within our technological capabilities. A section of the electromagnetic coils, 120 m long, may be simultaneously energized in which case, the maximum switching time is increased to about 10 ms.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 shows the electronic control module 30, which comprises a computer keyboard 30a, a computer with program 30, and a cable 30c containing wires connected to various control devices. FIGS. 2 and 3 show vacuum pump 27 connected by the main duct 28 to subsidiary ducts 29, 29', and 29", having respectively, valves 29v, 29'v and 29"v. Duct 29 is connected to the first airlock 21; duct 29' is connected to the mid-section of the launch tube 32; and duct 29" is connected to the second airlock 41. The electromagnetic door actuators 25a, 26a, 44a, and 45a respectively open or close airlock doors 25, 26, 44, and 45. Control wires 25c, 26c, 44c and 45c from the door actuators are connected via cable 30c to the electronic control module 30. The air control valve 49a, connected by the wire 49c to the cable 30c, controls the inlet air to the second airlock 41. The air, vacuum and electrical cycles are established by a program in the electronic control module 30, in accordance with the formulae and evaluations set forth herein.
Referring to FIG. 2, the Space Train™ 20 is initially positioned at an open air Station and Loading Platform 22. It is boarded and cargo loaded through doors 24. The Tube is vacuum-sealed by an Entrance Air-Lock with double doors 25, 26. The journey into space commences as the train is slowly moved into the Air-Lock, the door 25 closed and the Air-Lock evacuated. The door 26 is then opened, and the Train accelerated by the electromagnetic drive coils 31 at 8 g's for 157 sec. (2.6 minutes) to an exit velocity of about 12 km/s. Just before entering the atmosphere there is a 3 sec. period during which the acceleration is zero, providing time for the cushioned g-chair 51, shown in FIG. 5, to automatically revolve 180° about its vertical y axis. To prevent loss of the vacuum in the Tube, the Exit Air-Lock doors 44, 45 are opened and closed to enable the Train to pass. After the Train passes, the door 44 closes, and air enters the Air-Lock through the duct 42 shown in FIG. 4. This enables a gradual change from acceleration to deceleration shown in FIG. 13.
The mass, length and shape of the Train, and the Tube exit height and angle are chosen to minimize the atmospheric drag. Referring to the example shown in FIG. 6, the Tube 61 follows the curvature of the Earth for 915 km; then, to enable the Train to exit from the Tube at an angle of 3° to the horizontal, the Tube curves upward to a 3 km height in a distance of 114 km, at a radius of about 2175 km; such disposition being available naturally by suitably siting the Tube on favorable terrain. The Train may issue into the atmosphere, for example, through a thin "rupturable" disphragm at 45 located at the end of the Tube 61. As the Train enters the Atmosphere the maximum deceleration is 8 g's, quickly decreasing to about 1 g, and to almost 0 g.
The switching system for a space launcher is described in references 8 and 9. The switching time requirements in the switching system in this invention (milliseconds) is considerably greater than the switching time (microseconds), of the prior art reference. This is because of the greater length of the space vehicle in the present invention and hence, greater spacing between the electromagnetic coils. For example, in FIG. 14, Curve No. 2, right hand scale, the switching time of the present invention is 1 to 2.5 ms, which is within the present state of the art of switching devices. The switching of large amounts of electric power is common practice in present electric power plant distribution systems.
About 100,000 m 2 of Lepcon™ panels will be carried as cargo aboard the vehicle when it is launched. The Lepcon™ panels are about 0.6 cm thick. A package may contain 1000 Lepcon™ panels per m 3 ; and 100m 3 of cargo space may be provided on the Train. If the Train is 5 m in diameter and the wall thickness 0.3 m, the internal cross-section is about 15 m 2 . Using about a 75% packing factor, the 10 5 m 2 of Lepcon™ panels may be stored as cargo in about 10 m length of the vehicle. Another 10 m length of the vehicle may be used for the construction materials to assemble the Lepcon Solar-Electric power converting Array in space. To provide living and working rooms for the crew on long journeys, outboard structures may be constituted by the assembly in space of building materials carried as cargo; or, by separating and repositioning portions of the Space Train™. For example, such rooms may be positioned just outside the Solar-Electric Panel Array, and rotated to provide a suitable gravitational field, for example, 1 g, or a variable g in known manner [1].
Once the Space Train™ has passed beyond the Earth's atmosphere the Lepcon™ panels may be deployed as an Array in the form of a disc, which may be for example, circular, having a radius of about 180 m, and an area of 100,000 m 2 .
In the vicinity of the Earth-Sun distance, 1.5×10 11 m, the 10 5 m 2 of Lepcon™ Solar-Electric Panel Array will provide 100 Mw Solar-Electric Power to the propulsion system of the Space Train™, and for other on-board requirements. An excess portion of the electrical energy produced may be stored by suitable electrical storage means; for example, a superconducting electromagnetic ring.
Because of its large mass, a Space Train™ will carry everything needed as cargo and will be self-sufficient on a long voyage. After getting underway, the solar-electric power converting panels will be deployed as a disc; passenger, and crew living and work quarters may be assembled and located on the perimeter of the disc. The entire structure may revolve slowly (about 2 RPM to provide a variable or 1 g gravity and a normal life-sustaining environment). Alternatively, parts of the Space Train™ may be separated like the cars of a train and repositioned in space on the perimeter of the disc. One or more prefabricated Shuttles may be carried ready for use and separated as needed to land on the Earth, Moon, Mars, etc.
The electrically powered mass-driver propulsion system is herein termed a "Thrustor". The Thrustor provides the force to drive the Train™ in space. The Thrustor electrically accelerates and expels submicron (500-1500 A) particles, charged with one or a few charges per particle. These particles are expelled at the rate of 0.01 to 1 Kg/s, for example, 0.1 Kg/s. These particles are supplied from a certain mass stored as cargo; herein termed "expendable mass".
Expendable mass may comprise finely crushed, dry rock or a suspension of particles in water. The mass expelled may eventually be replaced during an interplanetary voyage from material such as rock mined on the Moon, Mars, Asteroids or other body. Such rock will be finely crushed and converted to submicron particles, for use as expendable mass expelled by the Thrustor.
The Train may include a facility with means to disintegrate expendable mass into submicron particles for use in the Thrustor to provide thrust for the Train.
One such means for disintegrating the finely crushed rock particles may comprise an "Impactor" for the breakup of larger particles into smaller particles. The impactor applies a large impact and liquid shear on particles suspended in water; for example, by directing a high velocity water jet containing the suspended rock particles onto sapphire or tungsten carbide surface on a disc. The water suspension may contain a small percentage of suitable surfactant to maintain the particles in suspension.
The particles may be graded according to size; for example, by an on-board facility employing several centrifugal separations at different RPM's in the range of 3000 to 20,000 RPM. The first separation at 3000 RPM concentrates, on a bottom layer on the centrifuge tube, particles larger than 5 μm, leaving smaller particles in suspension in water in the upper part of the centrifuge tube. Preferably a continuous centrifuge is employed.
A second separation, for example at 5000 RPM, concentrates particles between 0.5 μm and 5 μm, the smaller particle remaining in suspension in the upper portion of the centrifuge tube. This process may be repeated to obtain any size range. For example, at 9000 RPM all particles smaller than 1500 A may remain in suspension. The larger particles are returned to the Impactor for further breakup into smaller sizes, and the process is repeated until all the particles are broken into the required dimensions. The smallest particles, in the range of 500 to 1500 A, remain in suspension by Brownian Motion. These may be concentrated by a greater RPM, for example, 20,000 RPM, for use in the Thrustor. These RPM values are illustrative; other values may be used as determined in practice with suspensions of various materials.
The particle charging device in the Thrustor may comprise a plurality of orifices, for example, about 30 to 100 μm in diameter through which the particle-water suspension is forced forming a plurality of jets. An external ring electrode surrounding the jets applies an electric field to the water-particle jets which break apart and separate the charged particles by mutual repulsion. The water quickly evaporates leaving one or more charges on the particles, which are accelerated by the high voltage in the Thrustor.
An alternate method of forming the submicron particles may comprise the steps of feeding finely crushed rock into a high temperature plasma torch to vaporize, then cool and condense the vapor to form submicron particles in the presence of electrons or ions, thereby producing electrically charged submicron particles about 1000 A dia. with one or a few electric charges per particle. These electrically charged submicron particles are electrically accelerated and expelled by the Thrustor to provide the force to propel the Space Train™.
Alternatively, an Electric-Light Power Converter (laser) such as the Elcon™ laser beam [3] may be utilized to vaporize the rock particles to form submicron particles by cooling condensation and solidification from the vapor.
Another application of the principles disclosed herein, is rapid ground transportation by train over long distances such as, travelling the 4800 km distance between New York and Los Angeles in one hour; at 1.3 km/s average velocity, and 2.7 km/s peak velocity, at a small maximum acceleration of 0.3 g. With greater acceleration not exceeding 8 g, the travel time could be decreased to about 15 minutes. Because there is no atmospheric entry at high velocity, a vehicle of smaller mass may be employed. During the deceleration phase, most of the kinetic energy of the vehicle may be electromagnetically recovered and stored or used.
It will be understood that the examples given herein, under the heading "Mathematical Physics," are illustrative and may be modified for other design parameters. For example, if the Tube Exit were located on one of Earth's highest plateaus, at a height of about 6 km, the air pressure would be decreased and the exit angle increased. Examples are: H=5.4 km in the Pino Brava Plateau, Bolivia (P atm =0.51); H=6 km in the Nepal Himalaya Plateau (P atm =0.47). At 6 km height, the exit angle will be about 6°, the Mass of the Space Train will be about 2,800,000 Kg, the length about 160 m; and the energy to accelerate the vehicle to exit velocity will be decreased by about 15%. [17,18]
The theoretical mathematical physics analysis and calculations presented hereinabove are illustrative, and the scope of this invention is not be be limited thereby. Various modifications may be made to this invention without departing from the scope thereof.
For the purposes of the claims the "Space Train™" described hereinabove is also termed a "vehicle".
REFERENCES
1. PIONEERING THE SPACE FRONTIER
An Exciting Vision of Our Next Fifty Years in Space.
REPORT OF THE NATIONAL COMMISSION ON SPACE
Bibliography p. 203. Published by Bantam Books, Inc.;
666 Fifth Avenue, New York, NY 10103.
1.1 pp. 101,112-113.
1.2 pp. 122-123
1.3 pp 64, 103-104
1.4 pp. 103, 122-123
2. U.S. Pat. No. 4,445,050 issued to Alvin M. Marks on Apr. 24, 1984 entitled: Device for the Conversion of Light Power to Electric Power".
3. U.S. patent application Ser. No. 637,405 filed Aug. 3, 1984 entitled: "Femto Diode and Applications" now issued to Alvin M. Marks as U.S. Pat. No. 4,720,642 on Jan. 19, 1988.
4. U.S. Pat. No. 4,206,396 issued to Alvin M. Marks, June 3, 1980 entitled: "Charged Aerosol Generator with Uni-Electrode Source".
5. Cohen, E., ARL 63-88, May 1963.
"Research on the Electrostatic Generation and Acceleration of Submicron-Size Particles". Space Technology Laboratories, Inc., Redondo Beach, Calif.
Contract No. AF 33(616)-6775, Project 7116, Task 7116-03. Aeronautical Reserach Laboratories, Office of Aerospace Research, Wright Patterson Air Force Base, Ohio AD427739; Defense Documentation Center for Scientific and Technical Information, Cameron Station, Alexandria, Va.
6. Superconducting Energy Storage for Space Applications; with bibliography: 9 References; Eyssa, Boom and McIntosh Applied Superconductivity Center, University of Wisconsin Madison, Wis. 53706
Final Report to NASA
Grant NAG 3-170; Mar. 3, 1981-July 29, 1982.
Lewis Research Center, 21000 Brookpark Road Cleveland, Ohio 44135
7. THE ANNOTATED JULES VERNE: FROM THE EARTH TO THE MOON AND A TRIP AROUND IT
Walter James Miller
Thomas Y. Crowell, Publishers
10 East 53rd Street, New York, NY 10022
8. AN ELECTROMAGNETIC FIRST STAGE SPACE CARGO LAUNCHER
H. Kolm, P. Mongeau, O, Fitch, F. Williams,
P. Granau, K. McKinney.
American Institute of Aeronautics and Astronautics, Inc., 1981.
9. ELECTROMAGNETIC LAUNCHERS
H. Kolm, P. Mongeau, F. Williams
IEEE Transactions on Magnetics;
Vol. MAG-16, No. 5, September 1980
10. DYNAMICS AND DESIGN OF ELECTROMAGNETIC MASS DRIVERS
III P. 85-157 incl.; NASA SP-428, 1979
SPACE AND SPACE RESOURCES
Scientific and Technical Information Branch, Washington, D.C.
11. INTERNATIONAL CONFERENCE ON MAGLEV AND LINEAR DRIVES
May 14-16, 1986, Vancouver, B.C., Canada; 35 Papers Sponsored by: IEEE Vehicular Technology Society Co-sponsored by: Transportation Development Centre, Transport, Canada; Canadian Institute of Guided Ground Transport, Queens University
Published by: IEEE, Catalogue No. 86CH22376-4
12. MAGNETIC TRAINS TAKE OFF
Randall Black, Science Digest, p. 26, August 1984.
13. Ventilatory Response to Forward Acceleration
Zechman Cherniak and Hyude
Chronic Acceleleration Laboratory
Acceleration Section, Biophysics Branch
Aerospace Medicine Laboratory
Wright Patterson Air Force Base, Ohio
Journal of Applied Physiology, Vol. 15:2 pp. 907-910, 1960
14. Decreases in Arterial Oxygen Saturation and Associated Changes in Pressures and Roentgenographic Appearance of the Thorax During Forward (+G x ) Acceleration
Nolan, Marshall, Cronin, Sutterer, and Wood
Chronic Acceleration Laboratory
Aerospace Medicine, Vol. 34, p. 797, September 1963
15. A FEASIBLE UTILITY SCALE SUPERCONDUCTING MAGNETIC ENERGY STORAGE PLANT
Lloyd, Schoenung and Nakamura, Bechtel Inc. San Franscisco, CA; Lieurance and Hilal, General Dynamics Corp., San Diego, CA; J. D. Rogers, Los Alamos National Laboratory, Los Alamos, NM; J. R. Purcell, G.A. Technologies, Inc., San Diego, CA; W. V. Hassenzahl, Lawrence Berkeley Laboratory, Berkeley, CA.
IEEE Transactions on Energy Conversion, Vol. EC-1, No. 4, December 1986, pp. 63-68, with 10 references.
16. SUPERHARD TRANSPARENT COATINGS
USARTL-TR-78-19, June 1978.
Final report for the period November 1975-February 1977.
Robert L. Fogarty, Richard S. Hassard, John Uram Jr., Glenn Wintermute.
Goodyear Aerospace Corporation, Arizona Division, Litchfield Park, Ariz. 85340.
Prepared for: Applied Technology Laboratory, U.S. Army Research and Technology Laboratories (AVRADCOM), Fort Eustice, VA 23604.
ALUMINA-WATER SUSPENSION, pp. 16-17.
SUBMICRON PARTICLE SUSPENSIONS
Graphs of the particle parameters: size, time, rpm of centrifuge are shown in FIGS. 13, 14 and 15, pp. 52-58. Tables 13, p. 54 and B1, p. 103.
EQUIPMENT; Appendix D, FIG. D-1, p. 109 shows photo of Gaulin Submicron Disperser; FIG. D-2, p. 110 shows photo of Sorvall SS-3 Centrifuge.
17. Encyc. Brit., 1968 Ed., Articles on Bolivia and Nepal.
18. Handbook of Physics and Chemistry, 65th Ed., F 151, Values of Atmospheric Pressure vs. Height.
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The direct projection of a space vehicle, herein termed a "Space Train™", into space without combustile fuel is described. A mathematical physics analysis derives critical ranges of parameters, which inlcude a vehicle having a mass of about 3,000,000 Kg., a length of about 180 m and 5 m dia.; an acceleration of about 8 g's during its travel within 1000 km of a vacuum tube parallel to Earth's surface to a velocity of about 12 km/sec., the vehicle exiting from the tube into the atmosphere at an angle of about 3° and an elevation of about 3 km at a maximum deceleration of about 8 g's. An acceleration or deceleration of 8 g's is tolerable to humans in the special chair described herein. The energy imparted to this mass is provided by a conventional electric power source stored as electric energy in superconducting storage inductor rings. The electric energy is discharged to coils around the vacuum tube just in advance of the center of the moving vehicle. A solar electric powered mass thrustor is also described. The Space Train™ will decrease the cost of transportation into space by a factor of at least 100; opening the Space Frontier on a cost-efficient, profitable, reliable and safe basis.
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This application is a continuation-in-part of U.S. Provisional Application Ser. No. 60/048,272 filed Jun. 2, 1997.
BACKGROUND OF THE INVENTION
The present invention relates to the art of diagnostic imaging. It finds particular application in conjunction with nuclear or gamma cameras and will be described with particular reference thereto. It is to be appreciated, however, that the present invention will also find application in other non-invasive investigation techniques and imaging systems such as single photon planar imaging, whole body nuclear scans, positron emission tomography (PET) and other diagnostic modes.
Positron emission tomography (PET) scanners are known as coincidence imaging devices. In planar coincidence imaging, two radiation detectors oppose each other with a subject disposed between the detectors. Typically, one or more radiopharmaceuticals or radioisotopes capable of generating positron emission radiation are injected into the subject. The radioisotope preferably travels to an organ of interest whose image is to be produced. The detectors scan the subject along a longitudinal axis without rotation, otherwise known as limited angle tomography. Radiation events are detected on each detector and a coincidence circuitry compares and matches the events on each detector. Events on one detector which have a coincident event on the other detector are treated as valid data and may be used in image reconstruction.
Typically, the detector includes a scintillation crystal that is viewed by an array of photo multiplier tubes. The relative outputs of the photo multiplier tubes are processed and corrected, as is conventional in the art, to generate an output signal indicative of (1) a position coordinate on the detector head at which each radiation event is received, and (2) an energy of each event. The energy is used to differentiate between various types of radiation such as multiple emission radiation sources and to eliminate noise, or stray and secondary emission radiation. A two dimensional image representation is defined by the number of coincidence radiation events or counts received at each coordinate. However during a scan, only a fraction of the events detected are coincidence events. As such, scan times are increased in an effort to obtain a sufficient data sampling for image reconstruction which poses additional inconveniences to the subject and an increase in scanning costs.
The present invention provides a new and improved diagnostic imaging system and method which provides simultaneous positron and single photon imaging which overcomes the above-referenced problems and others.
SUMMARY OF THE INVENTION
In accordance with the present invention, a new and improved diagnostic imaging system and method for diagnostic imaging is provided. A nuclear camera system includes a gantry which defines an examination region for receiving a subject. The subject is injected with a substance which emits positron radiation, positron radiation and single photon radiation, positron radiation and radiation suitable to obtain information on attenuation, or any combination thereof. First and second radiation detectors are oppositely disposed on the gantry and have the examination region therebetween. The first and second radiation detectors simultaneously detect radiation from the examination region. A coincidence circuitry connects the first and second radiation detectors and determines the likelihood of that received radiation events come from a positron emitter. Subsystems are connected to the coincidence circuitry which determine the likelihood of a single event having a particular energy band, including an energy window appropriate to define a single gamma of a pair of gamma from a positron emitter, or any other isotopes present in the examination region, including radiation from the positron emitter. An event determiner is connected to the first and second radiation detectors which direct radiation events to a proper reconstruction processor according to characteristics of the radiation events such as timing (or coincidence), energy, location on the detector, or any combination thereof.
In accordance with another aspect of the present invention, a diagnostic imaging method is provided for imaging a subject which includes injecting the subject with first and second isotopes where the first isotope generates positron radiation and the second isotope generates single photon radiation. Selected energy values of radiation are collimated. The positron radiation and the single photon radiation are simultaneously detected and a type of radiation detected is determined. Coincidence data based on the positron radiation detected is generated and single photon data based on the single photon radiation detected is generated. An image representation of the subject is reconstructed from the coincidence data and from the single photon data.
One advantage of the present invention is that positron radiation and single photon radiation arc simultaneously collected by the same radiation detectors.
Another advantage of the present invention is that dual isotope imaging is performed which provides more clinically useful information.
It is a further advantage of the present invention that the image representation of the positron emitter is obtained by selecting events that are in coincidence, events that are in coincidence and with a proper energy, or simply events that have the proper energy, thus increasing the number of events in the final image. Events coming from a different selection path are either immediately combined or separated and analyzed independently.
It is still another advantage of the present invention that an image representation of a single photon emitter (if present in the examination region) is obtained simultaneously with the image representation of the positron emitter.
It is yet another advantage of the present invention that coincidence event image representations that are best when placed in the center of the examination region, can be combined, or analyzed separately with collimated events of the same radiation known to be best at the periphery of the examination region, and to be less affected by the non-uniform nature of attenuation material in the examination region.
Still further advantages of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating a preferred embodiment and are not to be construed as limiting the invention.
FIG. 1 is a diagrammatic illustration of a diagnostic imaging system in accordance with the present invention;
FIG. 2 is an illustration of a preferred embodiment of the present invention;
FIGS. 3 A- 3 D illustrates examples of a coincidence events detected;
FIG. 4A illustrates an example of a single detected event from a positron emittor;
FIG. 4B illustrates an example of a single detected event from a 20 single photon emittor;
FIG. 4C illustrates an example of a single detected event from transmission radiation;
FIG. 5 illustrates an alternative collimator in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, a diagnostic imaging system includes a subject support or table 10 which is mounted to stationary, vertical supports 12 at opposite ends. The subject table is selectively positionable up and down to center a subject 16 in the center of a circle along a longitudinal axis 14 . An outer gantry structure 20 is movably mounted on tracks 22 which extend parallel to the longitudinal axis. This enables the outer gantry structure to be moved parallel to the longitudinal axis 14 . An outer gantry structure moving assembly 24 is provided for selectively moving the outer gantry structure 20 along the tracks 22 in a path parallel to the longitudinal axis. In the illustrated embodiment, the longitudinal moving assembly includes drive wheels 26 for supporting the outer gantry structure on the tracks. A motive power source, such as a motor 28 , selectively drives one of the wheels which frictionally engages the track and drives the outer gantry structure and supported inner gantry structure and detector heads therealong. Alternately, the outer gantry can be stationary and the subject support configured to move the subject along the longitudinal axis.
An inner gantry structure 30 is rotatably mounted on the outer gantry structure 20 . A first camera or radiation detector head 32 is mounted to the inner gantry structure. A second radiation detector head 34 is mounted to the inner gantry structure opposite to the first camera head. The first and second detectors 32 , 34 are configured to detect positron emission radiation generated by a positron emission source injected into the subject. The inner gantry structure defines a central, subject receiving examination region 36 for receiving the subject table and, particularly along the longitudinal axis. The examination region 36 is enlarged to receive the detector heads in any of a variety of displacements from a central axis and angular orientations.
The detectors each include a scintillation crystal disposed behind a radiation receiving face 38 that is viewed by an array of photo multiplier tubes. The scintillation crystal emits a flash of light in response to incident radiation. The array of photo multiplier tubes convert the light into electrical signals. A resolver circuit resolves the x,y-coordinates of each light flash and the energy of the incident radiation. The relative outputs of the photo multiplier tubes are processed and corrected, as is conventional in the art, to generate an output signal indicative of a position coordinate on the detector head at which each radiation event is received, and an energy of each event.
With further reference to FIG. 1, the overall operation of the present invention may be summarized as follows. A subject to be imaged is injected with one or more isotopes which generate positron radiation, or positron radiation and single photon radiation. In the preferred embodiment, two isotopes are injected which have different energies. For example, a first isotope generates positron radiation in a range of 511 keV and the second isotope is generates single photon radiation in a range of 140 keV. For example, Tc-99 m emits photons having a primary photopeak of approximately 140 keV. During an imaging scan, the radiation detectors 32 , 34 both simultaneously detect and collect all types of radiation from the subject and examination region which may include positron coincidence radiation events, single photon radiation events, transmission radiation events, and any combination thereof depending on the radiation sources present. An event determiner 50 evaluates the event data and determines the type of radiation event and/or the type of radiation at each detected event. Based on selected factors of an event such as timing (coincidence between two events), energy, location or any combination of these factors, the radiation data is processed by a coincidence data processor 52 , a single event processor 54 , or is disregarded 56 . The coincidence processor can further direct events to a sub-processor according to location and/or energy of the event. The single photon processor 54 can further direct events to a sub-processor according to location and/or energy of the event. An image representation of each processor and sub-processor can be combined or analyzed separately.
With reference to FIG. 2, a preferred embodiment is shown including a high energy collimator 70 mounted on the radiation receiving face of the detectors 32 and 34 . The high energy collimator provides sufficient shielding to filter a large fraction of 511 keV gamma radiation 72 traveling at an angle with respect to an axis of the collimator 70 . Thus, single photon radiation 74 , coincidence positron radiation 76 , single event positron emission radiation, and transmission radiation (if present) which reach the detectors are collimated. The high energy collimator 70 provides-sufficient spatial filtering in the collimator to produce adequate images from high energy isotopes. Heavy filtering reduces the count rate of received radiation on the detectors allowing for longer integration times to be used to improve performances at low energy.
The high energy collimator 110 geometrically correlates coincidence events from the 511 keV positron emitters. Thus, all coincidence events are accepted as valid events irrespective of their energy. Even the scatter/scatter events which typically comprise a majority of the events occurring a thin scintillation crystal are accepted as valid data which would otherwise be disregarded.
With further reference to FIG. 2, the event determiner 50 collects all data 80 from the radiation events detected by the radiation detectors 32 and 34 . Each event is determined 82 whether it is valid based on predefined valid energy windows based on the energy characteristics of the injected isotopes and transmission radiation source (if present). If a detected event does not fall within of the predefined energy windows, the data is disregarded 84 as noise. If the event does fall within the selected energy windows, a determination 86 is made as to whether the event is a coincidence event. Based on this determination, the event data is directed to a coincidence circuitry 88 or a single photon data processor 90 .
The coincidence circuitry 88 determines coincidence between events by matching the event with a coincidence event on the other detector and determines a ray path traveled by the event. If a coincidence is found, coincidence data is generated and a coincidence reconstruction processor reconstructs the coincidence data into a coincidence or positron image representation 60 . Alternately, the coincidence circuitry 88 directs the event data to an energy filter 92 in a case where the coincidence determination results in a finding that one or both of the coincidence events underwent scattering. In the case of scattering, the event data is filtered and a sub-image 94 is reconstructed. Lastly, if the coincidence circuitry determines that the event resulted from a transmission radiation source, the event data is directed to a spatial filter 96 which filters the transmission event and a sub-image 98 representing a positron transmission source is reconstructed.
If the determination 86 results in the event not falling within the positron energy window, the event data is directed to the single photon processor 90 and an energy filter 100 where the event is processed according to its energy. Radiation data is generated and an image representation is reconstructed in accordance with the type of data which may be 511 keV representing a positron distribution 102 , emission data representing a single photon distribution 104 , or simple more data 106 . If, however, the event data is determined to be transmission energy 108 , a spatial filter 110 filters the event data into attenuation factors 112 . Once the positron image 60 and the single photon image 62 are reconstructed, the images may be displayed together for analysis or may be selectively combined such as by super imposing one on to the other to generate a resultant image.
With reference to FIGS. 3 A- 3 D, examples of possible coincidence events detected by the detectors 32 and 34 are shown, all of which are accepted as valid data. FIGS. 4 A- 4 C illustrate examples of single detected events which are accepted as valid data such as a high energy 511 keV radiation event (FIG. 4 A), a low energy 140 keV radiation event (FIG. 4 B), and a transmission radiation event (FIG. 4 C). A photoelectric effect event is represented by PE and a scatter event is represented by SC. The scatter events are typically disregarded, however with the present system, they are accepted as valid counts available for imaging. This results in an increase in the effective count rate and provides for dual isotope imaging. All detected events having energies which fall within the coincidence window are accepted for positron image reconstruction and all events having energies in anticoincidence and falling within a valid energy window are accepted for single photon reconstruction.
Using the high energy collimator 70 , spatial resolution is reduced only if the collimator provides the directional information on the two coincidence 511 keV gammas. An additional spatial constraint can be imposed after the coincidence trigger because the coincident events should be directly opposed to one another on the detectors 32 and 34 plus or minus a few degrees. Adjustments are made to select proper parameters to optimize the count rate and spatial resolution for the positron emitter and to provide sufficient spatial and energy resolution for the low energy single photon isotope.
Preferably, the coincidence circuitry and data processor 52 is used on long integration time events. In this mode, the count rate for the positron emitter is reduced as compared to using a standard bare scintillation crystal. Furthermore, typical coincidence counting using large area detectors is typically eliminated by the dose of the injected isotope, meaning that the injected dosage must be reduced so that the maximum count rate of the system is not exceeded. Thus, a stronger filter (e.g., collimator) can be applied so that the injected dose is not reduced in order to maintain an effective count rate in the image.
The following is an exemplary decision tree process in accordance with a hybrid coincidence/collimation mode.
Hybrid Coincidence/Collimation Mode
(collecting events of types shown in FIGS. 3 A- 3 D and 4 A- 4 C)
Event detected
In coincidence with another event on different detector
Evaluate position of the two events (FIGS. 3 A- 3 D)
Generate coincidence events data
Reconstruction
Distribution of positron emittor using coincidence events
Single event, no coincidence
Evaluate energy
Energy within the 511 keV energy window (FIG. 4A)
Distribution of positron emittor using single events
Energy within a single photon energy window (one or several windows) (if defined) (FIG. 4B)
Distribution of single photon emittor
Energy within transmission energy window (if defined) (FIG. 4C)
Distribution(s) of the attenuation coefficient (140 keV and 511 keV)
Event Rejected
With reference to FIG. 5, an alternative collimator 130 is shown which includes a first level of collimation 132 provided to collimate the high energy photons and a finer resolution collimator 134 provided within the large area of the first high-energy collimator. Thus, a one-dimensional axial filter and a high-resolution low energy collimator are combined. However, this configuration does not benefit from the advantageous of the full ultra-high energy collimator 70 and all coincidence events cannot be blindly accepted. The low energy image may be affected from the presence of the high-energy axial filter and from an absence of coincidence filter in the Compton region of the 511 keV isotope.
The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
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A gamma camera includes detector heads disposed about an examination region. A high energy collimator collimates the radiation received by each of the detector heads. Either a positron emitting radionuclide or a positron emitting radionuclide and a single photon emitting radionuclide is introduced into an object to be imaged. Radiation which is received by the detectors within a coincidence time interval and radiation which is received by either of the detectors but having an energy characteristic of a positron annihilation are used to generate coincidence data. Radiation which is not indicative of coincidence radiation but which has an energy characteristic of the single photon emitting radionuclide is used to generate single photon data. The data is processed and used to generate one or more images of the object.
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RELATED U.S. APPLICATION DATA
This application has priority to U.S. Provisional Application Ser. No. 60/216,085, filed Jul. 6, 2000.
BACKGROUND OF THE INVENTION
The present invention relates to a flip chart holder. More specifically, the invention is directed toward an updatable and lockable flip chart holder that can clip into the rail strip or channel of a shelf or fasten to a display at a retail store.
Merchandising and informational needs have evolved in the increasingly competitive marketplace. Point-of-purchase signage is important because many purchasing decisions are made while viewing the products on display. Sign holders with signage, such as flip charts, provide the consumer with educational or advertising information where it is quite useful. Flip charts are used to provide a variety of information. Flip charts are useful to provide more and better categorized information than single panel displays. Additionally, flip charts can often be tabbed so that desired information may be readily selected and reviewed.
Educational or promotional flip charts frequently need to be updated. With spiral bound flip chart pages, the entire flip chart would have to be removed. Such removal of an entire set of chart pages is not economical when only selected information needs to be updated.
Further, readily removable pages or sets of pages have both benefits and drawbacks. They are easier to use, but they are also easier to tamper with. Mischievous customers or others who are unauthorized can remove the chart pages or sets of pages that are not secured.
Accordingly, it would be desirable to have a shelf-front display system that can easily be updated while maintaining the security of the pages.
SUMMARY OF THE INVENTION
The invention may be described as a flip chart holder that allows manufacturers or promoters of products that are sold at retail to create consumer, educational, or promotional flip charts that can be easily and economically updated using rings that open similar to the rings of a binder. At the same time, locking the rings provides security so consumers cannot take the pages out of the flip chart holder. A lock for the rings can comprise an Allen screw or a similar device located at the center top portion of the flip chart holder and can be opened with an Allen wrench or a similar complementary tool.
A primary benefit of the present invention is that it is easy to use. Flip chart pages can be installed or removed by opening rings in a ring system similar to a three-ring binder. When the ring halves are opened, pages of the flip chart can be removed, inserted, or updated.
The present invention overcomes problems with the mischievous removal of pages. The flip chart holder contains a locking mechanism so that the rings can only be opened when the holder is unlocked. The locking mechanism is a simple device. In a preferred embodiment, the locking device is an insert that can be rotated into the cover to secure hinged leaves that are connected to the ring halves.
In a preferred embodiment, a mount is secured to the back surface of the backing panel. A mount may attach so that the holder hangs from a shelf front or various other displays. Shelving faces include C-channels as a common profile. C-channels are an open-faced design that allows signs, displays, or price tags to be easily slipped into the channel for viewing by the customer. There are standard 1¼ inch shelf channels. A channel adapter or bracket can be attached to the back surface of the backing panel so that the holder can be secured to the rail or channel on the face of a shelf. A variety of other mounts are available depending on the display. With other mounts, the holder can snap securely to wire fixtures. Also, the backing panel can clip on a pegboard or a slatwall with an adapter. Of course, the holder can also be fixedly mounted on a surface.
BRIEF DESCRIPTION OF THE DRAWINGS
The above mentioned and other features of this invention and the manner of obtaining them will become more apparent, and the invention itself will be best understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings in which:
FIG. 1 shows a flip chart holder of the present invention attached to a channel on a shelf face.
FIG. 2 shows a top view of a flip chart holder.
FIG. 3 shows a cross sectional view of an open ring system with an unlocked locking device.
FIG. 4 shows a cross sectional view of a closed ring system with a locked locking device.
FIG. 5 shows a page adapted to be used with a flip chart holder.
FIG. 6 shows a mount for use with a channel.
FIG. 7 shows another embodiment of a mount for a peg board or slatwall.
FIG. 8 shows yet another mount adaptable for a slatwall.
FIG. 9 shows a further mount for a slatwall.
FIG. 10 shows an additional mount for a surface mount.
FIG. 11 shows a below shelf mount.
FIG. 12 shows an alternate embodiment of a below shelf mount.
FIG. 13 shows a center shelf mount.
FIG. 14 shows an alternate center shelf mount.
FIG. 15 shows a mount for an edge of a glass shelf.
FIG. 16 shows an alternate mount for a glass shelf.
FIG. 17 shows a flush mount for a shelf with perforations.
FIG. 18 shows a multipurpose mount adaptable for clipping over wire.
FIG. 19 shows a mount for a shelf.
FIG. 20 shows a bendable mount for various purposes.
FIG. 21 shows a mount using an adhesive.
FIG. 22 shows a holder with pages and a page protector.
FIG. 23 shows a page protector.
DETAILED DESCRIPTION OF THE INVENTION
In the Figures, like reference numerals indicate the same elements throughout. FIG. 1 shows a flip chart holder 10 clipped to the rail strip or channel 12 of a shelf face. The flip chart holder 10 can similarly be fastened to a display at a retail store.
In greater detail, with reference first directed to FIG. 2, the holder 10 includes a ring system 14 attached on the face side 16 of a backing 18 and a mount 20 (See FIGS. 6-21) attached on the back surface 22 of the backing 18 . The ring system 14 and mount 20 are fixedly attached to opposite sides of the backing 18 . The preferred means of attachment 24 is a rivet. The same rivet 24 can hold the ring system 14 and the mount 20 to the backing 18 . The attachment means 24 of attaching the ring system 14 to the backing 18 and the mount 20 to the backing 18 also includes any type of adhesive, cement, glue, tape, screw, nut and bolt, clip, clasp, tie, hook, strap or other equivalent fastener.
The ring system 14 has a multi-faced, rounded or dual angle ring system cover 26 , a plurality of rings 28 and 30 , each having two ring halves 32 and 34 , 36 and 38 respectively, and a plurality of leaves 40 and 42 (See FIGS. 3 and 4 ). The rings 28 and 30 are mounted within the cover 26 that has openings 44 , 46 , 48 , and 50 in its upper surface 52 through which the respective ring halves 32 , 34 , 36 and 38 project. The ring halves 32 and 34 , 36 and 38 respectively are separated to open the rings 28 and 30 .
The ring system 14 preferably includes a pair of leaves 40 and 42 hingedly connected to each other for relative movement between them. A plurality of rings 28 and 30 are each formed of a pair of ring halves 32 and 34 , 36 and 38 respectively with one end of each ring half per ring attached to a separate one of the leaves 40 and 42 as shown in FIGS. 3 and 4. This allows for movement of the leaves 40 and 42 relative to each other to move the ring halves 32 and 34 , 36 and 38 respectively to open and close the rings 28 and 30 . FIG. 3 shows a cross sectional view of a ring system 14 with the ring 28 open. FIG. 4 shows a cross sectional view of a ring system 14 with the ring 28 closed.
Release levers or latches (not shown) are common to many three ring binders at each end of the ring system 14 to open and close the rings 28 and 30 . Such levers or latches are well known. The lever would contact both the leaves 40 and 42 . By pushing down on the lever, one leaf has counterclockwise rotation and the other leaf has clockwise rotation, or the lever otherwise functions in a similar fashion to act upon the leaves. These release levers can be used with this system 14 , but are preferably not included. A person opens the rings 28 and 30 by either pulling the ring halves 32 and 34 , 36 and 38 respectively apart, or by pushing outwardly on the lever arms. Ideally, in the preferred embodiment without levers, the rings 28 and 30 are opened by pulling each ring half (i.e., 32 from 34 , 36 from 38 ) away from each other.
As shown in FIG. 4, the leaves 40 and 42 , when the rings 28 and 30 are closed, form a predetermined angle with respect to each other so that the leaves 40 and 42 are substantially parallel, defined as less than fifteen degrees. The leaves 40 and 42 are ideally perfectly parallel to each other and the backing 18 when the rings 28 and 30 are closed. The distal ends of the leaves 40 and 42 are in their closest position to the backing 18 , i.e., away from the cover 26 in the center portion when viewed in the cross section.
As shown in FIG. 3, an obtuse angle is formed between the distal ends of the leaves 40 and 42 when the ring halves 32 and 34 are open. The angle when the rings 28 and 30 are open can be more or less than 15 degrees, but as apparent, when the rings 28 and 30 are open, a distal end of each leaf 40 or 42 is angled away from the backing 18 toward the cover 26 in the center portion in the cross section. The locking device 60 operates by preventing the leaves 40 and 42 from rotating toward the cover 26 .
A locking device 60 is installed on the cover 26 of the ring system 14 . The locking device 60 includes a cylinder with threads, such as a rod incised with advancing spiral threads. In a preferred embodiment, an aperture 62 (shown in FIG. 2) in the cover 26 provides the guide for a threaded screw of the locking device 60 , which can rotate in and out of the cover 26 . Preferably, the locking device 60 is installed in the center of the ring system 14 between the rings 28 and 30 . When the locking device 60 fully advances into the cover 26 with the rings 28 and 30 closed, the leaves 40 and 42 cannot rotate, thus precluding the rings 28 and 30 from opening.
A locking device 60 presses against the pair of leaves 40 and 42 when they are substantially parallel and are thus prevented from movement relative to each other. This prevents the ring halves 32 and 34 , 36 and 38 respectively, which are attached to the leaves 40 and 42 , from movement to open the rings 28 and 30 . FIG. 4 shows a cross sectional view of a closed ring system 14 with a locked locking device 60 .
Also, the leaves 40 and 42 and the attached ring halves 32 and 34 , 36 and 38 are readily movable when the locking device 60 is not pressed against the pair of leaves 40 and 42 . FIG. 3 shows the locking device 60 in an unlocked position so that the leaves 40 and 42 can be moved without interference from the locking device 60 .
The preferred locking device 60 advances by twisting into the cover 26 . The protective feature to preclude twisting by a mischievous customer could be an aperture 64 in the top surface of a screw. The shape of the aperture 64 corresponds to a tool. In a common, simple form, the aperture 64 can be a hexagon as shown in FIG. 2, and the corresponding tool would be an Allen wrench. A key could also be in various shapes to correspond with an aperture or even the circumference of a cylindrical rod. The locking device 60 could only be rotated by using the corresponding tool or key.
The backing 18 is any rigid, substantially flat material, preferably a plastic board. The scope of the invention encompasses a variety of materials for backings or some combination thereof. A backing 18 found to be appropriate is a 0.055 matte white polyboard. The backing 18 can also be wood, cardboard or even glass. For retail use, a preferred size of a backing 18 is seven inches wide by four inches in height. For that size holder, half-inch rings 28 and 30 were found to be suitable.
The rings 28 and 30 independently secure into a band without a gap between the ring halves 32 and 34 , 36 and 38 respectively to preclude pages 70 from falling out of the rings 28 and 30 . The rings 28 and 30 are part of a system similar to a system in the binder spine of a three-ring binder preferably without the end lever to open the rings 28 and 30 . Ideally, two rings 28 and 30 are used; however, one or more rings can be used depending on the flip chart panels or pages 70 being used.
As shown in FIG. 5, page 70 can be any type of paper or plastic sheet material. The preferred page 70 is durable or reinforced so that it cannot be torn out of the holder 10 . The pages 70 are adapted to provide educational or advertising information as desired. The pages 70 hang from rings 28 and 30 and rest against the face side 16 of a backing 18 . A plurality of holes 72 are made in the page 70 to correspond and align with the rings 28 and 30 . A tab 74 can extend from the bottom of the page 70 to index the information on the page. A series of tabs 74 can hang below the bottom of the top page 70 to facilitate easy reference and access to the information on the corresponding page 70 as best seen in FIG. 22 . To fit the four by seven inch backing 18 described above, the holes 72 are a quarter inch in diameter and one-eighth of an inch below the top edge.
The mount 20 can be a variety of adapters for channels, slatwalls, poles, peg holes, oval slots and t-slots. The slots may be in the horizontal surface of a shelf. A C-channel 12 is the most common shelf face in retail stores, and a preferred bracket 20 is shown in FIG. 6 . The legs 80 and 82 simply squeeze together so that the edges of the mount 20 attach inside the lip of the C-channel 12 . A foamed tape has been suitable to hold a three-inch aluminum bracket 20 to the back surface 22 of the backing 18 .
A variety of other mounts 20 are available depending on the display per FIGS. 7 through 21. It is contemplated that adhesives, such as 96 , can be used with any or all of these mounts 20 to secure the mount 20 to the back surface 22 of the backing 18 . Adhesives 96 may also secure the holder 10 to the display. With other mounts 20 , the holder 10 can clip on a pegboard (FIG. 7) or a slatwall (FIGS. 7 - 9 ). A holder 10 can snap securely to wire fixtures as shown in FIG. 8 and 9. A mount 20 can affix to end of a glass shelf per FIGS. 15 and 16. Of course, the holder 10 can be attached to a hole or slot in the shelf (per FIG. 10, 17 or 20 ) or fixedly mounted on a wall mount by any variety of attachment means.
Various mounts 20 are available for C-Channels 12 . FIG. 11 shows a below shelf mount 20 . FIG. 12 shows an alternate embodiment of a below shelf mount 20 . FIG. 13 shows a center shelf mount 20 . FIG. 14 shows an alternate center shelf mount 20 .
Mounts 20 can also attach onto the edge of a glass shelf facing outward. FIG. 15 shows a mount 20 for an edge of a glass shelf wherein teeth 90 and 92 attach to the edge of a glass shelf. FIG. 16 shows an alternate mount 20 for a glass shelf with similar teeth 90 and 92 .
FIG. 17 shows a flush mount 20 for a shelf with perforations or slots. Flat portion 93 lies on a shelf. Insert 94 attaches through aperture 95 into perforations or slots in the shelf.
FIG. 18 shows a multipurpose mount 20 adaptable for clipping over wire or other display parts. Adhesive 96 attaches to back surface 22 of the backing 18 . A release liner 98 can be supplied if this mount 20 is not previously attached to the backing 20 .
FIG. 19 shows a mount for a C-channel 12 of on a shelf. The legs 80 and 82 squeeze together so that the edges of the mount 20 attach inside the lip of the C-channel 12 .
FIG. 20 shows a bendable mount 20 for various purposes. The adhesive 96 attaches to back surface 22 of the backing 18 . Aperture 95 can be used on a shelf surface or as a hanger. Finally, FIG. 21 shows a mount 20 using an adhesive 96 that can be directly mounted on a display. Other mounts 20 are known in the art and are within the scope of this invention.
An optional page protector 99 is shown in FIGS. 22 and 23. A page protector 99 can be inserted between the pages 70 and the face side 16 of a backing 18 . A page protector 99 can conceal the locking device 60 and protect the pages 70 from rubbing against the locking device 60 . A suitable material for a page protector 99 includes any durable sheet material or board. A 0.016 white polyboard is an ideal material. To fit the four by seven inch backing 18 described above, the holes 100 are an eighth inch in diameter and one-quarter of an inch below the top edge, and the page protector 99 is seven inches by three and eleven-thirty-seconds inch.
The size, shape, geometry, and configuration of these examples can be readily changed to provide a holder 10 envisioned within the scope of the invention. The size and the shape of the holder 10 are partially dictated by the article or pages that are to be hung from the holder 10 .
A preferred method of using holder 10 is to install pages 70 by sliding holes 72 onto the bottom ring halves 34 and 38 and squeezing the halves 32 and 34 , 36 and 38 together. Then locking device 60 is tightened into the aperture 62 with a tool or key, so that the locking device 60 presses against the leaves 40 and 42 . When pages 70 need to be updated, locking device 60 is loosened, thereby taking pressure off of the leaves 40 and 42 . Contacting halves 32 and 34 , 36 and 38 are pulled away from each other, opening the rings 28 and 30 . With the rings 28 and 30 open, pages 70 can be removed or installed as appropriate. When updating the pages 70 is complete, the rings 28 and 30 are closed and the locking device 60 is tightened.
Although the preferred embodiment of the invention is illustrated and described in connection with a particular type of flip chart holder, it can be adapted for use with a variety of retail shelves, pages, and shapes. Other embodiments and equivalent materials and methods are envisioned within the scope of the invention. The examples of designs and shapes are for illustration purposes, and this flip chart holder can be used with a wide variety of configurations. Various features of the invention have been particularly shown and described in connection with the illustrated embodiments of the invention, however, it must be understood that these particular embodiments merely illustrate and that the invention is to be given its fullest interpretation within the terms of the appended claims.
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An updatable and lockable flip chart holder that can clip into the rail strip or channel of a shelf or fasten to a display at a retail store. The flip chart holder allows manufacturers or promoters of products that are sold at retail to create consumer, educational, or promotional flip charts that can easily and economically be updated by opening rings. The lockable flip chart has a panel, and attached to the panel is a ring system with each ring having two ring halves and hinged leaves connected to each other and attached to each ring half respectively. A locking mechanism on the ring system presses against the leaves to prevent the ring halves from opening. Locking the rings also provides security so consumers cannot take the pages out of the flip chart holder.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of application Ser. No. 11/757,892, filed Jun. 4, 2007, status allowed.
The present invention is related to the subject matter of U.S. patent application Ser. No. 10/922,029.
FIELD OF THE INVENTION
The present invention is directed generally at drilling blowout preventers used in drilling oil and gas wells, and specifically to a rotating pressure control device for use in both under-balanced drilling applications and managed pressure drilling applications.
BACKGROUND OF THE INVENTION
When the hydrostatic weight of the column of mud in a well bore is less than the formation pressure, the potential for a blowout exists. A blowout occurs when the formation expels hydrocarbons into the well bore. The expulsion of hydrocarbons into the well bore dramatically increases the pressure within a section of the well bore. The increase in pressure sends a pressure wave up the well bore to the surface. The pressure wave can damage the equipment that maintains the pressure within the well bore. In addition to the pressure wave, the hydrocarbons travel up the well bore because the hydrocarbons are less dense than the mud. If the hydrocarbons reach the surface and exit the well bore through the damaged surface equipment, there is a high probability that the hydrocarbons will be ignited by the drilling or production equipment operating at the surface. The ignition of the hydrocarbons produces an explosion and/or fire that is dangerous for the drilling operators. In order to minimize the risk of blowouts, drilling rigs are required to employ a plurality of different pressure control devices, such as an annular pressure control device, a pipe ram pressure control device, and a blind ram pressure control device. If a “closed loop drilling” method is used, then a rotating pressure control device will be added on top of the conventional pressure control stack. Persons of ordinary skill in the art are aware of other types of pressure control devices. The various pressure control devices are positioned on top of one another, along with any other necessary surface connections, such as the choke and kill lines for managed pressure drilling applications and nitrogen injection lines for under balanced drilling applications. The stack of pressure control devices and surface connections is called the pressure control stack.
One of the devices in the pressure control stack can be a rotating pressure control device also referred to as a rotating pressure control head. The rotating pressure control head is located at the top of the pressure control stack and is part of the pressure boundary between the well bore pressure and atmospheric pressure. The rotating pressure control head creates the pressure boundary by employing a ring-shaped rubber or urethane sealing element that squeezes against the drill pipe, tubing, casing, or other cylindrical members (hereinafter, drill pipe). The sealing element allows the drill pipe to be inserted into and removed from the well bore while maintaining the pressure differential between the well bore pressure and atmospheric pressure. The sealing element may be shaped such that the sealing element uses the well bore pressure to squeeze the drill pipe or other cylindrical member. However, some rotating pressure control heads utilize some type of mechanism, typically hydraulic fluid, to apply additional pressure to the outside of the sealing element. The additional pressure on the sealing element allows the rotating pressure control head to be used for higher well bore pressures.
The sealing element on all rotating pressure control heads eventually wear out because of friction caused by the rotation and/or reciprocation of the drill pipe. Additionally, the passage of pipe joints, down hole tools, and drill bits through the rotating pressure control head causes the sealing element to expand and contract repeatedly, which also causes the sealing element to become worn. Other factors may also cause wear of the sealing element, such as extreme temperatures, dirt and debris, and rough handling. When the sealing element becomes sufficiently worn, it must be replaced. If a worn sealing element is not replaced, it may rupture, causing a loss of hydraulic fluids and control over the well head pressure.
Currently, visual inspections or time based life span estimates are used to determine when to replace a worn sealing element. Visual inspections are subjective, and may be unreliable. Time based estimates may not take into account actual operating conditions, and be either too short or too long for a particular situation. If the time based estimate is too conservative, then sealing elements are replaced too frequently, causing unnecessary expense and delay. If the time based estimate is too aggressive, then the risk for rupture may be unacceptable.
U.S. patent application Ser. No. 10/922,029 (the '029 application) discloses a Rotating Pressure Control Head (RPCH) having a sealing element in an inner housing where the inner housing is rotatably engaged to an outer housing by an upper bearing and a lower bearing. The RPCH of the '029 application offers many improvements over the prior art including a shorter stack size, a quick release mechanism for inner unit change out, and a reduction in harmonic vibrations. Further improvements can be sought in ways to extend the life of the components. Wellbore fluid pressure, pressurized hydraulic fluid, and pipe friction against the sealing element exert a net upward or downward force on the inner housing that translates into a load on the upper and lower bearings. The load on the upper and lower bearings generates heat which is the most significant factor in bearing wear and life expectancy. A need exists for a way to balance the net force on the inner housing in order to reduce heat and wear on the bearings. Additionally, a need exists for an objective way to determine when a sealing element is sufficiently worn and needs to be replaced, without causing waste from early replacement, and without increasing the risk of rupture.
SUMMARY OF THE INVENTION
A Rotating Pressure Control Device (RPCD) uses pressure balancing so that a force transmitted through the bearings from an inner housing to an outer housing is balanced, thereby increasing the service life of the bearings.
The RPCD comprises an upper body and a lower body that form an outer housing. An inner housing rotates with respect to the outer housing. The inner housing has a sealing element that constricts around the drill pipe, and bearings are placed between the inner housing and outer housing to allow rotation of the inner housing within the outer housing.
An upper dynamic rotary seal is located between the inner housing and the outer housing and above the sealing element. A middle dynamic rotary seal is located between the inner housing and the outer housing and below the sealing element. A lower dynamic rotary seal is located between the inner housing and the outer housing below the middle dynamic rotary seal.
An upper piston area is created between the inner housing and the outer housing by the upper dynamic rotary seal and the middle dynamic rotary seal. A lower piston area is created below the expanded sealing element between the outside of the drill pipe and the lower dynamic rotary seal.
Wellbore fluid pressure, pressurized hydraulic fluid, and pipe friction against the sealing element cause a net upward or downward force on the inner housing with respect to the outer housing. These net upward or downward forces cause wear to the bearings. By adjusting hydraulic fluid pressure in the upper piston area, users can adjust the amount of downward force exerted by the upper piston area to compensate for the upward force exerted by the lower piston area. In addition, such adjustments also compensate for forces caused by friction between the drill pipe and sealing element. The reduction in force on the inner housing achieved by pressure balancing results in reduced bearing heat and wear.
Additionally, the RPCD has an electrically conductive wear indicator integrated with the drill pipe sealing element. A conductive strip is embedded inside the sealing element. The conductive strip makes electrical contact with a first electrode of an electrical indicator. A second electrode of the electrical indicator is in electrical contact with the drill pipe. When the sealing element is worn down to a pre-determined depth, exposing the embedded conductive strip, a closed circuit is formed from the electrical indicator through the first electrode, the embedded conductive strip, the drill pipe, and the second electrode, causing a signal on an electrical indicator, alerting users of the RPCD that it is time to replace the sealing element.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a cross sectional view of the RPCD;
FIG. 2 is a cross sectional view of the RPCD with the sealing element in an expanded position;
FIG. 3 is a perspective view of the RPCD;
FIG. 4 is a cross sectional view of the RPCD with a wear indicator top plate;
FIG. 5 is a detail view of a conductive bolt;
FIG. 6 is detail view of a conductive pin; and
FIG. 7 is a cross sectional view of the RPCD with a closed circuit caused by a worn sealing element.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a cross sectional view of pressure balanced rotating pressure control device 500 . Upper body 200 and lower body 100 form outer housing 150 . Inner housing 300 rotates inside outer housing 150 . Inner housing 300 contains sealing element 340 adapted to constrict around a drill pipe. Upper bearing 332 and lower bearing 334 affixed to inner housing 300 provide vertical and lateral support between inner housing 300 and outer housing 150 .
Input port 204 allows hydraulic fluid to enter outer housing 150 to reach channel 338 , cavity 330 , and spaces between inner housing 300 and outer housing 150 . Alternate input port 202 is capped with input plug 210 . Output port 208 allows hydraulic fluid to exit outer housing 150 . Alternate output port 206 is capped with output plug 212 . Wellbore fluid enters RPCD at input 102 and exits through output 104 .
Upper dynamic rotary seal 322 is located between inner housing 300 and outer housing 150 and above sealing element 340 and upper bearing 332 . Upper dynamic rotary seal 322 is shown here as two separate dynamic rotary seals.
Middle dynamic rotary seal 324 is located between the inner housing 300 and outer housing 150 , below sealing element 340 , and below lower bearing 334 . Middle dynamic rotary seal 324 has a wider diameter than upper dynamic rotary seal 322 .
Lower dynamic rotary seal 326 is located between the inner housing 300 and outer housing 150 below middle dynamic rotary seal 324 .
Vent port 106 allows open space between middle dynamic rotary seal 324 and lower dynamic rotary seal 326 to remain at atmospheric pressure. In addition, vent port 106 serves as a leak detection system because in the event that middle dynamic rotary seal 324 or lower dynamic rotary seal 326 begin to leak, fluid will drain from vent port 106 revealing the leak.
Pair of o-rings 312 sit between upper body 200 and lower body 100 . Upper sealing element o-ring (or upper alternate sealing element) 315 and lower sealing element o-ring (or lower alternate sealing element) 313 sit between sealing element 340 and inner body 300 .
FIG. 2 is a cross sectional view of pressure balanced rotating pressure control device 500 with sealing element 340 in an expanded position around drill pipe 400 .
Pressurized hydraulic fluid 440 enters outer housing 300 through input port 204 . Alternate input port 202 is capped with input plug 210 . Pressurized hydraulic fluid 440 expands sealing element 340 around drill pipe 400 . Hydraulic fluid 440 permeates the area between inner housing 300 and outer housing 150 between upper dynamic rotary seal 322 and middle dynamic rotary seal 324 . Hydraulic fluid 440 lubricates upper bearing 332 and lower bearing 334 . Pressurized hydraulic fluid 440 exits outer housing through output port 208 for recirculation. Alternate output port 206 is capped by output plug 212 .
Upper piston area 520 is defined by the equation A(up)=(π×(D(s) 2 −D(us) 2 )/4 where D(ms)=middle dynamic seal ring 324 outer diameter, and where D(us)=upper dynamic rotary seal 322 outer diameter. Hydraulic fluid 440 is induced into upper piston area 520 to expand sealing element 340 around drill pipe 400 , when hydraulic fluid 440 is so induced, it acts upon upper piston area 520 to create a downward force on inner housing 300 . Force on upper piston area 520 is defined by the equation F(up)=A(up)×P(h) where P(h)=induced hydraulic pressure. Pressurized hydraulic fluid 440 energizes upper piston area 520 exerting a downward force on inner housing 300 . Upper piston area 520 remains constant.
Lower piston area 510 is defined by the equation A(lp)=(π×(D(b) 2 −D(p) 2 )/4 where D(b)=the outer diameter of lower dynamic rotary seal 326 and where D(p)=the outer diameter of drill pipe 400 . Thus, a smaller diameter pipe results in a larger cross sectional area for lower piston area 510 . Pressurized wellbore fluid 410 acts upon lower piston area 510 to create an upward force on inner housing 300 . Force on lower piston area 510 is defined by the equation F(lp)=A(lp)×P(wb) where P(wb)=wellbore pressure. Wellbore fluid 410 exerts an upward force on inner housing 300 as it presses upward into lower piston area 510 . Lower piston area 510 does not remain constant and varies in size due to drill pipe diameter changes as the drill pipe is lowered, or raised, through RCPH 500 .
Vented area 345 is defined as an area between the outer diameter of middle dynamic rotary seal 324 and the outer diameter of lower dynamic rotary seal 326 . Vent port 106 allows vented area 345 to remain at atmospheric pressure. By keeping vented area 345 at atmospheric pressure, a pressure imbalance is created such that upper piston area 520 , when it is energized by pressurized hydraulic fluid 440 , creates a force opposite that of lower piston area 510 when it is energized by wellbore fluid 410 .
FIG. 3 is a perspective view of RPCH 500 showing upper piston area 520 and lower piston area 510 . Upper piston area 520 is an area between the outer diameter of middle dynamic seal ring 324 and the outer diameter of upper dynamic rotary seal 322 defined by the upper piston area formula set forth above. Lower piston area 510 is an the area between the outer diameter of lower dynamic seal element 326 and the outer diameter of drill pipe 400 defined by the lower piston area formula set forth above.
The upward and downward forces on inner housing 300 are also affected by the frictional drag of the pipe moving through the collapsed sealing element 340 , as described by the equation: F(f)=(π×D(p)×L)×P(h)×u where L=length of pipe 400 in contact with sealing element 340 , and where u=coefficient of drag between pipe 400 and sealing element 340 .
The sum of the total forces on inner housing 300 is calculated with the equation F(sum)=F(lp)−F(up)+/−F(f). The sign for the friction force F(f) depends on whether drill pipe 400 is moving upwards or downwards. If drill pipe 400 is moving upwards, F(f) is positive. If drill pipe 400 is moving downward, F(f) is negative. A positive F(sum) indicates a net upward force on inner housing 300 , the bearings and seals. A negative F(sum) indicates a net downward force on inner housing 300 , the bearings and seals.
Pressure balanced rotating pressure control device 500 allows drillers to use pressurized hydraulic fluid 440 to compensate for upward and downward forces on inner housing 300 . By compensating for differences in upward and downward forces on inner housing 300 , heat and/or wear on upper bearing 332 and lower bearing 334 will be reduced and the life of upper bearing 332 and lower bearing 334 will be expanded.
A wear indicator is used to signal when it is time to replace the drill pipe sealing element. FIG. 4 is a cross sectional elevation view of a wear indicator on pressure balanced RPCD 500 . Upper body 200 and lower body 100 form outer housing 150 . Inner housing 300 rotates inside outer housing 150 . Inner housing 300 contains sealing element 340 adapted to constrict around drill pipe 400 . Top plate 700 is attached to the top of RPCD 500 , which is electrically insulated from the top plate 700 .
Conductive strip 710 is embedded axially in sealing element 340 at a depth where, when worn down, sealing element 340 should be replaced. Conductive ring 720 contacts the top end of conductive strip 710 . Conductive strip 710 and conductive ring 720 are electrically isolated from inner housing 300 and other conductive surfaces by sealing element 340 .
Bolt 730 (described in FIG. 5 below) connects conductive ring 720 to first electrode 770 with brush 738 . First electrode 770 passes through top plate 700 . First electrode 770 leads to indicator 790 .
Second electrode 780 connects indicator 790 to pin 750 (described in FIG. 6 below). Pin 750 is located inside of top plate 700 . Spring 752 holds pin 750 against drill pipe 400 creating an electrical contact through conductor 758 .
FIG. 5 shows a cross-sectional detail of bolt 730 . Bolt 730 is a special insulated bolt having conductor 732 running axially through the center of bolt 730 which is electrically insulated from the body of the bolt 730 . Bolt conductor 732 extends below bolt 730 creating contact point 734 . Spring loaded electric brush 738 is located at top end 736 of bolt 730 . Spring loaded electric brush 738 is attached to bolt conductor 732 and is electrically isolated from the body of bolt 730 .
No alignment is required when installing sealing element 340 in RPCD 500 . Once sealing element 340 is installed inside inner housing 300 , bolt 370 is threaded through the upper portion of inner housing 300 , driving the contact point 734 into sealing element 340 . The location of bolt 730 is such that the contact point 734 will pierce conductive ring 720 establishing an electric circuit from conductive strip 710 in sealing element 340 , through conductive ring 720 and into bolt 730 . Note that bolt 730 rotates with inner housing 300 as drill pipe 400 is turned.
Commutator ring 772 on top plate 700 is aligned such that spring loaded electric brush 738 remains in contact with commutator ring 772 as inner housing 300 rotates with turning drill pipe 400 . Thus, an insulated electrical conductor path is established from conductive strip 710 in sealing element 340 , through conductive ring 720 , through bolt conductor 732 in bolt 730 , through spring loaded electric brush 738 , through commutator ring 772 , and out first electrode 770 .
FIG. 6 shows a detail of pin 750 mounted inside top plate 700 . Pin 750 is spring loaded inside top plate 700 , through outer aperture 702 and inner aperture 704 . Spring 752 exerts force between top plate 700 and rib 756 on pin 750 . Pin conductor 754 passes through pin 750 connecting pipe contactor 758 to second electrode 780 . Pin 750 is electrically insulated from top plate 700 .
Pin 750 is retracted as drill pipe 400 is lowered through RPCH 500 and is then allowed to spring against drill pipe 400 . Spring 752 keeps pipe contactor 758 in contact with drill pipe 400 as tool joints and other such changes in drill pipe 400 outside diameter pass through RPCH 500 . Thus, an electrical circuit is established from drill pipe 400 , through pipe contactor 758 , through pin conductor 754 inside pin 750 , and out through second electrode 780 .
FIG. 7 is a cross sectional elevation view of pressure balanced rotating pressure control device 500 with a closed circuit caused by worn sealing element 340 . Whenever sealing element 340 wears down, exposing conductive strip 710 , drill pipe 400 makes physical and electrical contact with conductive strip 710 . A closed circuit is formed from indicator 790 through first electrode 770 , brush 738 , bolt 730 , conductive ring 720 , conductive strip 710 , drill pipe 400 , conductor 758 , pin 750 , and second electrode 780 , causing a reading on indicator 790 . The reading on indicator 790 after the circuit is closed alerts users of RPCD 500 that it is time to replace sealing element 340 .
Persons skilled in the art are aware that a normally closed circuit could also be employed. With a normally closed circuit, the electrically conductive path is in place at all times until wear of the sealing element causes conductive strip 710 to sever, opening the circuit and causing indicator 790 to alert users of RPCD 500 that it is time to replace sealing element 340 . In other words, during normal operation, an indicator light would be on, and when the circuit is broken, the indicator light would turn off.
With respect to the above description, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function, manner of operation, assembly, and use are deemed readily apparent and obvious to one of ordinary skill in the art. The present invention encompasses all equivalent relationships to those illustrated in the drawings and described in the specification. The novel spirit of the present invention is still embodied by reordering or deleting some of the steps contained in this disclosure. The spirit of the invention is not meant to be limited in any way except by proper construction of the following claims.
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Force balancing adjusts hydraulic fluid pressure in an upper piston area of a Rotating Pressure Control Device (RPCD) that has an inner housing rotatably engaged within an outer housing by an upper bearing and a lower bearing. The hydraulic fluid pressure is adjusted to balance net force in a upper piston area and a lower piston area. The fluid pressure adjustment creates a force differential that balances the total load transmitted through the upper bearing and the lower bearing and thereby extends the life of the sealing element and bearings. Additionally, a wear indicator signals the end of the useful life of the drill pipe sealing element.
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FIELD OF THE INVENTION
[0001] The present invention relates to a process for the asymmetric hydrogenation of imines with hydrogen under elevated pressure in the presence of a catalyst system. The invention particularly relates to the use of the said catalytic system for the enantioselective hydrogenation of prochiral ketimines to asymmetric amines leading to the formation of herbicides.
BACKGROUND AND PRIOR ART
[0002] Catalytic hydrogenation of imine has been known for a relatively long time. In organic synthesis, catalytic hydrogenation processes using either homogeneous catalysts or heterogeneous catalysts have played an important role. Heterogeneous catalysts are insoluble; thus they can be readily separated from the reaction mixture and generally, offer the potential for ready re-use whereas homogeneous catalysts are soluble and so difficulties can be encountered in separating the homogeneous catalyst, both the metal and the accompanying ligands, from the product. This not only presents problems with the purity of the product, but also makes the re-use of the homogeneous catalyst problematic. These catalysts are known to exhibit the advantages of catalyzing hydrogenation reactions in the synthesis routes for the preparation of various herbicides with remarkable chemical specificity under relatively mild conditions. Accordingly, there is an increased emphasis on the use of such catalysts in the preparation of herbicides on a commercial scale.
[0003] One such catalyst system which has demonstrated good industrial potential for the hydrogenation of imines is the homogeneous iridium—xyliphos catalyst system, which has found extensive applicability for the preparation of various herbicides especially in the preparation of (S)-2-chloro-N-(2-ethyl-6-methylphenyl)-N-(2-methoxy-1-methylethyl)acetamide [Hans-Ulrich Blaser, Advanced Synthesis and Catalysis, 2002, 344,17-31].
[0004] These homogeneous catalysis processes have proved valuable. It has been observed in the case of relatively large batches or on an industrial scale, that the catalysts frequently tend to become deactivated to a greater or lesser extent depending on the catalyst precursor, the substrate and the ligands that are used. In many cases, especially at elevated temperatures it is not possible to achieve complete conversion; therefore, the catalyst productivity is too low from the point of view of economic viability.
[0005] Advanced synthesis and catalysis, vol. 34, pp.17-31 (2000), discusses hydrogenation of imines using Ir-xyliphos ligand, acetic acid as a solvent and an iodide as an additive. This publication discloses that in the presence of acetic acid and iodide additive, the catalyst activity of an Iridium-xyliphos catalyst system increased by a factor of 10 and the ee increased by 5-6%. However, the simultaneous presence of acetic acid and an iodide additive is required to achieve an appreciable conversion as the catalyst system per se. In the absence of added acetic acid and iodide additive, the catalyst shows negligible turn-over-frequency and enantiomeric selectivity. The use of acetic acid requires specialized equipment constructed of a corrosion resistant material, which increases the costs. Moreover, acetic acid leads to the formation of hydrogen iodide and other metal salts, which further makes the reaction workup complicated. Thus, it is desirable to arrive at a process for asymmetric hydrogenation of an imine involving a catalyst system that avoids the presence of acetic acid and still achieve an appreciable turn-over-frequency and enantiomeric selectivity.
[0006] The chemistry of synthesis of chiral fine chemicals, pharmaceuticals and agrochemicals has become increasingly more complicated often requiring multi-step reactions involving complicated catalyst systems, such as, e.g., expensive organometallic catalyst systems. Consequently, there has been increased emphasis on the development of new catalyst systems which have high activity and selectivity and which maintain their catalytic activity for a relatively extended period of time under desired reaction conditions.
[0007] Hitherto, there have been numerous attempts in the art towards an enantiomeric selective catalyst system for effecting stoichiometric efficient asymmetric hydrogenation of imines.
[0008] U.S. Pat. No. 6,822,118 describes a process for the hydrogenation of imines with hydrogen under elevated pressure in the presence of homogeneous iridium catalysts with appropriate ligand and with or without an inert solvent, wherein the reaction mixture contains an ammonium or metal chloride, bromide or iodide and additionally an acid. The catalysts in these homogeneous processes cannot be recovered or can be recovered only with expensive separation methods, which is always associated with undesirable losses. Thus, there remains a need in the art for a process for asymmetric hydrogenation of imines involving an improved catalyst system that overcomes the disadvantages associated with these hitherto known catalysts.
[0009] Chem. Reviews, 2003, 103, 3101-3118 discloses the ferrocenyl phosphine, xyliphos and josiphos ligands for hydrogenation of imines. This literature discusses the use of iodide and acid as additives for hydrogenation of imines. The disclosed process again requires the simultaneous presence of acetic acid and an iodide additive to achieve an appreciable turn-over-frequency and enantiomeric selectivity. However, as discussed above, the simultaneous presence of acetic acid and an iodide additive is undesirable.
[0010] US 2006/089469, whose contents are incorporated herein by reference in entirety, discloses asymmetrical, chiral hydroxyl diphosphines and their use as catalysts for enantioselective synthesis. The described organophosphorus compounds are combined with metal complex precursors in order to provide a suitable catalyst system. Paragraph [0025] discloses particularly preferred catalyst systems according to the invention disclosed comprising Ru and Rh complexes containing the described ligands.
[0011] This patent teaches the preparation of a ligand [(1R, 2R, 3S)-1,2-Dimethyl-2,3-bis(diphenylphosphinomethyl)cyclopentyl] methanol, while example 6 discloses the preparation of its Rh complex. Example 7 discloses the use of the rhodium complex prepared in accordance with example 6 for various hydrogenation reactions. This exemplified catalyst system is not disclosed to have been preferred for the asymmetric hydrogenation of an imine. Moreover, all the exemplified reactions were carried out at room temperature under a hydrogen pressure of I bar, which is contrary to the finding of the present invention.
[0012] It has further been observed on an industrial scale that the catalyst systems frequently tend to become deactivated depending on the catalyst precursor, the substrate and the ligands. It has further been found that not all catalyst systems that are known in the art enable a complete conversion of the starting materials into the target product with a high enantiomeric selectivity.
[0013] S-Metolachlor is one of the most important grass herbicides for use on soyabean, maize and other various crops. The racemic form of this known herbicide contains two chiral elements, a chiral axis and a stereogenic center leading to four stereo-isomers. It later came to be known that about 95% of the herbicidal activity of metolachlor resided in the two 1-S diastereomers. This meant that the same biological effect could be produced at about 65% of the use rate of the racemic product. However, a commercially feasible process for the enantioselective manufacture of S-Metolachlor has been compared to moving in a complicated labyrinth. The search for a catalyst for the enantioselective manufacture of S-Metolachlor is likened to a walk in a labyrinth that covers the “TON-EE” space i.e. finding a catalyst with a sufficient stereospecificity (greater than 74% enantiomeric excess) as well as productivity (at least 99% conversion efficiency). Thus, finding an efficient and enantioselective catalyst for the preparation of S-Metolachlor has been a long felt and challenging need in the art of herbicide synthesis.
[0014] Thus, there is a continuous need in the art for a process that enables an enantioselective hydrogenation of imines with a high conversion as well as a high enantiomeric excess of the target product wherein the catalyst system is cost effective.
OBJECTS OF THE INVENTION
[0015] Accordingly, it is an object of the present invention to provide a process for the asymmetric hydrogenation of imines.
[0016] It is yet another object of the present invention to provide a process for the asymmetric hydrogenation of imines in presence of catalyst system.
[0017] It is yet another object of the present invention to provide a process for the asymmetric hydrogenation of imines wherein the employed catalyst system comprises a ligand and a metal or a salt thereof.
[0018] Yet another object of the present invention is to provide a process for the asymmetric hydrogenation of imines having high conversion efficiency and high enantiomeric excess.
[0019] Yet another object of the present invention is to provide a process for the asymmetric hydrogenation of imines to an amine, which is useful for the preparation of S-Metolachlor.
SUMMARY OF THE INVENTION
[0020] A process for asymmetric hydrogenation of an imine having formula 1:
[0000]
[0000] to obtain an amine having formula 2:
[0000]
[0000] said process comprising contacting said imine having the above formula 1 with hydrogen under elevated pressure in a predetermined organic solvent in the presence of a catalyst system;
said catalyst system comprising a ligand complexed to a metal selected from iridium and rhodium or a salt thereof;
wherein said ligand is selected from a group comprising
(a) [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenylphosphinomethyl)-cyclopentyl]methanol; (b) (1S,4S, 11R)-1,11-bis-[(diphenylphosphanyl)-methyl]-11-methyl-1,2,3,4-tetrahydro-1,4-methano-phenazin; (c) (R)-3-Di-(3,5-dimethylphenyl)phosphino-2-(4-diphenylphosphino-2,5-dimethylthienyl-3)-1,7,7-trimethylbicyclo-[2.2.1]-hept-2-ene; (d) (S)-2-[(o-diphenylphosphino)-phenyl]-1-diphenylphosphino-ferrocene; (e) (S)-1-(Diphenylphosphino)-2-(S)-(o-diphenylphosphino-α-methoxybenzyl)ferrocene; (f) (+)-(S)-N,N-Dimethyl-1-[(R)-1′,2-bis-(Diphenylphosphino)-ferrocenyl]-ethylamine; and (g) [(S)-1-[(R)-2-diphenylphosphino)ferrocenyl]-ethyl-di(cyclohexyl)-phosphine.
[0028] In another aspect, the present invention provides an improved process for asymmetric hydrogenation of an imine having formula 1:
[0000]
[0000] to obtain an amine having formula 2:
[0000]
[0000] said process comprising contacting said imine having the above formula 1 with hydrogen under an elevated pressure of 80 bar at a temperature of about 50° C. in toluene in the presence of a catalyst system comprising a ligand having a formula [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenyl phosphine methyl)-cyclopentyl]methanol complexed to iridium metal or a salt thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Therefore, in an aspect, the present invention provides an enantiomeric selective process for the hydrogenation of imine with hydrogen under elevated pressure in presence of a catalyst system comprising a pre-defined bidentate diphosphine ligand complexed to a metal in presence of a predetermined inert solvent.
[0030] The imine preferably includes a compound having the formula 1
[0000]
[0000] which is asymmetrically hydrogenated to an amine having the following formula 2:
[0000]
[0031] Hitherto, the catalyst systems of the present invention have not been used for carrying out the hydrogenation of an imine, particularly an imine having the formula 1 described above and more so at an elevated hydrogen pressure preferred according to the present invention. It has been surprisingly found that reacting an imine having the formula 1 with hydrogen under elevated pressure in an inert solvent in the presence of a catalyst system comprising a predetermined ligand complexed to a metal selected from iridium and rhodium resulted into a high conversion efficiency and high enhanced enantiomeric selectivity in the formation of the resultant amine of formula 2. The substrate to catalyst ratio during said hydrogenation reaction of the present invention varied from about 200 to about 500000.
[0032] The predetermined ligand is selected from a group comprising:
(a) [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenylphosphinomethyl)-cyclopentyl]methanol; (b) (1S,4S,11R)-1,11-bis-[(diphenylphosphanyl)-methyl]-11-methyl-1,2,3,4-tetrahydro-1,4-methano-phenazin; (c) (R)-3-Di-(3,5-dimethylphenyl)phosphino-2-(4-diphenylphosphino-2,5-dimethylthienyl-3)-1,7,7-trimethylbicyclo-[2.2.1]-hept-2-ene; (d) (S)-2-[(o-diphenylphosphino)-phenyl]-1-diphenylphosphino-ferrocene; (e) (S)-1-(Diphenylphosphino)-2-(S)-(o-diphenylphosphino-α-methoxybenzyl)ferrocene; (+)-(S)-N,N-Dimethyl-1-[(R)-1′,2-bis-(Diphenylphosphino)-ferrocenyl]-ethylamine; and (g) [(S)-1-[(R)-2-diphenylphosphino)ferrocenyl]-ethyl-di(cyclohexyl)-phosphine.
[0040] The compound of formula 2 described above is thereafter reacted with chloroacetyl chloride in the presence of a base in a non-polar solvent at pre-defined temperatures to obtain a compound of formula 3. This reaction step is preferably carried out at a temperature of from about 0° C.-5° C.
[0000]
[0041] The compound of formula 3 described above is commercially marketed herbicide known as S-Metolachlor.
[0042] The compound of formula 1 may be prepared by reacting a compound of the formula 4 (2-ethyl-6-methyl aniline) with a corresponding ketone. For example, the compound having the following formula 4:
[0000]
[0000] is reacted with a ketone having the formula CH 3 OCH 2 C(O)CH 3 (methoxyacetone) to obtain a compound of formula 1. This reaction is conventionally known in the art and may be carried out using the known methods per se.
[0043] Although the process hereinabove has been described with reference to the specific imine compound of formula 1, it would readily occur to a person skilled in the art that it could be as conveniently carried out on an aryl imine as depicted hereunder.
[0044] The schematic representation of the chemical reaction occurring during the hydrogenation reaction of an aryl imine according to this aspect of the present invention is as hereunder:
[0000]
[0000] wherein R is C 1 -C 4 alkyl, preferably methyl; R′ is C 1 -C 4 alkoxy alkyl, preferably C 1 -C 4 alkoxymethyl or C 1 -C 4 alkoxyethyl, preferably methoxymethyl and Ar is phenyl substituted by one or more C 1 -C 4 alkyl.
[0045] The amine obtained from hydrogenation of imine can be converted in accordance with methods that are customary per se with chloroacetyl chloride into the desired herbicides of the chloroacetanilide type.
[0000]
[0046] In an embodiment of the present aspect, said metal is preferably selected from Iridium, Rhodium or a salt thereof.
[0047] The structures of the ligands that are preferred according to the present invention are shown below:
[0000]
(I) [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenylphosphinomethyl)-cyclopentyl]methanol
[0048]
(II) (1S,4S, 11R)-1,11-bis-[(diphenylphosphanyl)-methyl]-11-methyl-1,2,3,4-tetrahydro-1,4-methano-phenazin
[0049]
(III) (R)-3-Di-(3,5-dimethylphenyl)phosphino-2-(4-diphenylphosphino-2,5-dimethylthienyl-3)-1,7,7-trimethylbicyclo-[2.2.1]-hept-2-ene
[0050]
(IV) (S)-2-[(o-diphenylphosphino)-phenyl]-1-diphenylphosphino-ferrocene
[0051]
(V) (S)-1-(Diphenylphosphino)-2-(S)-(o-diphenylphosphino-α-methoxybenzyl)ferrocene
[0052]
(VI) (+)-(S)-N,N-Dimethyl-1-[(R)-1′,2-bis-(Diphenylphosphino)-ferrocenyl]-ethylamine
[0053]
(VII) [(S)-1-[(R)-2-diphenylphosphino) ferrocenyl]-ethyl-di(cyclohexyl)-phosphine
[0054] In an embodiment of the present aspect, said predetermined solvent is an inert organic solvent preferably selected from the group comprising toluene, 1,4-dioxane, methanol, tetrahydrofuran and dichloromethane. The word “inert” as herein in the context of an organic solvent denotes a solvent that does not itself participate in the reaction and is not intended to limit the scope of the invention in any manner.
[0055] The process of the present invention further may optionally comprise the addition of a predetermined additive. In a preferred embodiment of the present aspect, said additive is preferably selected from a group comprising diadamantyl butyl phosphonium hydroiodide (A), Diadamantyl benzyl phosphonium hydrobromide (B), Triphenyl phosphonium diiodide (C), Isopropyl triphenylphosphonium iodide (D), Triphenyl phosphonium dibromide (E), Methyl triphenyl phosphonium bromide (F), Tetrabutyl Ammonium Iodide (G), Copper(II) Triflate (H), Yetribium(II) Triflate (I) and Triphenyl phosphonium dichloride (J).
[0056] The process of the present invention is carried out at elevated pressure. The term elevated pressure as used herein means pressure ranging from about 5 bar to about 150 bar.
[0057] In a preferred embodiment, the process of the present invention is preferably carried out at a temperature of about 50° C. and at a hydrogen pressure of about 80 bar. In this preferred embodiment, the catalyst system comprises a ligand having formula [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenylphosphinomethyl)-cyclopentyl]methanol complexed to iridium metal or salts thereof. The process of the present embodiment is preferably carried out in toluene in the presence of an additive having the formula triphenyl phosphonium dibromide.
[0058] It has been further surprisingly found according to the present embodiment that even at a high substrate to catalyst ratio of up to about 500000, the resulting amine was found to have undergone at least 99% conversion at >=76% enantiomeric excess.
[0059] Thus, in a preferred embodiment, it was observed that when the process of present invention was carried out using ligand, [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol complexed with a Iridium at a substrate to catalyst ratio of up to about 500 000 in the presence of Triphenyl phosphonium dibromide as a preferred additive in toluene as a preferred solvent, the resulting product was found to have undergone 100% conversion at 76% enantiomeric excess.
[0060] It was sur p risingly found that the process of the present invention afforded ≧99% conversion and ≧76% enantiomeric excess even in absence of an additive or an acid which is generally used for hydrogenation of imine for achieving higher conversion and higher enantiomeric excess. The ligands according to the present invention thus avoid the need for a simultaneous presence of acetic acid and an iodide additive, which was required in the conventionally known art in order to achieve an appreciable conversion thereby avoiding the need for a specialized equipment constructed of a corrosion resistant material without compromising the turn-over-frequency and enantiomeric selectivity.
[0061] Thus, in another aspect, the present invention provides an improved process for asymmetric hydrogenation of an imine having formula 1:
[0000]
[0000] to obtain an amine having formula 2:
[0000]
[0000] said process comprising contacting said imine having the above formula 1 with hydrogen under an elevated pressure of 80 bar at a temperature of about 50° C. in toluene in the presence of a catalyst system comprising a ligand having a formula [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenyl phosphine methyl)-cyclopentyl]methanol complexed to iridium metal or a salt thereof.
[0062] In an embodiment of this aspect, the process is preferably carried out in the presence of a predetermined additive, which is triphenyl phosphonium dibromide (E).
[0063] The invention shall now be described with reference to the following specific examples. It should be noted that the example(s) appended below illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. Other than in the operating examples provided hereunder, or where otherwise indicated, all numbers expressing quantities of ingredients or reaction conditions are to be understood as being modified in all instances by the term “about”.
Example 1
i) Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using ligand [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenyl phosphinomethyl)cyclopentyl)methanol (1) in presence of different additives.
[0064] 0.001 mmol of ligand, [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol, (I), 0.0005 mmol of [Ir(COD)Cl] 2 and 0.004 mmol of the corresponding additive were mixed together under argon in 0.1 ml dichloromethane and the mixture was stirred at room temperature for 20 min. Meanwhile 0.1-5 mmol solution of the substrate in the corresponding solvent was introduced to the autoclave. The catalyst solution was then introduced to the autoclave and the autoclave was purged with hydrogen at an elevated pressure. The reaction mixture was warmed under in oil bath to the desired elevated temperature. After cooling and release of pressure, a sample of the reaction mixture was withdrawn from the autoclave. The solvent was evaporated and residue was dissolved in 200 μl isopropanol and 1 ml n-hexane and filtered through a short path of silica gel column. The filtrate was analyzed by
ii) Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Ligand Xyliphos in Presence of Different Additives
[0065] The experimental procedure of Example 1 (i) above was followed for a ligand {(R)-1-[(S)-2-diphenylphosphino)ferrocenyl]}ethyl-di(3,5-dimethyl)phosphine (xyliphos). The ligand xyliphos is one of the well known ligands which has been used for hydrogenation of imines.
[0066] The results for the final product for conversion (%) & ee (%) using different additives and different solvents in presence of ligand-xyliphos and ligands of present invention are tabulated in the accompanying Table 1.
[0000]
TABLE 1
Ligand: I
Ligand: xyliphos
Acid: none
Acid: acetic acid
Conversion
ee
Abs.
Conversion
ee
Abs.
(%)
(%)
conf.
(%)
(%)
conf.
Additive: D,
100
80
S
100
80
S
S/C ratio: 200
solvent:
toluene
Additive: B,
100
80
S
100
76
S
S/C ratio: 200
solvent:
toluene
[0067] The process of the present invention thus eliminates the need for the presence of acetic acid, which requires special handling equipment due to its corrosive nature.
Example 2
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Different Ligands
[0068] The experimental procedure of Example I above was followed for the different ligands of present invention. The results for the final product for conversion (%) and ee (%) using different additives and different solvents are tabulated in the accompanying Table 2 wherein ligands and additives are as described before.
[0000]
TABLE 2
Sr.
Conversion
ee
Abs.
No.
Ligand
Solvent
Additive
(%)
(%)
conf.
1.
I
Toluene
B
100
80
S
2.
I
1,4-dioxane
B
99
77
S
3.
III
1,4-dioxane
H
100
76
S
4.
VI
1,4-dioxane
A
100
76
S
5.
VI
1,4-dioxane
H
100
76
S
[0069] The results in Table 2 substantiate that the process of the present invention provides high conversion efficiency for the hydrogenation of imines, even in absence of any acid, such that the process enables at least 99% to 100% conversion of the starting material to the target product having >76% enantiomeric excess of the target product.
Example 3
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using ligand (S)-2-[(o-diphenylphosphino)-phenyl]-1-diphenylphosphino-ferrocene (IV)
[0070] 0.001 mmol of ligand (IV), 0.0005 mmol of [Ir(COD)Cl] 2 and 0.004 mmol of additive A were mixed together under argon in 0.1 ml dichloromethane and the mixture was stirred at room temperature for 20 min. Meanwhile 0.1 mmol solution of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline in dichloromethane was introduced to autoclave. Eventually 0.12 ml of acetic acid was added in the autoclave and the autoclave was purged with hydrogen and pressurized to 50 bar. The reaction mixture was warmed under stirring in an oil bath to 50° C. and reaction continued for 18 hr. Reaction mixture was cooled down and after pressure had been released, the final product of reaction mixture was withdrawn from autoclave, solvent was evaporated and the residue was dissolved in 200 μl isopropanol and 1 ml hexane and the whole was filtered through a short path of silica gel. The filtrate was analyzed by HPLC. The conversion of imine to amine was 99% comprising 88% of (S)-2-ethyl-N-(1-methoxypropan-2-yl)-6-methylaniline (ee 76%)
Example 4
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Different Ligands
[0071] The experimental procedure of Example 1 above was followed for the different ligands of present invention, wherein substrate to catalyst ratio is 3000. The results for the final product for conversion (%) and ee (%) using different additives and different solvents are tabulated in the accompanying Table 3 wherein ligands and additives are as described before.
[0000]
TABLE 3
Sr.
Conversion
ee
Abs.
No.
Ligand
Solvent
Additive
(%)
(%)
conf.
1.
I
Toluene
B
100
80
S
2.
I
Toluene
D
100
80
S
3.
I
1,4-dioxane
E
100
76
S
4.
III
1,4-dioxane
H
100
76
S
5.
VI
1,4-dioxane
A
100
76
S
6.
VI
1,4-dioxane
H
100
76
S
[0072] The results in Table 3 substantiate that the process of the present invention provides high conversion efficiency for the hydrogenation of imines, even at substrate to catalyst ratio 3000, such that the process enables 100% conversion of the starting material to the target product having >76% enantiomeric excess of the target product.
Example 5
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Ligand [(1R,2R,3S)-1,2-dimethyl -2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol (I)
[0073] The experimental procedure of Example 1 above was followed for ligand (I) of present invention, wherein substrate to catalyst ratio is 10,000. The results for the final product for conversion (%) and ee (%) is tabulated in the accompanying Table 4.
[0000]
TABLE 4
Sr.
Conversion
ee
Abs.
No.
Ligand
Solvent
Additive
(%)
(%)
conf.
1.
I
Toluene
E
100
76
S
[0074] The results in Table 4 substantiate that the process of the present invention provides high conversion efficiency for the hydrogenation of imines, even at substrate to catalyst ratio 10,000, such that the process enables 100% conversion of the starting material to the target product having 76% enantiomeric excess of the target product.
Example 6
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Rh(COD) 2 BF 4 and (R)-3-di-(3,5-dimethylphenyl)phosphino-2-(4-diphenylphosphino-2,5-dimethylthienyl-3)-1,7,7-trimethylbicyclo-[2,2,1]hept-2-ene (III)
[0075] 0.67 mg (0.001 mmol) of the ligand (III), 0.41 mg (0.001 mmol) of Rh(COD) 2 BF 4 and 0.24 mg (0.004 mmol) of acetic acid were mixed together under argon in 0.1 ml dichloromethane and the mixture was stirred at room temperature for 20 min). 41 mg (0.200 mmol) of the substrate 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline in methylene chloride solvent (0.4 ml of 0.5M solution of substarte in methylene chloride) was then added. The reaction mixtures were subsequently introduced into the autoclave and the autoclave was purged with hydrogen. Then under pressure of 40 bar hydrogen, the reaction was warmed at 40° C. for 18 hr. After cooling down and release of pressure a sample on analysis showed 99% conversion (GC analysis) with enantiomeric excess (ee) of S isomer of amine at 76% (chiral HPLC).
[0076] It has been surprisingly found that using commercially less expensive ligand-catalyst system, in an enantiomeric selective hydrogenation process of the present invention shows a high conversion efficiency for the hydrogenation of imines such that the process enables ≧99% conversion of the starting material to the target product having >76% enantiomeric excess of the target product.
[0077] The catalyst system comprising ligands of present invention affords a high conversion of the starting material to the target product having high enantiomeric excess of the target product even without acetic acid or additives and without changing the turn-over-frequency or enantiomeric selectivity the catalyst system.
Example 7
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Ligand [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenylphosphinomethyl)cyclopentyl]methanol (I)
[0078] 15.10 mg (0.0288 mmol) of ligand [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol, 6 mg (0.0089 mmol) of [Ir(COD)Cl] 2 and 60 mg (0.142 mmol) of triphenyl phosphonium dibromide were mixed together under argon in 10 ml toluene and the mixture was stirred at room temperature for 30 min. Meanwhile 25 g (0.122 mol) of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline in 20 ml toluene was introduced to the autoclave. The catalyst solution was then introduced to the autoclave and the autoclave was purged with hydrogen at 80 bar pressure. The reaction mixture was heated to 50° C. temperature. After reaction completion of 18 hr, the mass was cooled to room temperature and pressure was released. A sample on analysis showed complete conversion to amine. The reaction mixture was withdrawn from the autoclave.
[0079] The solvent was evaporated and residue was distilled under high vacuum (1-2 torr) to get 24.3 g pale yellow amine with 98% purity and 88% S-isomer (ee 76%).
Example 8
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Ligand [(1R,2R,3S)-1,2-dimethyl -2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol (I)
[0080] 7.20 mg (0.0137 mmol) of ligand [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol, 2.7 mg (0.0040 mmol) of [Ir(COD)Cl] 2 and 31 mg (0.073 mmol) of triphenyl phosphonium dibromide were mixed together under argon in 10 ml toluene and the mixture was stirred at room temperature for 30 min. Meanwhile 35 g (0.171 mol) of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline in 20 ml toluene was introduced to the 100 ml SS316 autoclave. The catalyst solution was then introduced to the autoclave and the autoclave was purged with hydrogen at 80 bar pressure. The reaction mixture was heated to 50° C. temperature. After reaction completion of 18 hr, the mass was cooled to room temperature and pressure was released. A sample on analysis showed complete conversion to amine The reaction mixture was withdrawn from the autoclave. The solvent was evaporated and residue was distilled under high vacuum (1-2 torr) to get 34.1 g pale yellow amine with 99% purity and 89% S-isomer (ee 78%).
Example 9
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Ligand [(1R,2R,3S)-1,2-dimethyl -2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol (I)
[0081] The experimental procedure of Example 7 above was followed with following quantities:
[0082] 5.70 mg (0.0109 mmol) of ligand [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol, 2.1 mg (0.0031 mmol) of [Ir(COD)Cl] 2 and 70 mg (0.166 mmol) of triphenyl phosphonium dibromide were mixed together under argon in 10 ml toluene and the mixture was stirred at room temperature for 30 min. Meanwhile 58 g (0.283 mol) of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline in 5 ml toluene was introduced to the 100 ml SS316 autoclave. The reaction was carried out exactly as per example 7. A sample on analysis showed complete conversion to amine. 56 g product was obtained after distillation under high vacuum (1-2 torr) as pale yellow oil in 97% purity and 87% S-isomer (ee 74%).
Example 10
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using ligand [(1R,2R,3S)-1,2-dimethyl -2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol (I)
[0083] The experimental procedure of Example 7 above was followed with following quantities:
[0084] 2.60 mg (0.005 mmol) of ligand [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol, 1.10 mg (0.0016 mmol) of [Ir(COD)Cl] 2 and 140 mg (0.332 mmol) of triphenyl phosphonium dibromide were mixed together under argon in 10 ml toluene and the mixture was stirred at room temperature for 30 min. Meanwhile 58 g (0.283 mol) of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline in 5 ml toluene was introduced to the 100 ml SS316 autoclave: The reaction was carried out exactly as per example 7. A sample on analysis showed complete conversion to amine. 57 g product was obtained after distillation under high vacuum (1-2 torr) as pale yellow oil in 98% purity and 88% S-isomer (ee 76%).
Example 11
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Ligand [(1R,2R,3S)-1,2-dimethyl -2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol (I)
[0085] 9.50 mg (0.0181 mmol) of ligand [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol, 4 mg (0.0059 mmol) of [Ir(COD)Cl] 2 and 490 mg (1.161 mmol) of triphenyl phsophonium dibromide were mixed together under argon in 10 ml toluene and the mixture was stirred at room temperature for 30 min. Meanwhile 250 g (1.22 mol) of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline in 20 ml toluene was introduced to 400 ml capacity autoclave. The catalyst solution was then introduced to the autoclave and the autoclave was purged with hydrogen at 80 bar pressure. The reaction mixture was heated to 50° C. temperature. After reaction completion of 18 hr, the mass was cooled to room temperature and pressure was released. The reaction mixture was withdrawn from the autoclave. A sample on analysis showed complete conversion to amine The solvent was evaporated and residue was distilled under high vacuum (1-2 torr) to get 245 g pale yellow amine in 98.5% purity and 89% S-isomer isomer (ee 78%).
Example 12
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Ligand [(1R,2R,3S)-1,2-dimethyl -2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol (I)
[0086] 7.50 mg (0.0143 mmol) of ligand [(1R,2R,3S)-1,2-dimethyl-2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol, 3 mg (0.0044 mmol) of [Ir(COD)Cl] 2 and 290 mg (0.6873 mmol) of triphenyl phosphonium dibromide were mixed together under argon in 10 ml toluene and the mixture was stirred at room temperature for 30 min. Meanwhile 280 g (1.366 mol) of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline in 20 ml toluene was introduced to 400 ml capacity autoclave. The catalyst solution was then introduced to the autoclave and the autoclave was purged with hydrogen at 80 bar pressure. The reaction mixture was heated to 50° C. temperature. After reaction completion of 18 hr, the mass was cooled to room temperature and pressure was released. A sample on analysis showed 99% conversion to amine. The material was taken out from autoclave and toluene was distilled off. The crude product was distilled under high vacuum (1-2 torr) to get 275 g pale yellow colour product in 98% purity and 89% S-isomer (ee 78%).
[0087] All above reactions were carried out at a defined temperature of 50° C. and defined pressure of 80 bar. Further experiments were carried out exactly with same quantities as in example 7 except the temperature and pressure of reaction. It was surprisingly found that the process of present invention show higher enantiomeric excess, ≧76% particularly at temperature 50° C. and pressure 80 bar.
Example 13
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Ligand [(1R,2R,3S)-1,2-dimethyl -2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol (I)
[0088] The reaction was carried out exactly with same quantities as in example 7 except the temperature of reaction. The temperature was 80° C. The reaction was complete in 18 hr, the mass was cooled to room temperature and pressure was released. A sample on analysis showed complete conversion to amine. The solvent was evaporated and residue was distilled under high vacuum (1-2 torr) to get 24.1 g pale yellow amine in 99% purity and 96.5% yield with 85% S-isomer (ee 70%).
Example 14
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Ligand [(1R,2R,3S)-1,2-dimethyl -2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol (I)
[0089] The reaction was carried out exactly with same quantities as in example 7 except the temperature of reaction. The temperature here was 40° C. The reaction was complete in 18 hr, the mass was cooled to room temperature and pressure was released. A sample on analysis showed 95% conversion to amine. The solvent was evaporated and residue was distilled under high vacuum (1-2 torr) to get 24.0 g pale yellow amine in 95% purity and 95% yield with 88% S-isomer (ee 76%).
Example 15
Hydrogenation of 2-ethyl-N-(1-methoxypropan-2-ylidene)-6-methylaniline using Ligand [(1R,2R,3S)-1,2-dimethyl -2,3-bis(diphenyl phosphinomethyl)cyclopentyl]methanol (I)
[0090] The reaction was carried out exactly with same quantities as in example 7 except the hydrogen pressure during reaction was 100 bars. The reaction was complete in 18 hrs, the mass was cooled to room temperature and pressure was released. A sample on analysis showed complete conversion to amine. The solvent was evaporated and residue was distilled under high vacuum (1-2 torr) to get 24.1 g pale yellow amine in 98% purity and 96.6% yield with 87% S-isomer (ee 74%).
[0091] It has been surprisingly found that using commercially less expensive ligand-catalyst system, in an enantiomeric selective hydrogenation process of the present invention shows a high conversion efficiency for the hydrogenation of imines such that the process enables >99% conversion of the starting material to the target product having ≧76% enantiomeric excess of the target product at an elevated hydrogen pressure.
[0092] The catalyst system comprising ligands of present invention gives high conversion of the starting material to the target product having high enantiomeric excess of the target product even without acetic acid and without affecting productivity and activity of the catalyst system. It has further been found that ligand I provides a superior turn-over-number at desirable conversion percentage and enantioselectivity, as shown in table 5 appearing hereinafter, which is not intended to limit the scope of the invention in any manner:
[0000]
TABLE 5
S
Experimental conditions
No.
Parameter
1
2
3
4
5
6
7
8
1
Temperature
50
80
40
50
50
50
50
50
(° C.)
2
Pressure
80
80
80
100
80
80
80
80
(bar)
3
Ligand
I
I
I
I
Xyliphos
I
I
I
4
Metal
Ir
Ir
Ir
Ir
Ir
Rh
Ir
Ir
5
Solvent
Toluene
Toluene
Toluene
Toluene
Toluene
Toluene
CH 2 Cl 2
Toluene
6
Additive
E
E
E
E
E
E
E
J
7
Yield
96.3
96.5
95
96.6
98
98
69
16
8
Purity
98
99
95
98
99
98
70.4
17
9
EE
76
70
76
74
66
a)
60
b)
10
TON
478854
19264
19264
19264
200
200
44456
75681
a) R-isomer of amine is obtained instead of S-isomer
b) The conversion to amine was only 16% in this case.
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The present invention relates to a process for the asymmetric hydrogenation of imines with hydrogen under elevated pressure in the presence of a catalyst system. In particular the present invention relates to the use of the said catalytic system for the enantioselective hydrogenation of prochiral ketimines to asymmetric amines leading to the formation of herbicides.
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FIELD OF THE INVENTION
[0001] The present invention relates to a biological process for the preparation of various carboxylic acids by the enzymatic oxidation of the corresponding alcohols with alcohol oxidase in very high yields. The alcohol oxidase is formed by bacteria of the genus Gluconobacter, preferably of the species Gluconobacter sp. HR 101 (DSM 12884). Thus, for example, benzoic acid is prepared from benzyl alcohol, butyric acid from n-butanol, isobutyric acid from isobutanol, isovaleric acid from isoamyl alcohol, 2-methylbutyric acid from 2-methylbutanol, 3-methylthiopropionic acid from 3-methylthiopropanol, phenylacetic acid from phenylethanol, propionic acid from propanol and cinnamic acid from cinnamyl alcohol.
BACKGROUND OF THE INVENTION
[0002] In addition to the long-known process for the manufacture of vinegar by oxidizing ethanol to give acetic acid using bacteria of the genus Acetobacter, there are also a few processes for the preparation of a few carboxylic acids using bacteria of the genera Acetobacter or Gluconobacter or using yeasts.
[0003] For example, DE 3,713,668 describes the preparation of aliphatic carboxylic acids by microbial oxidation of aliphatic alcohols with bacteria of the species Gluconobacter roseus. In this process, the alcohols, after a growth phase of more than 24 hours, were added directly to the culture medium with the organism. The preferred pH range was stated as 4 to 4.5. Only low yields of 13 g of n-butyric acid/l 2 g of isobutyric acid/l, 7 g of 2-methylbutyric acid/l and 17 g of 3-methylbutyric acid/l of fermentation solution were obtained.
[0004] DE 19 503 598 describes a process for the preparation of propionic acid or butyric acid and salts thereof. They use a bacterium of the species Gluconobacter oxydans. After cultivation for 9 to 10 hours, n-propanol or n-butanol was repeatedly added in portions as a function of the pO 2 value. In this way they achieved yields of 43.7 g/l of propionic acid and 49 g/l of butyric acid.
[0005] EP 0 563 346 describes a process for the preparation of carboxylic acids by oxidizing corresponding alcohols or aldehydes using a yeast of the genus Saccharomyces, Hansenula, Pichia, Candida or Kluyvermyces. A disadvantage in this respect is that, using the yeasts, only low product concentrations are obtained, very high biomass concentrations have to be used and long process times. For example, after four days, only less than 0.6 g/l of 3-methylthiopropanolic acid was obtained, and for the 90% conversion of 0.01% of isoamyl alcohol, 6 days were needed.
[0006] J. Chem. Tech. Biotechnol. 1997, 68, 214-218 describes the biotransformation of a few aliphatic alcohols and 2-phenylethanol into the corresponding acids using bacteria of the species Acetobacter aceti. A disadvantage here, too, are the low product concentrations obtained. For example, the highest product concentration described for the oxidation of butanol to butyric acid was given as 39.3 g/l after 60 hours.
[0007] J. Chem. Tech. Biotechnol. 1997, 70, 294-298 describes the bacterium Acetobacter pasteurianus for the oxidative preparation of certain carboxylic acids. A disadvantage in this respect is the use of air-lift bioreactors since the high stream of air which is required for aerating and thoroughly mixing the culture causes relatively large amounts of the volatile starting materials and products to be stripped off. The cold trap containing liquid nitrogen, which is connected downstream for this reason, is not practicable on an industrial scale.
SUMMARY OF THE INVENTION
[0008] We have found a process for the preparation of aliphatic, aromatic and thiocarboxylic acids in bioreactors, which is characterized in that cultures comprising bacteria of the genus Gluconobacter are used.
[0009] Surprisingly, the use of the novel organisms of the genus Gluconobacter enables very high yields not only of aliphatic, but also of aromatic and thiocarboxylic acids to be achieved. This is true both with regard to the product concentration in the solution, the percentage molar conversion of the starting materials, and also with regard to the space-time yield. Here, as well as the composition of the media and the pH, which is maintained at pH 6.4, a parameter which is of particular importance for the process is the nature of the continuous addition of the substrate.
DETAILED DESCRIPTION OF THE INVENTION
[0010] Preferred bacteria for the process according to the present invention are bacteria of the type Gluconobacter sp. HR 101 (DSM 12884).
[0011] Preference is given to using the bacterium in pure culture.
[0012] Suitable nutrient media for the organisms used according to the present invention are synthetic, semisynthetic or complex culture media. These can comprise carbon-containing and nitrogen-containing compounds, inorganic salts, and optionally, trace elements and vitamins.
[0013] Carbon-containing compounds which may be suitable are carbohydrates, hydrocarbons or standard organic chemicals. Examples of compounds which may preferably be used are sugars, alcohols or sugar alcohols, organic acids or complex mixtures.
[0014] The sugar is preferably glucose. The organic acids which may preferably be used are citric acid or acetic acid. The complex mixtures include, for example, malt extract, yeast extract, casein or casein hydrolyzate.
[0015] Suitable nitrogen-containing substrates are inorganic compounds. Examples thereof are nitrates and ammonium salts. Organic nitrogen sources can also be used. These include yeast extract, soybean flour, casein, cottonseed meal, casein hydrolyzate, wheat gluten and corn steep liquor.
[0016] Examples of the inorganic salts which can be used are sulfates, nitrates, chlorides, carbonates and phosphates. The metals which are preferably present in said salts are sodium, potassium, magnesium, manganese, calcium, zinc and iron.
[0017] The cultivation temperature is preferably in the range from 10 to 40° C. The range is more preferably from 20 to 35° C.
[0018] The pH of the medium is preferably 4 to 8. A more preferred range is from 6.2 to 6.5.
[0019] In principle, all bioreactors known to the person skilled in the art can be used for carrying out the process according to the present invention. Preferential consideration is given to any equipment which is suitable for submerged processes. This means, according to the present invention, that it is possible to use vessels with or without a mechanical mixing device. Examples of the latter include shaking apparatuses, and bubble column reactors or loop reactors. The former preferably include all known appliances which are fitted with stirrers of any design.
[0020] The process according to the present invention can be carried out continuously or batchwise. The fermentation time required to achieve a maximum amount of product depends on the specific nature of the organism used. However, in principle, the fermentation times are between 2 and 200 hours.
[0021] Aliphatic carboxylic acids for the process according to the present invention are butyric acid, isobutyric acid, isovaleric acid, 2-methylbutyric acid and propionic acid.
[0022] Aromatic carboxylic acids for the process according to the present invention are benzoic acid, phenylacetic acid and cinnamic acid.
[0023] A thiocarboxylic acid for the process according to the present invention is 3-methylthiopropionic acid.
[0024] According to the process of the invention, preference is given to reacting butyric acid, isobutyric acid, isovaleric acid, 2-methylbutyric acid, propionic acid, phenylacetic acid and 3-methylthiopropionic acid.
[0025] According to the process of the invention, particular preference is given to reacting isobutyric acid, isovaleric acid, 2-methylbutyric acid and phenylacetic acid.
[0026] The invention is illustrated in more detail below by reference to examples:
EXAMPLES
Example 1
Preparation of the Preculture
[0027] A 500 ml Erlenmeyer flask with a baffle is inoculated with 100 ml of a sterile medium consisting of 1.25 g of D-mannitol and 0.75 g of yeast extract at pH 6.5, with 0.9 ml of a glycerol culture of Gluconobacter sp. HR 101 (DSM 12884). The flask is incubated for 16 hours on a rotary shaker at 30° C. and 140 rpm. The number of microbes in the preculture is about 2×10 9 CFU/ml.
Example 2
Preparation of Natural n-butyric Acid from Natural n-butanol
[0028] 125 g of mannitol and 75 g of yeast extract are dissolved in 9.9 l of water in a 10 l fermenter, 10 ml of antifoam are added and the pH is adjusted to 6.3. The thus prepared medium is sterilized for 30 minutes at 121° C.
[0029] The speed of the stirrer is 500 rpm, and the aeration is 5 l/mm; the temperature is 30° C. After these parameters have been set, the preculture according to Example 1 is used for the inoculation.
[0030] After a fermentation time of 17 hours the addition of n-butanol is started via a pump. The metered addition of the substrate is controlled via a flow controller. n-Butanol is added in accordance with the following flow profile:
TABLE 1 Fermentation time Flow rate 0 h 0 g/lh 17 h 1.0 g/lh 20 h 4.0 g/lh 27 h 3.0 gIlh 30 h 2.5 g/lh 35 h 2.0 g/lh 50 h 1.5 g/lh 50.5 h 2.0 g/lh 53 h 1.5 g/lh 57 h 1.0 g/lh 63 h 0 g/lh 66 h 1.0 g/lh 68 h 1.5 g/lh 71 h 1.0 g/lh 73 h 0 g/lh
[0031] During feeding, the pH is kept constant in the range 6.2-6.4 using NH 4 + .
[0032] The fermentation is complete after 74 hours. The final concentration of n-butyric acid is 95 g/l according to HPLC analysis. The molar conversion is just below 90%.
Example 3
Preparation of Natural Isobutyric Acid from Natural Isobutanol
[0033] 125 g of mannitol and 75 g of yeast extract are dissolved in 9.9 l of water in a 10 l fermenter, 10 ml of antifoam are added and the pH is adjusted to 6.3. The thus prepared medium is sterilized for 30 minutes at 121° C.
[0034] The speed of the stirrer is 500 rpm, and the aeration is 5 l/min; the temperature is 30° C. After these parameters have been set, the preculture according to Example 1 is used for the inoculation.
[0035] After a fermentation time of 22.5 hours the addition of isobutanol is started via a pump. The metered addition of the substrate is controlled via a flow controller. Isobutanol is added in accordance with the following flow profile:
TABLE 2 Fermentation time Flow rate 0 h 0 g/lh 22.5 h 1.0 g/lh 23.5 h 4.0 g/lh 30 h 3.0 g/lh 35 h 2.5 g/lh 50 h 2.0 g/lh 50.3 h 2.5 g/lh 53 h 1.5 g/lh 58 h 1.0 g/lh 60 h 0 g/lh 64 h 1.0 g/lh 67 h 0 g/lh 68 h 1.5 g/lh 73 h 1.0 g/lh 74 h 0 g/lh
[0036] During the feeding, the pH is kept constant in the range 6.2-6.4 using NH 4 + .
[0037] The fermentation is complete after 74 hours. The final concentration of isobutyric acid is 92.7 g/l according to HPLC analysis. The molar conversion is just below 88%.
Example 4
Preparation of Natural 2-methylbutyric Acid from Natural 2-methylbutanol
[0038] 125 g of mannitol and 75 g of yeast extract are dissolved in 9.9 l of water in a 10 l fermenter, 10 ml of antifoam are added and the pH is adjusted to 6.3. The thus prepared medium is sterilized for 30 minutes at 121° C.
[0039] The speed of the stirrer is 500 rpm, and the aeration is 5 l/min; the temperature is 30° C. After these parameters have been set, the preculture according to Example 1 is used for the inoculation.
[0040] After a fermentation time of 17 hours the addition of 2-methylbutanol is started via a pump. The metered addition of the substrate is controlled via a flow controller. 2-Methylbutanol is added in accordance with the following flow profile:
TABLE 3 Fermentation time Flow rate 0 h 0 g/lh 17 h 1.0 g/lh 20 h 4.0 g/lh 28 h 3.5 g/lh 31 h 3.0 g/lh 35 h 2.5 g/lh 39 h 2.0 g/lh 45 h 1.5 g/lh 51 h 1.0 g/lh 55 h 0 g/lh
[0041] During the feeding, the pH is kept constant in the range 6.2-6.4 using NH 4 + .
[0042] The final concentration of 2-methylbutyric acid is 80 g/l according to HPLC analysis. The molar conversion is just below 89%.
Example 5
Preparation of Natural Isovaleric Acid from Natural Isoamyl Alcohol
[0043] 125 g of mannitol and 75 g of yeast extract are dissolved in 9.9 l of water in a 10 l fermenter, 10 ml of antifoam are added and the pH is adjusted to 6.3. The thus prepared medium is sterilized for 30 minutes at 121° C.
[0044] The speed of the stirrer is 500 rpm, and the aeration is 5 l/min; the temperature is 30° C. After these parameters have been set, the preculture according to Example 1 is used for the inoculation.
[0045] After a fermentation time of 17 hours the addition of isoamyl alcohol is started via a pump. The metered addition of the substrate is controlled via a flow controller. Iso-amylalcohol is added in accordance with the following flow profile:
TABLE 4 Fermentation time Flow rate 0 h 0 g/lh 17 h 1.0 g/lh 20 h 4.0 g/lh 28 h 3.5 g/lh 31 h 3.0 g/lh 35 h 2.5 g/lh 39 h 2.0 g/lh 44 h 1.5 g/lh 48 h 1.0 g/lh 49.5 h 0 g/lh 55 h 1.0 g/lh 58 h 0 g/lh 63 h 1.0 g/lh 66 h 0 g/lh
[0046] During the feeding, the pH is kept constant in the range 6.2-6.4 using NH 4 + .
[0047] The fermentation is complete after 70.5 hours. The final concentration of isovaleric acid is 82 g/l following work-up of the fermentation solution. The molar conversion is just below 85%.
Example 6
Preparation of Natural Propionic Acid from Natural n-propanol
[0048] 125 g of mannitol and 75 g of yeast extract are dissolved in 9.9 l of water in a 10 l fermenter, 10 ml of antifoam are added and the pH is adjusted to 6.3. The thus prepared medium is sterilized for 30 minutes at 121° C.
[0049] The speed of the stirrer is 500 rpm, and the aeration is 5 l/min; the temperature is 30° C. After these parameters have been set, the preculture according to Example 1 is used for the inoculation.
[0050] After a fermentation time of 17 hours the addition of propanol is started via a pump. The metered addition of the substrate is controlled via a flow controller. Propanol is added in accordance with the following flow profile:
TABLE 5 Fermentation time Flow rate 0 h 0 g/lh 17 h 1.0 g/lh 20 h 3.5 g/lh 27 h 3.0 g/lh 29 h 2.0 g/lh 35 h 1.5 g/lh 60 h 1.0 g/lh 82 h 0 g/lh 87 h 1.0 g/lh 90 h 0 g/lh
[0051] During the feeding, the pH is kept constant in the range 6.2-6.4 using NH 4 + .
[0052] The fermentation is complete after 92 hours. The final concentration of propionic acid is 94 g/l according to HPLC analysis. The molar conversion is 88.3%.
Example 7
Preparation of Natural Phenylacetic Acid from Natural Phenylethanol
[0053] 125 g of mannitol and 75 g of yeast extract are dissolved in 9.9 l of water in a 10 l fermenter, 10 ml of antifoam are added and the pH is adjusted to 6.3. The thus prepared medium is sterilized for 30 minutes at 121° C.
[0054] The speed of the stirrer is 500 rpm, and the aeration is 5 l/min; the temperature is 30° C. After these parameters have been set, the preculture according to Example 1 is used for the inoculation.
[0055] After a fermentation time of 17 hours the addition of phenylethyl alcohol is started via a pump. The metered addition of the substrate is controlled via a flow controller. Phenylethyl alcohol is added in accordance with the following flow profile:
TABLE 6 Fermentation time Flow rate 0 h 0 g/lh 17 h 1.0 g/lh 20 h 4.0 g/lh 23.5 h 2.0 g/Ih 24 h 2.5 g/lh 30 h 2.0 g/lh 37 h 1.5 g/lh 41 h 1.0 g/lh 43.8 h 0 g/lh 50.5 h 1.0 g/lh 53 h 0 g/lh 58 h 1.0 g/lh 60 h 0 g/lh 65 h 1.0 g/lh 67 h 0 g/lh
[0056] During the feeding, the pH is kept constant in the range 6.2-6.4 using NH 4 + .
[0057] The maximum product concentration is reached after 48 hours. The concentration of phenylacetic acid is 54 g/l according to HPLC analysis. The molar conversion is 88.5%.
[0058] Transferring the process to the 200 l scale gave 52 g/l; the molar conversion in this case was 95%.
Example 8
Preparation of Natural Benzoic Acid from Benzyl Alcohol
[0059] 125 g of mannitol and 75 g of yeast extract are dissolved in 9.9 l of water in a 10 l fermenter, 10 ml of antifoam are added and the pH is adjusted to 6.3. The thus prepared medium is sterilized for 30 minutes at 121° C.
[0060] The speed of the stirrer is 500 rpm, and the aeration is 5 l/min; the temperature is 30° C. After these parameters have been set, the preculture according to Example 1 is used for the inoculation.
[0061] After a fermentation time of 21.25 hours the addition of benzyl alcohol is started via a pump. The metered addition of the substrate is controlled via a flow controller. Benzyl alcohol is added in accordance with the following flow profile:
TABLE 7 Fermentation time Flow rate 0 h 0 g/lh 21.25 h 1.0 g/lh 23 h 3.0 g/lh 28 h 2.5 g/lh 31 h 2.0 g/lh 34 h 1.5 g/lh 37 h 1.0 g/lh 40 h 0 g/lh 43 h 1.0 g/lh 47.5 h 0 g/lh 50.5 h 1.0 g/lh 54 h 0 g/lh 57 h 1.0 g/lh 60 h 0 g/lh 63 h 1.0 g/lh 65 h 0 g/lh
[0062] During the feeding, the pH is kept constant in the range 6.2-6.4 using NH 4 + .
[0063] The fermentation is complete after 68 hours. The final concentration of benzoic acid is 51 g/l according to HPLC analysis. Virtually all of the starting material was converted.
Example 9
Preparation of Natural Cinnamic Acid from Cinnamyl Alcohol
[0064] 125 g of mannitol and 75 g of yeast extract are dissolved in 9.9 l of water in a 10 l fermenter, 10 ml of antifoam are added and the pH is adjusted to 6.3. The thus prepared medium is sterilized for 30 minutes at 121° C.
[0065] The speed of the stirrer is 500 rpm, and the aeration is 5 l/min; the temperature is 30° C. After these parameters have been set, the preculture according to Example 1 is used for the inoculation.
[0066] After a fermentation time of 17 hours, the addition of cinnamyl alcohol is started via a pump. In order to have the cinnamyl alcohol in the liquid phase, the starting material was heated. Cinnamyl alcohol is added according to the following flow profile:
TABLE 8 Fermentation time Flow rate 0 h 0 g/lh 17 h 1.2 g/lh 20 h 2.4 g/lh 21 h 3.6 g/lh 25.25 h 0 g/lh 26.25 h 2.4 g/lh 28 h 1.2 g/lh 30 h 0 g/lh 31 h 1.2 g/lh 32 h 0 g/lh
[0067] The fermentation is complete after 44 hours. The final concentration of cinnamic acid is 27 g/l according to HPLC analysis. Virtually all of the starting material was converted.
Example 10
Preparation of Natural 3-methylthiopropionic Acid from 3-methylthiopropanol
[0068] 125 g of mannitol and 125 g of yeast extract are dissolved in 10 l of water in a 10 l fermenter, 10 ml of antifoam are added and the pH is adjusted to 6.3. The thus prepared medium is sterilized for 30 minutes at 121° C.
[0069] The speed of the stirrer is 500 rpm, and the aeration is 5 l/min; the temperature is 27° C. After these parameters have been set, the preculture according to Example 1 is used for the inoculation.
[0070] After a fermentation time of 16 hours, the addition of 3-methylthiopropanol is started via a pump. The substrate is metered in accordance with the following flow profile:
TABLE 9 Fermentation time Flow rate 0 h 0 g/lh 16 h 1.0 g/lh 17.66 h 2.0 g/lh 19 h 3.0 g/lh 20.8 h 4.2 g/lh 21.8 h 4.8 g/lh 23.2 h 4.2 g/lh 23.8 h 2.6 g/lh 42.5 h 2.2 g/lh 48.8 h 0 g/lh
[0071] During the feeding, the pH is kept constant in the range 6.2-6.4 using NH 4 + .
[0072] The fermentation is complete after 65 hours. The final concentration Of 3-methylthiopropionic acid is 82.6 g/l according to HPLC analysis. The molar conversion is almost 100%.
Example 12
Comparison of the Space-Time Yield of the Present Invention with Those of the Known Processes
[0073] In the example below (Table 9), the space-time yields of the novel production process using Gluconobacter sp. DSM 12884 are compared with those of the known processes in order to demonstrate the superiority of the process of the present invention.
TABLE 10 Product Test Process time concentration Space-time Number Product [hours] [g/l] yield [g/l/h] Process 1 Butyric acid 120 13 0.11 DE-A-37 13 668 2 Butyric acid 60 39.3 0.66 J. Chem. Tech. Biotechnol. 1997, 68, 214-218 3 Butyric acid 80 49 0.61 DE-A-195 03 598 4 Buryric acid 90 60 0.67 J. Chem. Tech. Biotechnol. 1997, 70, 294-298 5 Buryric acid 73 95 1.3 Present invention 6 Propionic acid 70 43.7 0.62 DE-A-1 95 03 598 7 Propionic acid 90 60 0.67 J. Chem. Tech. Biotechnol. 1997, 70, 294-298 8 Propionic acid 92 94 1.02 Present invention 9 Isobutyric acid 42 21 0.5 DE-A-37 13 668 10 Isobutyric acid 74 92.7 1.25 Present invention 11 Isovaleric acid 25 17 0.68 DE-A-37 13 668 12 Isovaleric acid 90 45 0.5 J. Chem. Tech. Biotechnol. 1997, 70, 294-298 13 Isovaleric acid 70.5 82 1.16 Present invention 14 2-Methylbutyric acid 24 7 0.29 DE-A-37 13 668 15 2-Methylbutyric acid 90 44 0.49 J. Chem. Tech. Biotechnol. 1997, 70, 294-298 16 2-Methylburyric acid 52 80 1.54 Present invention
[0074] As Table 10 shows, use of the present invention with Gluconobacter sp. DSM 12884 in the already-described alcohol oxidations results in a large increase in both the space-time yield and the absolute product concentration. For example, in the case of butyric acid, the space-time yield increases by 94% and the product concentration by 58%, when the present invention (Test No. 5) is compared with the best result from the prior art (Test No. 4). In the case of propionic acid, the space-time yield increases by 52% and the product concentration by 57%. The increases in the case of isobutyric acid are even greater, being 150% for the space-time yield and 341% for the product concentration. The increases for isovaleric acid and 2-methylbutyric acid are 132% and 82%, and 214% and 82% respectively.
[0075] Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
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The present invention relates to a process for the preparation of aliphatic, aromatic and thiocarboxylic acids, where cultures comprising bacteria of the genus Gluconobacter are used.
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This is a continuation of application Ser. No. 674,438, filed Nov. 23, 1984, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for cutting cord reinforced rubber sheet and more particularly an apparatus for longitudinally cutting such cord reinforced rubber sheet into strips of ply stock of the type employed in the construction of pneumatic tires.
In pneumatic tires, certain of the principal components thereof are sheets or plies of cord-reinforced rubber which form the carcass and belts of the tires. In the manufacture of such plies, parallel reinforcing cords of fabric, glass, or metal are pressed through a pair of rolls in cooperation with calendering rolls which work unvulcanized rubber onto the parallel cords as they pass through the rolls to form a continuous rubber sheet with reinforcing cords embedded therein. Thereafter, the sheet is cut diagonally or "bias" cut into strips so that the parallel cords are disposed at a desired "bias" angle to the cut edges. This bias cutting operation, as well as a bias cutter therefor, are described, for example, in U.S. Pat. No. 4,069,729.
The bias cut strips are then spliced end to end to form the reinforced rubber sheet with the cords therein located at a desired "bias" angle relative to the longitudinal center line of the sheet. The strips which form this sheet are sometimes bias cut to a width which is greater than a particular tire ply specification width so that the sheet formed from the strips can supply more than a single width of tire ply stock. For example, the sheet of spliced bias cut strips from which belt ply stock of a particular width is taken may be formed to twice that particular width. In this instance, the bias sheet formed from strips from the bias cutter must then be longitudinally cut into predetermined widths of ply stock before being usable in the construction of a tire.
An apparatus cut to a multiwidth sheet normally includes a slitting device comprising a lower stationary anvil-type blade member and an upper rotating disc-like slitter cooperating in shear with the anvil-type blade. The anvil-type blade member usually has a linear or straight cutting edge.
An anvil-type blade cooperates with a rotating disc-like slitter to shear the sheet that is fed to and from such slitting device. The rotation of the peripheral cutting edge or edges on the rotating slitter induces a downward shearing action to interact with the linear cutting edge of the anvil-type blade member.
The sheet which is longitudinally cut to form the strips sometimes can have an irregular edge. In these instances, the longitudinal slitting device may be augmented by a trimmer to maintain the sheet at a uniform width by trimming the irregular edge of the sheet.
A trimming device is usually located beside the slitting device and usually comprises a lower stationary anvil-type blade member and an upper rotating disc-like trimmer similar to the slitting device.
The interaction of the rotating disc-like slitter or trimmer with a stationary anvil-type blade wears the linear cutting edge of the anvil-type blade rapidly. This requires frequent blade changes resulting in downtime of the apparatus, necessary maintenance to replace or sharpen the worn blades and misalignment between the blade and the rotating slitter or trimmer.
Use of a linear edge anvil blade which reciprocates, such as described in U.S. Pat. No. 3,858,474 can prolong somewhat the periods of use of the anvil blade before sharpening or replacement is necessary. However, the changing of the blade can still result in misalignment of the reciprocating anvil cutter and the rotating slitter.
Another way to prolong lower anvil life which has been suggested is to replace the linear anvil cutter with an indexing or slowly turning disc-like blade with a plurality of linear edges along its peripery. This disc-like lower blade requires an additional means to turn the cutter at the desired slow speed and can result in slitting operations which are not as precise or "clean" as when lower stationary anvil-type blades are used.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved apparatus for longitudinally cutting cord reinforced rubber sheet into at least two strips of tire ply stock.
The principal component of the apparatus of the present invention is a slitting device which comprises a rotatable upper disc-like slitter and a rotatable lower disc-like slitter. The upper slitter has a cutting means along its periphery and the lower slitter has a cutting means along its periphery. The rotating upper slitter contacts the lower slitter effecting the rotation of the lower slitter through friction such that the upper and lower slitter rotate essentially at the same speed. The cutting means of said upper slitter cooperates in shear with the cutting means of said lower slitter. Preferably the cutting means along the periphery of the upper slitter is a plurality of linear cutting edges and the cutting means along the periphery of the lower slitter is a curvilinear or circular edge.
The apparatus of the present invention may further include a trimming device located adjacent to the slitting device which comprises a rotatable upper disc-like trimmer and a rotatable lower disc-like trimmer similar in construction to the upper and lower slitters of the slitting device. The rotating upper trimmer contacts the rotatable lower trimmer effecting the rotation of the lower trimmer through friction such that the upper and lower trimmer rotate essentially at the same speed. The cutting means of said upper trimmer cooperates in shear with the cutting means of said lower trimmer.
The apparatus of the present invention for longitudinally cutting bias sheet into widths of ply stock can be used for significantly longer periods before sharpening and/or replacement of blades or cutters is necessary, resulting in less down time, less maintenance and misalignment problems and substantial factory operating cost savings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of a preferred embodiment of an apparatus according to the invention with parts shown in section, broken away or omitted;
FIG. 2 is an end view taken along the line 2--2 in FIG. 1;
FIG. 3 is an enlarged longitudinal sectional view taken along line 3--3 in FIG. 2;
FIG. 4 is an enlarged end view taken along the line 4--4 in FIG. 1;
FIG. 5 is an enlarged longitudinal sectional view taken along the line 5--5 in FIG. 4.
DETAILED DESCRIPTION
In FIG. 1 an apparatus 10 to longitudinally cut a cord reinforced rubber sheet 12 according to the invention is shown in a presently preferred embodiment. The apparatus 10 comprises a slitting device 30 and a trimming device 130. The trimming device 130 is used to maintain the sheet 12 at a uniform width, if required, by trimming a boundary strip 13 of the sheet 12. The trimming device 130 may be omitted if sheet width uniformity is assured by other means or if such a uniformity is not of concern. A pair of conveyors as disclosed in U.S. Pat. No. 3,858,474, may be used to feed said sheet material to and take strips from the apparatus 10.
The slitting device 30 and trimming device 130 are supported on a frame 90 which includes an upper horizontal supporting table 96 and four vertical support members or legs 92 each having a foot 95 to support the frame 90. The bottom face 98 of the table 96 is welded or otherwise secured to the top of each leg 92. Welded or otherwise secured to the lower portions of legs 92 are four lower horizontal support beams 94. Each device 30 and 130 may be secured to the bottom face 98 of the table 96 in such a fashion as to allow axial adjustment of the devices as indicated by arrows A for longitudinally cutting various sizes of sheet 12 into various sizes of ply stock. Holes 97 exist in the table to allow motors 49 and 149 to power respectively the slitting device 30 and trimming device 130.
The slitting device 30, as seen in FIGS. 1, 2 and 3, comprises an upper slitter drive 28, an upper disc-like slitter 32 and a lower disc-like slitter 34 rotatably mounted in and supported by a slitter support generally referenced 80. The upper slitter 32 is mounted for rotation about horizontal axis 33 and the lower slitter 34 is mounted for rotation about another horizontal axis 35.
Slitter support 80 includes an upper section 81 and a lower section 82. Upper section 81 includes an upper shaft journal box or housing 85 and a support arm 83 with a mounting flange 84. Mounting flange 84 of support arm 83 is attached to the bottom face 98 of the table 96 by bolts 43 or may be otherwise secured to the table 96 by conventional means. The flange 84 may be secured in a manner (not shown) to allow for axial adjustment of support arm 83 for reasons previously mentioned. Lower section 82 of slitter support 80 includes a lower shaft journal box or housing 87 and an extension plate 86. Lower section 82 is secured to upper section 81 by bolts 54 registered through oversized openings 88 in extension plate 86. The oversized openings 88 allow for vertical adjustment of lower section 82 relative to upper section 81 as indicated by arrow D.
Upper section journal housing 85 and lower section journal housing 87 are provided with bearings 45 and 59, respectively (see FIG. 3), to support rotating shafts within such housings. An upper slitter shaft 36 is mounted for rotation within journal housing 85 while a lower slitter shaft 58 is mounted for rotation within journal housing 87.
Suitably secured at one end 40 of the upper slitter shaft 36 is the upper disc-like slitter 32 of slitting device 30, which has an outer periphery 64, a pair of flat surfaces 76, and a central bore 65, as shown in FIG. 3. Each margin of the periphery 64 comprises a series of sixteen linear cutting edges 67 of equal length defining a polygonal cutting edge. Wear resistance of the cutting edges 67 may be improved if each cutting edge 67 is composed of a hard material such as carbide. The slitter 32 is secured to the shaft 36, positioned between a flange 38 and a retainer 37. The retainer 37 has a bore 39 and an extension 27 which registers through bore 65 of the slitter 32, radially positioning the slitter 32 on retainer 37. The end 40 of the shaft 36 fits into the bore 39 of the retainer 37, radially positioning the retainer 37 and the slitter 32 on the shaft 36. An assembly comprising the slitter 32 positioned on the retainer 37 is secured by three bolts 41 or other conventional means to the flange 38, an enlarged portion of the shaft 36. A collar 46 secured to the shaft 36 by a key or by other suitable conventional means, axially positions the shaft 36 relative to the journal box 85.
Rotation of the upper slitter 32 is effected through the shaft 36 driven by a motor 49 (see FIG. 1) bolted or otherwise secured to the upper face of table 96. The motor 49 causes rotation of an output shaft (not shown) connected to a speed reducer 50. Rotation output of the speed reducer 50 is transmitted through a shaft 63 to an output pulley 51 secured by conventional means to the shaft 63. Rotation of the pulley 51 rotates a pulley 47 through a belt 52 or other conventional drive means. The pulley 47 is secured to an end of shaft 36 by a mounting flange 48.
Suitably secured at one end 44 of lower slitter shaft 58 is the lower disc-like slitter 34 of slitting device 30 which has an outer periphery 68, a pair of flat surfaces 77, and a central bore 69. Each margin of the periphery 68 comprises a circular cutting edge 71 The wear resistance of the lower slitter 34 can be improved if each cutting edge 71 is composed of a hard material such as carbide. The slitter 34 is secured to the shaft 58 positioned between a flange 74 and a retainer 73. The retainer has a bore 75 and an extension which registers through bore 69 of the slitter 34 radially positioning the slitter 34 on retainer 73. The end of the shaft 158 fits into the bore 75 of the retainer 73, radially positioning the retainer 73 and the slitter 32 on the shaft 58. An assembly comprising the slitter 34 positioned on the retainer 73 is secured by three bolts 41 or other conventional means to the flange 74, an enlarged portion of the shaft 58.
The lower slitter 34 is positioned relative to upper slitter 32 such that the rotation of upper slitter 32 causes lower slitter 34 to rotate through frictional contact between adjacent faces 76 and 77 of the upper and lower slitters. As shown in FIG. 3, one flat annular face 76 of the upper slitter 32 contacts one flat surface 77 of the lower slitter 34. When upper slitter 32 rotates, for example, in direction indicated by arrow B, frictional contact between upper and lower slitter faces 76 and 77 will effect rotation of the lower slitter 34 in the direction indicated by arrow C.
The trimming device 130, as seen in FIGS. 1, 4 and 5, is similar in most respects to the slitter device 30 and the description will be abbreviated t demonstrate the principal similarities and differences between the two devices 30 and 130. Trimming device 130 comprises an upper trimmer drive 128, an upper disc-like trimmer 132 and a lower disc-like trimmer 134 rotatably mounted in and supported by a trimmer support 180. In a preferred embodiment of the invention, the upper trimmer 132 is mounted for rotation coaxially with the upper slitter 32 and the lower trimmer 134 is mounted for rotation coaxially with the lower slitter 34.
Trimmer support 180 includes an upper section 181 and a lower section 182. Upper section 181 includes an upper shaft journal box or housing 185 and a support arm 183 with a mounting flange 184 for securing trimmer support 180 to the bottom face 98 of the table 96 by bolts 143. Lower section 182 of trimmer support 180 includes a lower shaft journal box or housing 187, an extension plate 186, and a strip support plate assembly 194. Lower section 182 is secured to upper section 181 by bolts 154 registered through oversized openings 188 in extension plate 186. The support plate assembly 194 comprises a strip support plate 198 and a strip support plate housing 196 which is attached to the extension plate 186 by four bolts 199 or secured to plate 186 by other conventional means. The support plate 198 is attached to the housing by bolts (not shown) or can be attached by other conventional means. Additionally mounted on the lower section 182 is a trim scrap deflector 190 which deflects the cut boundary strip 13 from the trimming device 130.
Upper section journal housing 185 and lower section journal housing 187 are provided with bearings 145 and 159, respectively (see FIG. 5), to support rotating shafts within such housings. An upper trimmer shaft 136 is mounted for rotation in their journal housing 185 while a lower trimmer shaft 158 is mounted for rotation within journal housing 187.
Suitably secured at one end 140 of the trimmer shaft 136 is the upper disc-like trimmer 132 of trimming device 130, which has an outer periphery 164, a pair of flat surfaces 176, and a central bore 165, as shown in FIG. 5. Each margin of the periphery 164 comprises a series of sixteen linear cutting edges 167 of equal length defining a polygonal cutting edge. Wear resistance of the cutting edges 167 may be improved if each cutting edge 167 is composed of a hard material such as carbide. The trimmer 132 is secured to the shaft 136, positioned between a flange 138 and a retainer 137. The retainer 137 has a bore 139 and an extension 127 which registers through bore 165 of the trimmer 132, radially positioning the trimmer 132 on retainer 137. The end 140 of the shaft 136 fits into the bore 139 of the retainer 137, radially positioning the retainer 137 and the trimmer 132 on the shaft 136. An assembly comprising the trimmer 132 positioned on the retainer 137 is secured by three bolts 141 or other conventional means to the flange 138, an enlarged portion of the shaft 136 in a similar arrangement to that of securing the upper slitter 32 by the retainer 37 and the flange 38. A spring 110 located on the shaft 136 is pressed between a journal box lip 112 and a collar 114 which is threaded onto shaft 136 or secured to the shaft 136 by other conventional means to allow for axial adjustment of spring 110. The spring 110 biases the upper trimmer 132 leftwardly as viewed in FIG. 5, that is, towards the lower trimmer 134. A collar 146 secured to the shaft 136 by a key or by other suitable conventional means, axially positions the shaft 136 relative to the journal box 185.
Rotation of the upper trimmer 132 is effected through the shaft 136 driven by a motor 149. The motor 149 causes rotation of an output shaft (not shown) connected to a speed reducer 150. Rotation output of the speed reducer 150 is transmitted through a shaft 163 to an output pulley 151 secured by conventional means to the shaft 163. Rotation of the pulley 151 rotates a pulley 147 through a belt 152 or other conventional drive means. The pulley 147 is secured to an end of shaft 36 by a mounting flange 148.
Suitably secured at one end 144 of lower trimmer shaft 158 is the lower disc-like trimmer 134 which has an outer periphery 168, a pair of flat surfaces 177, and a central bore 169. Each margin of the periphery 168 comprises a circular cutting edge 171. As in the upper trimmer 132 the wear resistance of the lower trimmers 134 can be improved if each cutting edge 171 is composed of a hard material such as carbide. The trimmer 134 is secured to the shaft 158 positioned between a flange 174 and a retainer 173. The retainer 173 has a bore 175 and an extension 153 which registers through bore 169 of the trimmer 134, radially positioning the trimmer 134 on retainer 173. The end 144 of the shaft 158 fits into the bore 175 of the retainer 173, radially positioning the retainer 173 and the trimmer 132 on the shaft 158. An assembly comprising the trimmer 134 positioned on the retainer 173 is secured by three bolts 141 or other conventional means to the flange 174, an enlarged portion of shaft 158. A snap ring 160 secured to the shaft 158 by conventional means axially positions the shaft 158 relative to the journal box 187.
The lower trimmer 134 is positioned relative to the upper trimmer 136 such that the rotation of upper trimmer 132 causes lower retainer 134 to rotate through frictional contact between adjacent faces of the upper and lower trimmers. As shown in FIG. 5, one flat annular face 176 of the upper trimmer 132 contacts one flat surface 177 of the lower trimmer 134 similar to the arrangement in the slitting device 30. When the upper trimmer 132 rotates, for example, in a direction indicated by arrow E, frictional contact between upper and lower trimmer faces 166 and 167 will effect rotation of the lower trimmer 134 in the direction indicated by arrow F.
Longitudinally cutting a cord reinforced rubber sheet 12 on apparatus 10 begins by conveying sheet 12 to the slitting device 30 and trimming device 130. The sheet 12 often comprises steel reinforcing cords, although the reinforcing cords could be textile or glass. The slitting device 30 is positioned to longitudinally cut the sheet 12 into strips of stock of predetermined width.
The combination of a sixteen-sided linear edge on the periphery of the upper slitter 32 or trimmer 132 and the circular edge on the periphery of the slitter 34 or lower trimmer 134 can be replaced by other combinations. The slitting device may be composed of both the upper and lower slitters having linear edges; both the upper and lower slitters have circular cutting edges, or the upper slitter having a circular cutting edge and the lower slitter having the linear cutting edges. Identical combinations apply to the trimming device.
While there has been shown and described a preferred embodiment of the present invention, it will be understood by those skilled in the art that various rearrangements and modifications can be made therein without departing from the scope of the invention which is to be measured by the accompanying claims.
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Disclosed is an apparatus to longitudinally cut a cord reinforced rubber sheet into at least two strips of tire ply stock while the sheet is being conveyed past the apparatus. The apparatus includes a slitting device that utilizes shear-type action to cut through the sheet by the interaction of rotating disc-like upper and lower slitters. The upper slitter is power driven while the lower slitter is rotated by frictional contact between the upper and lower slitter. The apparatus may include a trimming device for trimming a boundary strip of the sheet. The trimming device also utilizes shear-type action to trim the sheet by rotating disc-like upper and lower trimmers similar to the upper and lower disc-like slitters of the slitting device.
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[0001] This application is a continuation application of and claims priority to U.S. patent application Ser. No. 12/014,610 filed on Jan. 15, 2008. This application also claims priority under 35 U.S.C. §119(a) to Patent Application No. 10-2007-0017384 filed in the Republic of Korea on Feb. 21, 2007, the entire contents of both which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This present invention relates to a method and a terminal for displaying a received message with an icon.
[0004] 2. Description of the Related Art
[0005] Mobile terminal now allow users to send and receive multimedia messages (MMS) or short messages (SMS). When a user's mobile terminal receives a message, the mobile terminal displays, for example, a small image in the shape of an envelope to indicate to the user a new message has been received.
[0006] However, the mobile terminal displays the small envelope icon regardless of whether the message is an SMS message, MMS message or e-mail message. Therefore, the user can not distinguish what type of message they have received.
SUMMARY OF THE INVENTION
[0007] Accordingly, one object of the present invention is to address the above-noted and other objects.
[0008] Another object of the present invention is to provide information that assists the user in determining how many and what type of messages they have received on their terminal.
[0009] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, the present invention provides in one aspect a method for displaying a received message on a terminal. The method includes receiving messages, displaying on a display unit of the terminal different icons according to a type of the received messages, and displaying on the display unit of the terminal information indicating a number of unread received messages among the received messages. The present invention also provides a corresponding mobile communication terminal.
[0010] In another aspect, the present invention provides a method for displaying a received message on a terminal. The method includes receiving multimedia messages, and displaying on a display unit of the terminal different icons according to a type of contents attached to the received multimedia messages. The present invention also provides a corresponding mobile communication terminal.
[0011] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings, which are given by illustration only, and thus are not limitative of the present invention, and wherein:
[0013] FIG. 1 is a block diagram illustrating a terminal for displaying a received message according to an embodiment of the present invention.
[0014] FIG. 2 is a flowchart illustrating a method for displaying a received MMS message according to an embodiment of the present invention.
[0015] FIG. 3 is a flowchart illustrating a method for displaying a received SMS message according to an embodiment of the present invention.
[0016] FIG. 4 is a flowchart illustrating a method for displaying a received email message according to an embodiment of the present invention.
[0017] FIG. 5A is an overview illustrating multiple MMS icons indicating that multiple MMS messages have not been read.
[0018] FIG. 5B is an overview illustrating a single MMS icon indicating that a single MMS message has not been read.
[0019] FIG. 6A is an overview illustrating multiple SMS icons indicating that multiple SMS messages have not been read.
[0020] FIG. 6B is an overview illustrating a single SMS icon indicating that a single SMS message has not been read.
[0021] FIG. 7A is an overview illustrating multiple e-mail icons indicating that multiple e-mail messages have not been read.
[0022] FIG. 7B is an overview illustrating a single e-mail icon indicating that a single e-mail message has not been read.
[0023] FIG. 8 is an overview illustrating icons when an SMS message, two MMS messages, and three e-mail messages have not been read.
[0024] FIG. 9A is an overview illustrating an icon indicating a basic MMS message.
[0025] FIG. 9B is an overview illustrating an icon indicating image contents.
[0026] FIG. 9C is an overview illustrating an icon indicating audio contents.
[0027] FIG. 9D is an overview illustrating an icon indicating video contents.
[0028] FIG. 9E is an overview illustrating an icon indicating combined contents.
[0029] FIG. 10 is a flowchart illustrating a method for displaying a received message including image contents according to an embodiment of the present invention.
[0030] FIG. 11 is a flowchart illustrating a method for displaying a received message including image or audio contents according to an embodiment of the present invention.
[0031] FIG. 12 is a flowchart illustrating a method for displaying a received message including combined contents according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0033] FIG. 1 is a block diagram illustrating a terminal 100 for displaying a received message according to an embodiment of the present invention. As shown, the terminal 100 includes a communicating unit 110 , an input unit 120 , a controller 130 , a display unit 140 , a message processing unit 150 and a storage unit 160 .
[0034] The communicating unit 110 wirelessly receives an SMS message, an MMS message, or an e-mail message from a mobile communication network. Hereinafter, a message including an SMS message, an MMS message, and an e-mail message will also be referred to as a ‘multimedia message’.
[0035] Further, the input unit 120 is used to select a menu regarding an operation of the terminal 100 . In addition, when a multimedia message is received through the communicating unit 110 from the mobile communication network, the controller 130 controls the message processing unit 150 to analyze information about the message and display information (e.g., an icon) regarding a type of the received message and the number of messages that a user has not read yet.
[0036] That is, the controller 130 analyzes the received multimedia message and displays an icon indicating a type of corresponding contents attached to the received multimedia message based on a result of the analysis. Further, the display unit 140 displays an operational state or status of the terminal 100 and also displays an icon indicating a type of a received message and the number of messages user has not read yet.
[0037] In addition, the display unit 140 includes an indicator area where an RSSI (Received Signal Strength Indication) of an antenna, a remaining battery capacity, and whether a message has been received or not is displayed. Accordingly, the display unit 140 displays various icons indicating the type of the received message and the number of messages which have not been read in the indicator area.
[0038] Further, the message processing unit 150 recognizes the type of the message received through the communicating unit 110 based on a message classification field included in a header of the received message. That is, the message processing unit 150 recognizes whether the received message is an SMS message, an MMS message, or an e-mail message, and analyzes whether a single message or multiple messages have not been read by the user.
[0039] Next, the message processing unit 150 transfers the analysis information on the received message to the controller 130 . In addition, the message processing unit 150 analyzes the multimedia message received through the communicating unit 110 , and transfers information on contents attached to the multimedia message to the controller 130 .
[0040] Thus, the controller 130 displays an icon indicating a type of the corresponding contents attached to the received multimedia message on the display unit 140 . Further, the storage unit 160 stores the received message and various types of icons indicating types of received messages and of contents.
[0041] Next, FIG. 2 is a flowchart illustrating a method for displaying a received MMS message according to an embodiment of the present invention. The overviews shown in FIGS. 5A and 5B will also be referred to in the description of FIG. 2 .
[0042] As shown in FIG. 2 , the terminal 100 receives a message through the communicating unit 110 from the mobile communication network (S 202 ). Then, the controller 130 analyzes the message information through the message processing unit 150 with respect to the received message (S 204 ). As discussed above, the received message includes a header and content of the message, and the header of the message includes a message classification field indicating a type of the message.
[0043] Thus, the controller 130 classifies the received message using the message classification field as to whether the received message is an SMS message including text, an MMS message including a music or video file or an e-mail message having an e-mail format. The controller 130 also discriminates whether a single message or multiple messages has/have not been read yet by the user.
[0044] Further, as shown in FIG. 2 , when the received message is an MMS message (Yes in S 206 ), the controller 130 checks whether multiple MMS messages have not been read by the user (S 208 ). Further, the storage unit 160 stores icons indicating whether the received message is the MMS message, the SMS message, or the e-mail message.
[0045] Then, in step S 208 , the controller 130 determines if multiple MMS messages have not been read by the user according to the analysis results. The controller 130 also reads MMS icons indicating MMS messages from the storage unit 160 and displays the multiple MMS icons as shown in FIG. 5A when there are multiple unread MMS messages (S 210 ).
[0046] That is, the controller 130 stores icons indicating multiple MMS messages, multiple SMS messages or multiple e-mail messages in the storage unit 160 , and when multiple MMS messages have not been read by the user, the controller 130 reads the MMS icons indicating multiple MMS messages and displays the icons on the display unit 140 .
[0047] For example, FIG. 5A is an overview illustrating multiple MMS icons 510 indicating that multiple MMS messages have not been read. As shown, the multiple MMS icons 510 include a type indicator 512 indicating MMS messages. Further, as shown in FIG. 5A , the controller 130 displays the MMS icons 510 in the indicator area of the display unit 140 . The controller can also display the MMS icons 510 in a blinking manner to alert the user there are unread messages.
[0048] The controller 130 can also display the MMS icons 510 in a different color to discriminate the MMS icons 510 from other icons. Further, the controller 130 can display the multiple MMS icons 510 next to each title of the messages on a non-read list in an MMS reception box. The controller 130 can also display the MMS icons in an area different than the indicator area.
[0049] Meanwhile, as shown in FIG. 2 , when the controller 130 determines a single MMS message has not been read by the user according to the analysis results (No in S 208 ), the controller 130 reads an MMS icon indicating a single MMS message from the storage unit 160 and displays the single MMS icon on the display unit 140 as shown in FIG. 5B (S 212 ).
[0050] In more detail, FIG. 5B is an overview illustrating a single MMS icon 520 indicating that a single MMS message has not been read. Similar to FIG. 5A , the single MMS icon 520 in FIG. 5B includes a type indicator 522 indicating the type of message is a MMS message.
[0051] Further, the controller 130 can display the single MMS icon 520 in the indicator area of the display unit 140 , and display the single MMS icon 520 in a blinking manner. Also, the controller 130 can display the single MMS icon 520 in a different color so as to discriminate the single MMS icon 520 from other icons. The controller 130 can also display the single MMS icon 520 next to each title of messages on a list which have not been read in the MMS reception box.
[0052] In addition, when displaying the icon indicating the MMS message, the controller 130 can display an icon indicating whether there is an attachment file to the MMS message and an icon indicating what type of the attachment file is. Further, the controller 130 can display an icon as to whether a single file has been attached to the MMS message or multiple files have been attached to the MMS message.
[0053] Next, a description will be given for SMS messages with respect to the flowchart shown in FIG. 3 and the overviews shown in FIGS. 6A and 6B . FIG. 1 will also be referred to in this description. In more detail, FIG. 3 illustrates the processes performed by the controller 130 when the controller 130 determines the message is not an MMS message in step S 206 of FIG. 2 .
[0054] As shown in FIG. 3 , the controller 130 determines if the message is an SMS message (S 310 ). When the controller 130 determines the received message is an SMS message (Yes in S 310 ), the controller 130 checks whether multiple SMS messages have not been read (S 312 ). In addition, when the controller 130 determines multiple SMS messages have not been read (Yes in S 312 ), the controller 130 reads multiple SMS icons indicating SMS messages from the storage unit 160 and displays the multiple SMS icons on the display unit 140 as shown in FIG. 6A (S 314 ).
[0055] In more detail, FIG. 6A is an overview illustrating multiple SMS icons 610 indicating that the multiple SMS messages have not been read. As shown, the multiple SMS icons 610 a type indicator 612 indicating the SMS messages. Further, when the controller 130 determines there are not multiple SMS messages (No in S 312 ). the controller 130 determines a single SMS message has not been read by the user, reads an SMS icon indicating SMS message from the storage unit 160 and displays only the single SMS icon on the display unit 140 as shown in FIG. 6B (S 316 ).
[0056] In more detail, FIG. 6B is an overview illustrating the single SMS icon 620 indicating that the single SMS message has not been read. As shown, the single SMS icon 620 includes a type indicator 622 indicating the SMS message. As discussed with respect to FIGS. 5A and 5B , the controller 130 displays the single SMS icon 620 and the multiple SMS icon 612 in the indicator area of the display unit 140 , and/or in a blinking manner.
[0057] The controller 130 can also display the icons 610 and 620 in a different color so as to discriminate the icons from other icons. The controller 130 can also display the icons 610 and 620 next to each title of messages on a list which have not been read in the SMS reception box.
[0058] Next, a description will be given for e-mail messages with respect to the flowchart shown in FIG. 4 and the overviews shown in FIGS. 7A and 7B . FIG. 1 will also be referred to in this description. In more detail, FIG. 4 illustrates the processes performed by the controller 130 when the controller 130 determines the message is not an SMS message in step S 310 of FIG. 3 .
[0059] As shown in FIG. 4 , the controller 130 first determines if the message is an e-mail message (S 420 ). If the controller 130 determines the received message is an e-mail message (Yes in S 420 ), the controller 130 checks whether multiple e-mail messages have not been read (S 422 ).
[0060] Similar to the other examples regarding MMS and SMS messages, when the controller 130 determines multiple e-mail messages have not been read by the user (Yes in 422 ), the controller 130 reads e-mail icons indicating e-mail message from the storage unit 160 and displays multiple e-mail icons on the display unit 140 as shown in FIG. 7A (S 424 ). Further, when the controller 130 determines only a single message has not been read (No in S 422 ), the controller 130 reads an e-mail icon indicating an e-mail message from the storage unit 160 and displays the single e-mail icon on the display unit 140 as shown in FIG. 7B .
[0061] Further, FIGS. 7A and 7B are similar to FIGS. 5A and 5B and 6 A and 6 B. That is, FIG. 7A illustrates multiple e-mail icons 710 indicating that the multiple e-mail messages have not been read and a type indicator 712 indicating the e-mail message. FIG. 7B illustrates a single e-mail icon 720 indicating that a single e-mail message has not been read and a type indicator 722 indicating the e-mail message.
[0062] Similar to the other examples, the icons can be displayed in a blinking manner, using a different color, or next to each title of messages on a non-read list of an e-mail reception box.
[0063] Next, FIG. 8 is an overview illustrating icons when an SMS message, an MMS message and an e-mail message have not been read according to another embodiment of the present invention. In more detail, when the user has not read any of received SMS, MMS and e-mail messages, the controller 130 displays an SMS icon 812 indicating a SMS message, an MMS icon 814 indicating an MMS message, and an e-mail icon 816 indicating an e-mail message on the display unit 140 as shown in FIG. 8 .
[0064] Namely, the controller 130 reads the SMS icon, the MMS icon and the e-mail icon from the storage unit 160 , and displays the icons in an overlap manner as shown in FIG. 8 . Alternatively, the controller 130 may also display an integrated icon indicating all of the SMS, MMS and email messages. In this instance, the integrated icon includes the SMS icon 812 indicating the SMS message, the MMS icon 814 indicating the MMS message, and the e-mail icon 816 indicating the e-mail message as a single icon.
[0065] Further, the SMS icon 812 , the MMS icon 814 and the e-mail icon 816 shown in FIG. 8 each have a different color so that the icons can be discriminated from each other. In addition, when displaying the non-read messages, the controller 130 can display the number of the messages that have not been read together with characters (S, M, E) indicating types of the messages. For example, and as shown in FIG. 8 , when a single SMS message has not been read, S: 1 can be displayed, when two MMS messages have not been read, M: 2 can be displayed, and when three e-mail messages have not been read, E: 3 can be displayed.
[0066] Further, when the received message is an MMS message, the controller 130 can display an icon indicating whether or not the MMS message includes an attachment file and an icon indicating a type of the attachment file, and can also display an icon indicating whether a single attachment file or multiple attachment files has/have been attached. These features will now be described in more detail with respect to FIGS. 9-12 . FIG. 1 will also be referred to in this description.
[0067] As shown in FIG. 10 , the controller 130 determines the terminal 100 has received an MMS message through the communicating unit 110 (Yes in S 1010 ). Here, the MMS message refers to a notification message from an MMS server (not shown) that there is an MMS message transmitted to the terminal. That is, when a terminal of the other party creates and sends an MMS message to the terminal 100 , the MMS server transmits the notification message with fields defined as shown in the below Table 1 to the terminal 100 .
[0000]
TABLE 1
Field name
Field value
Description
X-Mms-Message-
Message-type-
Compulsory,
Type
value =
Indicating
m-send-req
characteristics
of data packet
X-Mms-
Transaction-id-
Compulsory,
Transaction-ID
value
A unique
key value
indicating
packet
X-Mms-MMS-
MMS-version-
Compulsory,
Version
value
Indicating
MMS version
Date
Date-value
Optional,
Indicating
date
From
From-value
Compulsory,
Address of
person who
created
message
To
To-value
Optional,
Naming
receiver.
Cc
Cc-value
Optional
item
Bcc
Bcc-value
Optional
item
Subject
Subject-value
Optional,
Inputting
title of
MM
X-Mms-Message-
Message-class-
Optional,
Class
value
Classifying
message
X-Mms-Expiry
Expiry-value
Optional,
Amount
stored
in MMSC
X-Mms-Priority
Priority-value
Optional,
Importance
level of
message
X-Mms-Sender-
Sender-visibility-
Optional,
Visibility
value
Sender is
not to be
seen
X-Mms-Delivery-
Delivery-report-
Optional,
Report
value
Choose to
be reported
X-Mms-Read-Reply
Read-reply-
Optional,
value
Receiving
report on
whether
it was read
X-Mms-Reply-
Reply-charging-
Optional,
Charging
value
Used when
sender
charges
reply fee
X-Mms-Reply-
Reply-charging-
Optional,
Charging-
deadline-value
Charging
Deadline
reply fee
within
certain
time in
case of
charging
reply fee
X-Mms-Reply-
Reply-charging-
Optional,
Charging-
size-value
Charging
Size
only
particular
size in
case of
charging
reply fee
X-Mms-Reply-
Reply-charging-
Optional,
Charging-ID
ID-value
ID of
original
MM as
returned
in case of
charging
reply fee
Content-Type
Content-type-
Compulsory,
value
Type of
contents
of MM
[0068] Thus, as shown in FIG. 10 , when the MMS message is received (Yes in S 101 ), the controller 130 analyzes a type of contents of the received MMS message through the message processing unit 150 (S 1020 ). Namely, the controller 130 analyzes whether the MMS message includes only text or whether the MMS message includes image (picture) contents, audio contents, or video contents through a contents type field included in the notification message. Here, the image contents correspond to a photo image captured by a digital camera or a picture or an image created using a graphic tool.
[0069] Further, the MMS message may only include text data, and not image (picture) contents, audio contents, or video contents according to the analysis results. Thus, if the received MMS message does not contain any contents besides text, the controller 130 can display a character or an icon indicating that there are not any contents. Namely, as shown in FIG. 9A , the controller 130 displays an icon indicating the basic MMS message on the display unit 140 . As shown in FIG. 9A , the displayed icon includes a type indicator 910 indicating the type of the received message.
[0070] In addition, as shown in FIG. 10 , when the controller 130 determines the received MMS message includes image (picture) contents according to the analysis results (Yes in S 1030 ), the controller 130 reads an image contents icon indicating image (picture) contents among contents icons stored in the storage unit 160 and displays the icon on the display unit 140 as shown in FIG. 9B (S 1040 ).
[0071] As shown in FIG. 9B , the displayed icon is an image contents icon 920 including a type indicator 922 indicating the MMS message and a contents indicator 924 indicating image contents are included in the MMS message. As shown, the contents indicator 924 is expressed in the shape of a camera, but the contents indicator 924 can be expressed in a different shape. The controller 130 can also display only a character indicating that the image contents are included in the received MMS message.
[0072] Next, when the controller 130 determines the message does not include image contents (No in S 1030 ), the controller 130 determines if audio contents are included (S 1110 in FIG. 11 ). When the controller 130 determines the contents included in the received MMS message are audio contents (or sound contents) (Yes in S 1110 ), the controller 130 reads an icon indicating audio contents among contents images stored in the storage unit 160 and displays the icon on the display unit 140 as shown in FIG. 9C (S 1120 ).
[0073] As shown in FIG. 9C , the displayed icon is an audio contents icon 930 including a type indicator 932 indicating the MMS message and a contents indicator 934 indicating audio contents are included in the MMS message. As shown, the contents indicator 934 is expressed in the shape of musical notes, but the icon can be expressed in a different shape. The controller 130 can also only display a character indicating audio contents are included in the MMS message.
[0074] Next, as shown in FIG. 11 , when the controller 130 determines the message does not include audio contents (No in S 1110 ), the controller 130 determines if the message includes video contents (S 1130 ). When the controller 130 determines the contents included in the received MMS message are video contents (Yes in S 1130 ), the controller 130 reads an icon indicating video contents among the contents images stored in the storage unit 160 and displays the on the display unit 140 as shown in FIG. 9D (S 1140 ).
[0075] As shown in FIG. 9D , the icon is a video contents icon 940 including a type indicator 942 indicating the MMS message and a contents indicator 944 indicating that the video contents are contained in the MMS message. As shown, the contents indicator 944 has the shape of a film, but the indicator 944 can be also expressed in a different shape. Further, the controller can also only display a character indicating that the video contents are contained in the MMS message.
[0076] Further, the flowchart in FIG. 12 illustrates when the controller 130 determines there are no image contents in step S 1030 of FIG. 10 . As shown in FIG. 12 , the controller 130 determines if the contents contained in the received MMS message are combined contents including an image, audio, and video (S 1210 ). When the controller 130 determines the contents are combined contents (Yes in S 1210 ), the controller 130 reads an image contents icon, an audio contents icon, and a video contents icon from the storage unit 160 and displays the icons on the display unit 140 as shown in FIG. 9E . The controller 130 can also read a combined contents icon indicating all of the image contents, the audio contents, and the video contents from the storage unit 160 display the combined icon on the display unit 140 .
[0077] As shown in FIG. 9E , the combined contents icon 950 includes a type indicator 952 indicating the MMS message and contents indicators 954 indicating that the respective contents are contained in the MMS message. Further, the contents indicators 954 may be expressed by mixing the shapes of the camera, the musical note, and the film.
[0078] Similar to the other icons discussed above, the controller 130 can display the combined contents icon 950 in the indicator area of the display unit 140 , display the combined contents icon 950 in a blinking manner, and/or display the contents indicators 954 of the combined contents icon 950 in different colors to discriminate the icon from other icons or contents. The controller 130 can also display the combined contents icon 950 next to each title of messages on the list of the MMS reception box. Further, the controller 130 can display only a character indicating that the MMS message contains the image contents, the audio contents, and the video contents.
[0079] Accordingly, when the user receives a multimedia message on their terminal, he/she can easily recognize what type of message has been received, how many messages have been received, and also can easily recognize what type of contents are contained in the received multimedia message.
[0080] In addition, according to embodiments of the present invention, when a message is received by the terminal, the received message is analyzed and information (e.g., one or more icons) is displayed to inform the user about the received message(s). Thus, the user can easily recognize what type of message has been received and/or how many messages have been received.
[0081] As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to be embraced by the appended claims.
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A mobile terminal including a communicating unit, a display unit including an indicator area notifying an alarm when a message is received, and a controller configured to receive a message from at least one other terminal, and display message information on the indicator area of the display unit. Further, the message information including a first image selected according to a type of the received message, and a second image selected according to a type of the attached file.
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TECHNICAL FIELD
[0001] The disclosure relates in general to a test method for a memory, and more particularly to a method for testing a memory by half page read.
BACKGROUND
[0002] Flash memory plays an important role in an electronic device. For example, a memory card having the flash memory may be used to increase the storage capacity of a mobile device. After the memory chips are manufactured, the memory chips are tested. Therefore, how to fast test the memory is one of the targets.
SUMMARY
[0003] The disclosure is directed to a method for testing a memory which reduces test time by half page read. In half page read, a single half of each of the memory cells is read and tested.
[0004] According to one embodiment, a test method for testing a memory device including a memory array is provided. The memory array includes a plurality of symmetric memory cells, a plurality of word lines and a plurality of bit lines. In testing a first word line of the word lines, a first bit line of the bit lines is charged to test a single bit of a first half of a first symmetric memory cell adjacent to the first bit line; and a second bit line of the bit lines is charged to test a single bit of a second half of a second symmetric memory cell adjacent to the second bit line. In testing a second word line of the word lines, the first bit line of the bit lines is charged to test a single bit of the second half of a third symmetric memory cell adjacent to the first bit line; and the second bit line of the bit lines is charged to test a single bit of the first half of a fourth symmetric memory cell adjacent to the second bit line. In testing each of the word lines, each of the bit lines is charged once.
[0005] According to another embodiment, a test method for testing a memory device including a memory array is provided. The memory array includes a plurality of symmetric memory cells, a plurality of word lines and a plurality of bit lines. A half page read is performed on the memory array, wherein there are a first number of at least one defective lines of the memory array found during the half page read, and in the half page read, either one of a first half and a second half of each of the symmetric memory cells is read. The at least one defective line found during the half page read is repaired. A whole page read is performed on the repaired memory array and a defective status is recorded, wherein there are a second number of the at least one defective lines of the memory array found during the whole page read, and in the whole page read, both the first half and the second half of each of the symmetric memory cells are read. Whether the memory device passes test is determined based on the defective status and a relationship between the first and the second number.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 shows a function block for a memory device.
[0007] FIG. 2 shows a memory array.
[0008] FIGS. 3A-3B show test according to an embodiment of the application.
[0009] FIG. 4 shows a test flow according to another embodiment of the application, which is performed before mass product.
[0010] FIG. 5 shows a test flow according to still another embodiment of the application, which is performed after mass product.
[0011] In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are schematically shown in order to simplify the drawing.
DETAILED DESCRIPTION
[0012] Technical terms of the disclosure are based on general definition in the technical field of the disclosure. If the disclosure describes or explains one or some terms, definition of the terms is based on the description or explanation of the disclosure.
[0013] Each of the disclosed embodiments has one or more technical features. In possible implementation, one skilled person in the art would selectively implement part or all technical features of any embodiment of the disclosure or selectively combine part or all technical features of the embodiments of the disclosure.
[0014] FIG. 1 shows a function block for a memory device. As shown in FIG. 1 , the memory device 100 at least includes: a memory array 110 , a first redundancy circuit 120 , a second redundancy circuit 130 and an error correction circuit (ECC) 140 .
[0015] The memory array 110 includes a plurality of memory cells, a plurality of word lines and a plurality of bit lines. The memory cells are arranged in an array. Each memory cell is a symmetric memory cell. The symmetric memory cell includes a left half and a right half; and each of the left half and the right half stores at least one bit. The bit number of the left half is the same as that of the right half.
[0016] In the memory array 110 , the word lines are, for example, along x direction (i.e. horizontal direction) and the bit lines are, for example, along y direction (i.e. vertical direction).
[0017] The first redundancy circuit 120 is, for example, an x-direction redundancy circuit. After test, if the number of the defective memory cells on the word line reaches a first threshold, then the first redundancy circuit 120 may be used to replace (repair) the memory cells on the word line.
[0018] The second redundancy circuit 130 is, for example, a y-direction redundancy circuit. After test, if the number of the defective memory cells on the bit line reaches a second threshold, then the second redundancy circuit 130 may be used to replace (repair) the memory cells on the bit line.
[0019] After test, if the number of the defective memory cells on the word line or the bit line is smaller than the first/second threshold, then the ECC 140 may be used to replace (repair) the defective memory cells.
[0020] FIG. 2 shows the memory array 110 . As shown in FIG. 2 , in the memory array 110 , the word line WL 0 is coupled to the memory cells 210 _ 0 _ 0 , 210 _ 0 _ 1 , 210 _ 0 _ 2 , . . . , 210 _ 0 _N, 210 _ 0 _(N+1), 210 _ 0 _(N+2), . . . . N is a positive integer. Similarly, the word line WL 1 is coupled to the memory cells 210 _ 1 _ 0 , 210 _ 1 _ 1 , 210 _ 1 _ 2 . . . 210 _ 1 _N, 210 _ 1 _(N+1), 210 _ 1 _(N+2) and so on. For simplicity, FIG. 2 shows two word lines WL 0 and WL 1 but the application is not limited by this.
[0021] The memory cell 210 _ 0 _ 0 includes a gate coupled to the word line WL 0 , a source and a drain. One of the source and the drain of the memory cell 210 _ 0 _ 0 is coupled to the bit line BL 0 , and the other of the source and the drain of the memory cell 210 _ 0 _ 0 is coupled to the bit line BL 1 . The coupling of other memory cells is similar.
[0022] The memory cells coupled to the same word line may be grouped in a plurality of pages. Furthermore, the left half bits and the right half bits of the same memory cell may be of different pages. As shown in FIG. 2 , the left half bit of the memory cell 210 _ 0 _ 0 is of page 0 but the right half bit of the memory cell 210 _ 0 _ 0 is of page 32 . In FIG. 2 , the number shown in the half bit of the memory cell refers to the page number of the half bit of the memory cell.
[0023] How to perform memory test according to the embodiment of the application is described as follows. For simplicity, the word lines WL 0 , WL 1 . . . are sequentially tested. The application is not limited thereby.
[0024] In the embodiment, in half page read, a single half (either one of the left half and the right half) of each memory cell is read. That is to say, not both the left half and the right half of the memory cell are read and tested. Further, in testing the same word line, each bit line is charged/sensed once. Further, in testing, the left half bits of about 50% of the memory cells on the same bit line are read and tested, and the right half bits of about the other 50% of the memory cells on the same bit line are read. Similarly, in testing, the left half bits of about 50% of the memory cells on the same word line are read, and the right half bits of about the other 50% of the memory cells on the same word line are read.
[0025] FIGS. 3A-3B show test according to an embodiment of the application. For simplicity, in testing, the word line which is applied by a test voltage is marked with “+V”; and on the contrary, the word line which is applied by a ground voltage is marked with “GND”. Further, in testing the word line, the memory cells of the same page are concurrently read and tested.
[0026] As shown in FIG. 3A , in testing page 0 of the word line WL 0 , the bit lines BL 1 and BLN are concurrently charged to test the left half bit of the memory cell 210 _ 0 _ 0 and the right half bit of the memory cell 210 _ 0 _N, respectively. In FIGS. 3A and 3B , the dotted arrow refers to that, the left/right half bit of the memory cell is tested by the charged bit line.
[0027] Similarly, in testing page 48 of the word line WL 0 , the bit lines BL 2 and BL(N+1) are concurrently charged to test the left half bit of the memory cell 210 _ 0 _ 1 and the right half bit of the memory cell 210 _ 0 _(N+1), respectively. In testing page 8 of the word line WL 0 , the bit lines BL 3 and BL(N+2) are concurrently charged to test the left half bit of the memory cell 210 _ 0 _ 2 and the right half bit of the memory cell 210 _ 0 _(N+2), respectively.
[0028] Further, in testing the word line, the bits of the same page on the same word line are concurrently test. After the whole page on the same word line is tested, the next page on the same word line is tested. For example, as shown in FIG. 3A , in testing the word line WL 0 , the test sequence may be page 0 , page 2 (not shown) . . . and so on.
[0029] That is, as shown in FIG. 3A , the bit lines BL 1 , BLN, . . . and so on are concurrently charged to test bits of the page 0 of the word line WL 0 . In testing page 8 of the word line WL 0 , the bit lines BL 3 , BL(N+2), . . . and so on are concurrently charged to test bits of the page 8 of the word line WL 0 . In testing page 48 of the word line WL 0 , the bit lines BL 2 , BL(N+1), . . . and so on are concurrently charged to test bits of the page 48 of the word line WL 0 .
[0030] Similarly, in FIG. 3B , for testing the page 32 of the word line WL 1 , the bit lines BL 0 and BL(N+1) are concurrently charged to test the right half bit of the memory cell 210 _ 1 _ 0 and the left half bit of the memory cell 210 _ 1 _N, respectively. For testing the page 16 of the word line WL 1 , the bit lines BL 1 and BL(N+2) are concurrently charged to test the right half bit of the memory cell 210 _ 1 _ 1 and the left half bit of the memory cell 210 _ 1 _(N+1), respectively. For testing the page 40 of the word line WL 1 , the bit lines BL 2 and BL(N+3) are concurrently charged to test the right half bit of the memory cell 210 _ 1 _ 2 and the left half bit of the memory cell 210 _ 1 _(N+2), respectively.
[0031] Further, in testing the same page on the same word line, the left half bits of 50% of the memory cells of the same page on the same word line are concurrently read and tested, and the right half bits of the other 50% of the memory cells of the same page on the same word line are concurrently read and tested.
[0032] In the embodiment of the application, in order to reduce the test time, in testing the same word line, each of the bit lines is charged/sensed once. Thus, in testing the same word line, not every page is read and tested. Of course, during the test of the whole memory array 110 , all pages are read and tested. For example, in testing the word line WL 0 , the page 0 is read and tested, but the page 32 is neither read nor tested. Similarly, in testing the word line WL 1 , the page 32 is read and tested, but the page 0 is neither read nor tested.
[0033] Besides, in the embodiment, in testing the same word line, about 50% of the bit lines (or said, the first bit line group) are concurrently charged to read and test the left half bits of the memory cells on the left side of the first bit line group; and about the other 50% of the bit lines (or said, the second bit line group) are concurrently charged to read and test the right half bits of the memory cells on the right side of the second bit line group. In testing the next word line, the bit lines of the first bit line group are concurrently charged to read and test the right half bits of the memory cells on the right side of the first bit line group; and the bit lines of the second bit line group are concurrently charged to read and test the left half bits of the memory cells on the left side of the second bit line group. This is referred as “reverse read”.
[0034] In the embodiment of the application, “half page read” is defined as that, if the bit on a single half of each memory cell is read and tested, then the bit on the other half of each memory cell is neither read nor tested.
[0035] In the application, “whole page read” is defined as that, the bits on both the left and the right halves of each memory cell are read and tested.
[0036] In prior test, the bits on both the left half and the right half of each memory cell are read and tested, and thus, in testing the same word line, each of the bit lines are charged twice. This results in a long test time in prior test. In the embodiment of the application, the bit on a single half of each memory cell is read and tested; and in testing the same word line, each bit line is charged once. Thus, the test time in the embodiment of the application may be reduced to 50%, compared with the prior test time.
[0037] In order to have an uniform test result, in the embodiment of the application, as for the same bit line, in testing the word line, the bit line may test bit of the left half of the memory cell on the left side of the bit line; but in testing the next word line, the bit line may test bit of the right half of the memory cell on the right side of the bit line. This test may have uniform test on a plurality of memory cells for assuring test quality and reliability.
[0038] FIG. 4 shows a test flow according to another embodiment of the application, which is performed before mass product. In step 410 , the half page read is performed on the memory array 110 to find all defective lines. For example, if the number of the defective memory cells on the word line WL 0 reaches the first threshold, then the word line WL 0 is checked as a defective line. Step 410 is for finding all defective lines on the word lines and on the bit lines. After the defective lines are found, the defective lines are repaired. For example, the first redundancy circuit 120 is used to repair/replace the defective word line (i.e. the whole defective word line is replaced by the redundancy word line of the first redundancy circuit 120 ); and the second redundancy circuit 130 is used to repair/replace the defective bit line (i.e. the whole defective bit line is replaced by the redundancy bit line of the second redundancy circuit 130 ). The number of the defective lines found in the step 410 is recorded as R1.
[0039] In step 415 , the whole page read is performed on the repaired memory array to obtain ECC status. The ECC status refers to the ECC bit number which is used in repairing the memory array and the ECC array. The ECC status is output from the ECC 140 . The ECC array is in the ECC 140 and the memory cells in the ECC array may be defective. That is, the ECC status may refer as the defective status of the memory array and the ECC array of the ECC 140 .
[0040] As described above, if the number of the defective memory cells on the word line/bit line reaches the first/second threshold, then the word line/bit line is replaced by the first/second redundancy circuit 120 / 130 . Alternatively, if the number of the defective memory cells on the word line/bit line is under the first/second threshold, then defective memory cells on the word line/bit line are repaired by the ECC 140 .
[0041] In step 420 , the whole page read is performed on the memory array 110 to find the number (R2) of the defective lines.
[0042] In step 425 , whether the ECC status is smaller than or equal to 1 bit is determined. If the ECC status is smaller than or equal to 1 bit, then the defective memory cells in the memory array is few. Thus, the memory device may pass the test. Besides, in the embodiment, the memory device which passes the test is further analyzed.
[0043] In step 430 , whether R2=R1 is determined. If R2=R1, then the number of the defective lines found by the half page read is equal to the number of the defective lines found by the whole page read. That is, the defective status of the memory cells of the memory array 110 is not serious and thus in the whole page read, no new defective line is found. Thus, the memory device is determined as “test pass” (step 435 ).
[0044] On the contrary, if R2 is not equal to R1 in the step 430 , then it means that new defective line(s) is/are found in the whole page read. However, the memory device may be repaired by the ECC because there are few defective memory cells in the memory array. Thus, the memory device is determined as “test pass” (step 440 ).
[0045] If no in step 425 , then it means that the defective status of the memory device is more serious (because the ECC status is higher than 2 bits). The memory device is determined as “test failure” in the embodiment of the application. Besides, in the embodiment, the memory device which is failed in the test is further analyzed.
[0046] In step 445 , whether R2=R1 is determined. If R2=R1, it means that no new defective line is found in the whole page read. However, the embodiment determines that the ECC of the memory device has serious defects which result the ECC status higher than 2 bits. Thus, the memory device is determined as “test failure” (step 450 ).
[0047] If R2 is not equal to R1 in step 445 , then it means the memory array of the memory device has serious defects which result finding of new line(s) in the whole page read. Thus, the memory device is determined as “test failure” (step 455 ).
[0048] FIG. 5 shows a test flow according to still another embodiment of the application, which is performed after mass product. In step 510 , all bits of each of the memory cells are set as bit “1”. The half page read is performed on the memory array to find and repair all defective lines of the memory array.
[0049] In step 520 , the repaired defective line(s) is/are read again to determine whether the repair is successful.
[0050] In step 530 , all word lines of the memory array are grouped and tested, and the ECC status of each word line group is checked. For example, 32 word lines are grouped as a word line group, and the whole page read is performed on each of the word line groups to check the ECC status of each word line group. If the whole page read of the current word line group indicates that the ECC status is smaller than or equal to 3 bits, then the whole page read is performed on the next word line group. On the contrary, if the whole page read of the current word line group indicates that the ECC status is higher than 3 bits, then the memory device is determined as “test failure”. If any word line group is failed in the test, the memory device is determined as “test failure”. The step 530 is repeated until all word line groups of the memory array pass the test, and thus the memory device is determined as “test pass”.
[0051] In step 540 , the test result is output.
[0052] Besides, in test, the above embodiments of the application may be combined. For example, in performing the test flow of FIG. 4 or FIG. 5 , the half page read of FIG. 4 or FIG. 5 may be implemented by the half page read of FIG. 2 .
[0053] Further, in testing, the test flow of FIG. 4 may be performed first, and then the test flow of FIG. 5 is performed on the memory device which is passed the test flow of FIG. 4 .
[0054] As described above, the test flow of FIG. 4 or FIG. 5 applies the test method in FIGS. 3A and 3B , and thus the test time is shortened. Besides, the embodiment uses ECC to assure correctness of the test.
[0055] It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed embodiments. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.
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A test method tests a memory device including a memory array having a plurality of symmetric memory cells, a plurality of word lines and a plurality of bit lines. In testing a first word line, a first bit line is charged to test a single bit of a first half of an adjacent first symmetric memory cell; and a second bit line is charged to test a single bit of a second half of an adjacent second symmetric memory cell. In testing a second word line, the first bit line is charged to test a single bit of the second half of an adjacent third symmetric memory cell; and the second bit line is charged to test a single bit of the first half of an adjacent fourth symmetric memory cell. In testing each of the word lines, each of the bit lines is charged once.
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FIELD OF INVENTION
The invention relates to the use of somatostatin or one of its agonist analogues for preparing a medicament intended to regulate the ovarian follicular reserve in non-menopausal women, or the use of a somatostatin antagonist analogue for preparing a medicament intended to accelerate the start of growth of the quiescent follicles in non-menopausal women. The invention also relates to the in vitro use of somatostatin or one of its agonist analogues in order to inhibit the start of growth of quiescent follicles in ovarian tissue, or the in vitro use of a somatostatin antagonist analogue in order to accelerate the start of growth of quiescent follicles in ovarian tissue.
BACKGROUND OF INVENTION
In women, as in all mammals, fertility is dependent on the presence in the ovaries of female gametes called “oocytes”. In humans, the oocyte capital is constituted once and for all at birth; the number of oocytes is then comprised between 500 000 and 1 million per ovary. These oocytes are surrounded by a few granulosa cells; this functional group is called an ovarian follicle (Gougeon, A., Endocrine Reviews (1996),17, 121-155). At birth, but also throughout life until menopause, the majority of the ovarian follicles are in a dormant state.
From its constitution, the oocyte capital progressively diminishes: thus, there are approximately 200 000 follicles per ovary at puberty, approximately 80 000 at 20 years of age, approximately 30 000 at 30 years of age, approximately 10 000 at 40 years of age, the capital being practically depleted at around 50 years of age (cf. Gougeon, A. and Lefevre, B., <<Folliculogénèse et maturation ovocytaire>> in Médecine de la reproduction , 3 rd edition, Ed. Flammarion, p. 49). The depletion of the oocyte capital corresponds clinically to menopause. The dormant follicles present in the ovary at a given time constitute the “ovarian reserve”.
Two mechanisms are involved in the progressive depletion of the ovarian reserve. Approximately 80% of the follicles disappear at the start of apoptosis, while the remaining 20% start to grow. The latter then begin a long process of development (approximately 6 months) in which a minority of them (approximately 400 over a lifetime) will arrive at the stage of preovulatory follicles containing a mature oocyte which is able to be to be fertilized (Gougeon, A., Endocrine Reviews (1996), 17, 121-155). The majority of the growing follicles disappear through apoptosis leading to their involution; apoptosis strikes them at any stage of their development.
The change from the quiescent follicle stage to the growing follicle stage is a phenomenon which is continuous but of variable intensity. In particular, it accelerates in the 10 to 15 years preceding menopause, from approximately 38 years of age.
The factors stimulating the first stages of growth (starting from the large primary follicle) are relatively well known. They include gonadotropins (LH and FSH) but particularly growth factors and steroids such as androgens. However, the mechanisms controlling the initiation of follicle growth are not well known. It is well established that this stage of folliculogenesis is not dependent on gonadotropins (LH and FSH) (cf. for example Bullun, S. and Adashi, E., Williams Textbook of Endocrinology , Tenth Edition (2003), 587-664). A hormone known as AMH (Anti-Mullerian hormone) could be involved in maintaining the quiescence of the follicles while a peptide known as Kit-Ligand (also called SCF) could be involved in activating the growth of dormant follicles. In addition, a growth factor known as GDF-9 seems to be important for maintaining the growth once it is triggered.
Somatostatin (SST) is a cyclic peptide present in two forms in the organism, one form containing 14 amino acids and one form containing 28 amino acids. The biological activity of these two forms of SST is similar. The SST-14 form is the predominant form in the central nervous system. It inhibits the secretion of the growth hormone by the somatotrope cells of the anterior pituitary. The SST-28 form is preferably expressed in the stomach and the pancreas. The biological activity of SST is induced by means of a series of membrane receptors coupled with a protein G, 5 sub-types of which have been characterized, namely the sub-types SSTR1 to SSTR5 (Reubi, J. C., Cancer Res. , 47, 551-558; Resine, T., et al., Endocr. Review , 16, 427-442; Lamberts, SW. et al., Endocr. Review , 12, 450-482).
The presence of SST in the ovary has been demonstrated in several species including pigs (Mori, T. et al., Acta Endocrinol . (Copenh.) (1984), 106(2), 254-259), rats (McNeill, D. L. et al., Am. J Anat . (1987), 179(3), 269-76) and in women (Holst et al., Hum. Reprod . (1994), 9(8), 1448-1451). SST receptors have been identified in the ovary of the rat (Lidor, A. et al., Gynecol. Endocrinol . (1998), 12(2), 97-101) as well as in the human ovary in particular the sub-types 1, 2A and 5 (Strauss et al., Hum. Reprod . (2003), 18, Suppl. 1, P-495).
The contribution of SST in ovarian physiology has been studied by several authors. In rats, the in vivo administration of SST seems to reduce the number of pituitary cells producing LH and FSH as well as the number of preovulatory follicles in the ovary (Nestorovic et al., Histochem. J . (2001), 33(11-12), 695-702). In vitro, SST inhibits aromatase and the production of progesterone, stimulated by FSH, in a model of granulosa cells (Andreani, C. L. et al., Hum. Reprod . (1995), 10(8), 1968-1973). In pigs, SST inhibits the increase in cAMP induced by LH and forskolin in the granulosa cells (Rajkumar, K. et al., J. Endocrinol . (1992), 134(2), 297-306), and seems to inhibit the nuclear maturation of the preovulatory oocyte (Mori, T. et al., Acta Endocrinol . (Copenh.) (1985), 110(3), 408-412). In women, in vitro studies on granulosa cells from preovulatory follicles suggest a direct role of SST in inhibiting the synthesis of IGF-BP1 and of progesterone (Holst, N. et al., Fertil. Steril . (1997), 68(3), 478-482). In women, in vivo, SST is capable of reducing the secretion of LH by the pituitary, reducing the production of androgens and the IGF-1 serum levels. By contrast, SST increases the serum levels of IGF-BP3 (Fulghesu, A. M. et al., Fertil. Steril . (1995), 64(4), 703-708; Piaditis, G. P. et al., Clin. Endocrinol . (Oxf.) (1996), 45(5), 595-604). SST was co-administered with FSH during treatment to induce ovulation in patients who are infertile as a result of a polycystic ovary syndrome. The capacity of SST to reduce the LH serum levels, and to reduce the serum levels of growth hormone and of IGF-I has been confirmed. This endocrine effect is not however accompanied by a significant impact on the follicle growth induced by the administration of FSH (Lidor, A. et al., Gynecol. Endocrinol . (1998), 12(2), 97-101; van der Meer, M. et al., Hum. Reprod . (1998), 13(6), 1465-1469). In summary, until now a marginal effect of SST on the pituitary secretion of LH and on the production of progesterone by the granulosa cells of preovulatory follicles has been reported.
BRIEF SUMMARY OF THE INVENTION
The applicants have now discovered, in a surprising manner, that SST and its analogues have the capacity to inhibit the transition of the follicles from a quiescent stage to a growth stage and that this faculty allows new therapeutic uses for these compounds.
The benefit of this discovery resides primarily in the possibility of using SST or an SST agonist analogue for preparing a medicament intended to diminish or inhibit the start of growth of follicles in the quiescent stage. Secondly, it is also possible to use an antagonist analogue of this peptide in order to prepare a medicament intended to accelerate the start of growth of the quiescent follicles.
There exists a set of clinical situations for which it would be desirable from a medical perspective for the patient to slow the use of the ovarian reserve in order to delay the depletion of the latter and therefore to preserve the ovarian function and fertility. These situations are typically, and in a non-exclusive manner, patients at risk of early menopause. It is well known that certain patients have premature depletion of their follicular capital. Menopause then occurs before 40 years of age and sometimes even before thirty years of age. It is often possible to predict this early menopause on the basis of family antecedents, or genetic anomalies such as Turner syndrome (complete or partial). In this situation, the administration of SST or of one of its agonist analogues is a preventive measure and aims to slow the start of growth of the quiescent follicles.
The same applies for patients having difficulty conceiving and for whom the chronological age or biological age of their ovaries corresponds to the period of acceleration of activation of the quiescent follicles: slowing this depletion of follicular capital should make it possible to increase the efficiency of the treatments and the chances of becoming pregnant.
Another clinical situation which may benefit from a treatment by SST or by one of its agonist analogues is the graft (preferably an autograft) of an ovary or of ovary fragments. In this context, the resumption of ovarian function is often temporary and is accompanied by a premature depletion of the number of primordial follicles (Baird, D. T. et al., Endocrinology (1999), 140, 462-471). It has in fact been demonstrated that, during the transplantation, the granulosa cells of the growing follicles are more inclined to start apoptosis than those of the primordial follicles (Liu, J. et al., Hum. Reprod . (2002), 17, 605-611). Moreover, the removal of ovarian tissue and its fragmentation causes the primordial follicles to move rapidly and en masse toward a stage of late primary follicles (cf. Wandji S-A, et al., Hum. Reprod . (1997), 12, 1993-2001; cf. also the control group of the example of the present application).
In the context of this application, somatostatin agonist analogues (or somatostatin) can be added to the various media for sampling, washing, preserving, freezing and thawing of ovarian tissue for the purpose of grafts. The invention therefore also relates to the corresponding media comprising a somatostatin agonist analogue. It also relates to the use of a somatostatin agonist analogue as a protective adjuvant for the media for sampling, washing, preserving, freezing and thawing of ovarian tissue.
Moreover, the in vitro use of somatostatin or of somatostatin agonist analogues can also be useful in the field of toxicological analyses and in the in vitro production of mature oocytes from fresh or frozen ovarian tissue. As regards the former, during tests of the effect of new chemical entities on ovarian follicles and their growth, the addition to the follicle sample of a somatostatin agonist analogue makes it possible to slow the follicle growth and thus to more easily observe any effect of acceleration of said growth caused by said new chemical entities. The addition of somatostatin antagonist makes it possible to move the follicular reserve towards the growth phases and to better evaluate the impact of new chemical entities on this phenomenon. As regards the in vivo production of mature oocytes, the addition to the follicle sample of a somatostatin agonist analogue allows the follicle growth to be slowed during the initial phase of culture. The addition of somatostatin antagonist in a second phase subsequently allows the follicular reserve to be moved toward the growth phases allowing a greater number of mature follicles and therefore of fertilizable oocytes to be obtained.
The use of somatostatin agonist analogues (or of somatostatin) in patients with polycystic ovaries is also beneficial. In fact, numerous observations suggest that polycystic ovaries have an abnormally high follicle population (cf. Hughesdon, Obstet. Gynecol. Surv . (1982), 37(2), 59-77). The excessive production of androgens by these follicles in an excessive quantity could be the origin of the metabolic and endocrine disorders observed in these patients. Moreover, a significant reduction of this follicle population by ovarian resection, cauterization or ultraviolet radiation, constitutes one of the most effective therapies because it allows the patients to ovulate at approximately 80% and to become pregnant at a cumulative rate of 75% over 18 months. Thus, the regular administration of a somatostatin agonist analogue (or of somatostatin) should bring about a reduction in the number of growing follicles and therefore of the supernumerary antral follicles producing androgens resulting in the resumption of fertile ovulatory cycles of a temporary or permanent nature.
Moreover, the use of somatostatin agonist analogues (or of somatostatin) in patients who are about to have, are currently having or have had chemotherapy or irradiation (for therapeutic or other purposes) reduces the risk of early menopause by preventing the accelerated activation of the follicular reserve which would make it more sensitive to the chemotherapy agents or to the ionizing radiation.
Other applications can also be envisaged, in particular in the veterinary field. The invention could be used to save species, the use of somatostatin agonist analogues (or of somatostatin) allowing the ovarian reserve of females to be preserved. Similarly, somatostatin antagonist analogues can be used in the context of in vitro or in vivo fertilizations in animals of high commercial value. Such animals with high commercial value can in particular be horses, bovines, ovines or goats; they can also be animals of transgenic origin.
In addition to the pathologies mentioned above, a systematic slowing of the depletion of the ovarian reserve could be envisaged in women not suffering from any ovarian dysfunction. In industrialized countries, the continuous extension of life expectancy (currently approximately 83 years in France) is accompanied by an extension of the post-menopausal period and of the problems associated with it: cardiopathies, osteoporosis, cutaneous aging, etc. Doubts are raised as to the long-term safety of hormonal substitute treatments for menopause. An attractive alternative would consequently be delaying the age at which menopause occurs. This would thus reduce the post-menopausal period and the associated risks. This delay would not however mean that fertility could be maintained up to 60 plus years of age. Numerous works suggest that ovarian function is maintained as long as a minimum number of follicles of the reserve is maintained, and that despite a “normal” ovarian function (steroid levels barely affected), the chances of pregnancy are extremely low.
In situations where it is sought to slow the use of the ovarian reserve, according to the invention natural somatostatin (SST14 or SST28), or, preferably, a somatostatin agonist analogue (natural or synthetic), will be used. The somatostatin agonist analogue can be a cyclic or non-cyclic polypeptide, a fusion or recombination protein, a non-peptidic chemical entity (i.e. peptidomimetic) or also an “SS-like” peptide such as corticostatin. The agonist analogues to be used must have high affinity for the SST receptor and induce a functional activity thereof such as the inhibition of the secretion of growth hormone by pituitary somatotrope cells and/or the inhibition of the in vitro proliferation of pituitary adenoma cells. Preferably, the somatostatin agonist analogue has high affinity for all or at least 2 or 3 of the sub-types of SST receptors or a greater affinity for at least one of the sub-types 1, 2, 3, 4 and 5 (for example for sub-type 2).
Agonist analogues of somatostatin have been described in particular in the patent application PCT WO 01/00676 or WO 98/08528 or also in the patents U.S. Pat. Nos. 6,387,932, 6,268,342, 6,057,338, 6,025,372.
DETAILED DESCRIPTION OF THE INVENTION
According to a particular variant of the invention, the somatostatin agonist analogues are compounds of general formula (I)
in which:
X 1 is a radical of formula (a) or (b)
R 1 independently representing each time it occurs an optionally substituted phenyl radical in which the optional substituents are independently chosen from a halogen atom and the methyl, ethyl, methoxy and ethoxy radicals,
R 2 representing —Z 1 —CH 2 —R 1 , —CH 2 —CO—O—CH 2 —R 1 ,
Z 1 being O or S;
X 2 is an α-amino acid having an aromatic residue on the side chain C α , or an amino acid unit chosen from Dab, Dpr, Dpm, His, (Bzl)HyPro, thienyl-Ala, cyclohexyl-Ala and t-butyl-Ala;
A is a divalent residue chosen from Pro,
R 3 is NR 8 R 9 —C 2-6 alkylene, guanidino-C 2-6 alkylene or C 2-6 alkylene-COOH, R 3a is H, C 1-4 alkyl or has, independently, one of the meanings given for R 3 , R 3b is H or C 1-4 alkyl, R a is OH or NR 5 R 6 , R b is —(CH 2 ) 1-3 — or —CH(CH 3 )—, R 4 is H or CH 3 , R 4a is benzyl optionally substituted on the aromatic ring, each of R 5 and R 6 is independently H, C 1-4 alkyl, ω-amino-C 1-4 alkylene, ω-hydroxy-C 1-4 alkylene or acyl, R 7 is a direct bond or C 1-6 alkylene, each of R 8 and R 9 is independently H, C 1-4 alkyl, ω-hydroxy-C 2-4 alkylene, acyl or CH 2 OH—(CHOH) c —CH 2 — in which c is 0, 1, 2, 3 or 4, or R 8 and R 9 form together with the nitrogen atom to which they are attached a heterocyclic group which can include an additional heteroatom, and R 11 is benzyl optionally substituted on the aromatic ring, —(CH 2 ) 1-3 —OH, CH 3 —CH(OH)—or —(CH 2 ) 1-5 —NR 5 R 6 , and ZZ a is a natural or unnatural α-amino acid unit;
it being understood that X 1 , X 2 and Lys each have the configuration L;
or are pharmaceutically acceptable salts or protected forms of compounds of general formula (I).
ZZ a can have a configuration D or L. ZZ a can be for example Thr, Ser, Ala, Val, lle, Leu, Nle, His, Arg, Lys, Nal, Pal, Tyr, Trp, Phe substituted on the aromatic ring or N α -benzyl-Gly. When ZZ a is Phe, its benzene ring can be substituted for example by NH 2 , NO 2 , CH 3 , OCH 3 or a halogen atom, preferably in position para. When ZZ a is Phe, its benzene ring is preferably not substituted.
When A comprises a Pro amino acid residue, any substituent present on the proline ring, for example R 3 —NH—CO—O— etc., is preferably in position 4. Such substituted proline residues can be in the cis form, for example
such as in the trans form. Each geometric isomer individually as well as mixtures of these isomers are included in the uses according to the invention.
When A is
in which NR 8 R 9 forms a heterocyclic group, said group can be aromatic or saturated and can include a nitrogen atom or a nitrogen atom and a second hetero atom chosen from nitrogen and oxygen. Preferably, the heterocyclic group is for example pyridyl or morpholino. The C 2-6 alkylene radical in this residue is preferably —CH 2 —CH 2 —.
An acyl group such as R 5 , R 6 , R 8 and R 9 in A can for example be an R 12 CO— group in which R 12 is H, C 1-4 alkyl, C 2-4 alkenyl, C 3-6 cycloalkyl or benzyl, and methyl or ethyl.
When R 4a or R 11 in A is benzyl substituted on the aromatic ring, the benzene ring can be substituted as indicated above for ZZ a .
According to a preferred variant of the invention, the somatostatin agonist analogues are compounds of general formula (II)
in which R is NR 10 R 11 —C 2-6 alkylene or guanidine-C 2-6 alkylene, and each of R 10 and R 11 is independently H or C 1-4 alkyl
or are pharmaceutically acceptable salts or protected forms of compounds of general formula (II).
Preferably, R is NR 10 R 11 —C 2-6 alkylene. The preferred compounds of general formula (II) are those such that R is 2-aminoethyl (and in particular the peptide SOM 230 of the formula cyclo[{4—(NH 2 —C 2 H 4 —NH—CO—O—)Pro}-Phg-DTrp-Lys-Tyr(4-Bzl)-Phe] the structure of which is reproduced below).
By “protected form” of a compound of general formula (I) or (II), is meant in the present application a somatostatin analogue in which at least one of the amino groups is protected and the deprotection of which (which preferably is itself carried out in physiological medium) leads to a compound of general formula (I) or (II). Suitable protective groups for amino groups are for example those described in Protective Groups in Organic Synthesis , T. W. Greene, J. Wiley & Sons NY (1981), 219-287. An example of such a protective group for an amino group is the acetyl group.
Among the somatostatin agonist analogues which can be used according to the invention, lanreotide, octreotide, vapreotide, SOM 230 (see structure below), MK-678 (peptide of structure cyclo(N-Me-Ala-Tyr-D-Trp-Lys-Val-Phe)), BIM-23190 (peptide of structure N-hydroxyethylpiperazinyl-acetyl-D-Phe-cyclo[Cys-Tyr-D-Trp-Lys-Abu-Cys]-Thr-NH 2 ), BIM-23197 (peptide of structure Hepes-D-Phe-cyclo[Cys-Tyr-D-Trp-Lys-Abu-Cys]-Thr-NH 2 in which Abu represents aminobutyric acid), BIM-23268 (peptide of structure cyclo[Cys-Phe-Phe-D-Trp-Lys-Thr-Phe-Cys]-NH 2 ), PTR-3173 (see structure below), TT-232 (of structure D-Phe-cyclo[Cys-D-Trp-Lys-Cys]-Thr-NH 2 ), and their pharmaceutically acceptable salts can more particularly be mentioned; the synthetic peptide of formula c[Tic-Tyr-DTrp-Lys-Abu-Phe] and its pharmaceutically acceptable salts can also be mentioned; finally the KE 108 peptide of formula Tyr 0 -(cyclo-D-Dab-Arg-Phe-Phe-D-Trp-Lys-Thr-Phe) described in particular in Reubi et al., Eur. J. Pharmacol . (2002), 456, 45-49, can be mentioned. The use of lanreotide, octreotide or one of their pharmaceutically acceptable salts, and more particularly lanreotide or one of its pharmaceutically acceptable salts is quite particularly preferred.
In a similar way to the compounds of general formula (I) or (II), the above-mentioned peptides can also be presented in a protected form. The definition of the protected form given above for the compounds of general formulae (I) or (II) is applicable mutatis mutandis.
According to a preferred variant of the invention, the patients for whom the medicament based on somatostatin or a somatostatin agonist analogue mentioned above is intended are women having an early menopause risk factor, and in particular women with a family history of early menopause. According to a particular variant of the invention, the patients for whom the medicament based on somatostatin or somatostatin agonist analogue mentioned above is intended are women who have an X chromosome microdeletion or a partial Turner syndrome.
The second benefit of the discovery mentioned above resides in the possibility of preparing a medicament based on a somatostatin antagonist analogue in order to accelerate the start of growth of the quiescent follicles. In fact, one couple in six of those who wish to achieve a pregnancy has difficulty conceiving. Although there are many causes, two types of treatment have emerged and are commonly used in human medicine for the treatment of sterility. These treatments, also called “Medically Assisted Procreation” (MAP), consist firstly of inducing the simultaneous growth of several preovulatory follicles. This makes it possible to obtain several mature oocytes, and therefore several embryos, and thus to increase the chances of conception. This is achieved by the administration of one or more medicaments stimulating the pituitary secretion of gonadotropins (FSH and LH), such as an anti-estrogen (for example clomiphene citrate or tamoxifen) or an aromatase inhibitor (for example letrozole, anastrazole or exemestane). The simultaneous growth of several preovulatory follicles can also be induced by the administration of a preparation of human FSH (extractive or recombinant) combined or not combined with LH. When the follicles have reached a preovulatory size, depending on the cause of sterility, two treatment options exist. The first is to carry out an intrauterine insemination (IUI) and the second is to remove the oocytes from the ovary by aspiration of the follicles (between 5 and 15 oocytes) and to carry out an insemination in the laboratory (in vitro), either by simple coincubation of the oocytes with the partner's sperm (IVF) or by microinjection of sperm directly into the oocyte (ICSI). It is essential to obtain several mature oocytes in order to optimize the success rates (pregnancy rates) obtained with these treatments; however in certain women, despite appropriate ovarian stimulation, the number of oocytes obtained is low or even equal to one. This difficulty in responding to the stimulating treatment is a result of the limited number of growing follicles present in the ovaries of these patients. It is therefore of considerable therapeutic benefit to be able to activate follicles of the ovarian reserve and make them enter the growth phase.
Another subject of the present invention is the use of a somatostatin antagonist analogue for preparing a medicament intended to accelerate the start of growth of the quiescent follicles in non-menopausal women.
The administration of such a medicament over a period of 1 to 12 months in women leads to an increase in the number of follicles in the growth phase and which are therefore able to be stimulated with the standard treatments in order toreach the stage of preovulatory follicles.
Another application of the ability of the somatostatin antagonist analogues to induce early follicle growth is their in vitro use in follicle cultures for the production of mature oocytes intended for fertilization. The somatostatin antagonist analogue is added to the culture media used to support in vitro follicle development. The invention therefore also relates to the corresponding media comprising a somatostatin antagonist analogue. Moreover, the ability of the somatostatin antagonist analogues to induce early follicle growth can also be used in the field of toxicological analyses. In particular, during tests of the effect of new chemical entities on follicle growth, the addition to the follicle sample of a somatostatin antagonist analogue makes it possible to accelerate follicle growth and thus to more easily observe any effect of slowing of said growth caused by said novel chemical entities.
The somatostatin antagonist analogue can be a cyclic or non cyclic polypeptide, a fusion or recombination protein, a non-peptide chemical entity (i.e. a peptidomimetic) or also a “SS-like” peptide such as corticostatin. The antagonist analogues to be used must have a high affinity for the SST receptor and inhibit the functional activity of SST14 or SST28 such as the inhibition of the secretion of growth hormone by somatotrope cells of the pituitary and/or the inhibition of the in vitro proliferation of pituitary adenoma cells. Preferably, the somatostatin antagonist analogue has a high affinity for all or at least 2 or 3 of the sub-types of SST receptors or a greater affinity for at least one of the sub-types 1, 2, 3, 4 and 5 (for example for sub-type 2).
A somatostatin antagonist analogue which can be used for the preparation according to the invention can for example be a peptide of general formula
A 1 -cyclo{D-Cys-A 2 -D-Trp-A 3 —A 4 -Cys}-A 5 —Y 1 (III)
in which:
A 1 is an optionally substituted aromatic α-amino acid; A 2 is an optionally substituted aromatic α-amino acid; A 3 is Dab, Dap, Lys or Orn; A 4 is β-Hydroxyvaline, Ser, Hser, or Thr; A 5 is an optionally substituted aromatic D- or L-α-amino acid; and Y 1 is OH, NH 2 or NHR 1 , R 1 being (C 1-6 )alkyl;
each optionally substituted aromatic α-amino acid being optionally substituted with one or more substituents independently chosen from the group comprising a halogen atom and the groups NO 2 , OH, CN, (C 1-6 )alkyl, (C 2-6 )alkenyl, (C 2-6 )alkynyl, (C 1-6 )alkoxy, Bzl, O-Bzl and NR 9 R 10 , R 9 and R 10 each being independently H, O, or (C 1-6 )alkyl; and
each nitrogen atom with a peptide amide bond and the amino group of A 1 being optionally substituted with a methyl group, it being understood that there is at least one such methyl group in a peptide of general formula (III);
or a pharmaceutically acceptable salt of a peptide of general formula (III).
By “aromatic α-amino acid” is meant an amino acid residue of formula
in which Z 1 is a radical containing an aromatic ring and Z 2 is a hydrogen atom or a radical containing an aromatic ring. Examples of such radicals containing an aromatic ring include, but are not limited to, a benzene or pyridine ring and the following structures with or without one or more X substituents on the aromatic ring (X being, independently each time that it occurs, a halogen atom, NO 2 , CH 3 , OCH 3 , CF 3 or OH):
Other examples of an “aromatic α-amino acid” according to the invention are substituted His, such as MeHis, His (τ-Me) or His (π-Me).
Other somatostatin antagonist analogues have been described in particular in the patent applications PCT WO 98/08528, WO 98/08529, WO 98/24807, WO 98/44921, WO 98/44922, WO 98/45285 and WO 99/22735, or also in the patents U.S. Pat. Nos. 6,387,932, 6,262,229, 6,063,796, 6,057,338, 6,025,372, 5,925,618, 5,846,934 and 4,508,711.
Among the somatostatin antagonist analogues which can be used according to the invention and their pharmaceutically acceptable salts, there may more particularly be mentioned:
the following peptides of general formula (III):
Cpa-cyclo[D-Cys-Pal-D-Trp-N-Me-Lys-Thr-Cys]-D-Trp-NH 2 ; Cpa-cyclo[D-Cys-Tyr-D-Trp-N-Me-Lys-Thr-Cys]-Nal-NH 2 ; Cpa-cyclo[D-Cys-Pal-D-Trp-N-Me-Lys-Thr-Cys]-Nal-NH 2 ;
the peptide known by the code name AC-178,335 (of structure acetyl-D-His-D-Phe-D-Ile-D-Arg-D-Trp-D-Phe-NH 2 ); the octapeptide known by the code name ODN-8 (cf. FIG. 1 of Proc. Natl. Acad. Sci . USA (2000), 97(25), 13973-13978);
the peptide known by the code name SB-710411 (of structure Cpa-cyclo[D-Cys-Pal-D-Trp-Lys-Val-Cys]-Cpa-amide);
the peptide known by the code name BIM-23056 (of the structure represented below);
the compound known by the code name BN-81674 (of the structure represented below);
the compound known by the code name SRA-880 (of the structure represented below);
and their pharmaceutically acceptable salts.
In a similar way to the compounds of general formula (I) or (II), the above-mentioned peptides (including those corresponding to general formula (III)) can also be presented in a protected form. The definition of the protected form given above for the compounds of general formulae (I) or (II) is applicable mutatis mutandis.
By somatostatin agonist analogue is meant in the present application a compound for which the effective dose DE 50 determined in the test of the agonist effect described below is less than or equal to 1 μM for at least one of the somatostatin sub-receptors.
By somatostatin antagonist analogue is meant in the present application a compound for which the effective dose DE 50 determined in the test of the antagonist effect described below is less than or equal to 1 μM for at least one of the somatostatin sub-receptors.
By pharmaceutically acceptable salt is meant in particular in the present application addition salts with inorganic acids such as hydrochloride, hydrobromide, hydroiodide, sulphate, phosphate, diphosphate and nitrate or with organic acids such as acetate, maleate, fumarate, tartrate, succinate, citrate, lactate, methanesulphonate, p-toluenesulphanate, pamoate and stearate. Also included in the field of the present invention, when they can be used, the salts formed from bases such as sodium or potassium hydroxide. For other examples of pharmaceutically acceptable salts, reference can be made to “Salt selection for basic drugs”, Int. J Pharm . (1986), 33, 201-217.
According to the present invention, the pharmaceutical preparations containing somatostatin or one of its agonist or antagonist analogues applicable in this invention can be administered by parenteral route (subcutaneous, intramuscular, intraperitoneal, intravenous, or in an implant), by oral, vaginal, rectal, nasal, sublingual or transdermal route. The vaginal route is preferred because it allows effective concentrations of the active ingredient to be delivered to the ovary while minimizing systemic exposure. The somatostatin or the somatostatin analogue used is formulated with the necessary excipients known to a person skilled in the art, in order to allow an effective and reproducible administration for each administration route.
The dose of a product according to the present invention, intended for the treatment of the above-mentioned diseases or problems, varies according to the method of administration, the age and body weight of the subject to be treated as well as the condition of the subject, and the final decision is made by the attending doctor or vet. Such a quantity determined by the attending doctor or vet is called “therapeutically effective quantity” here.
The following typical situations for a use according to the invention could however be envisaged:
A patient of approximately 20 to 25 years of age (for example) has a partial Turner syndrome through X chromosome microdeletion. Her ovarian function is apparently normal with regular ovulatory cycles. Her FSH serum level is slightly higher during the luteal-follicular transition period (for example FSH=approximately 9.2 IU/litre). The ovarian ultrasound carried out by trans-vaginal route shows ovaries of normal volume with a slightly reduced number of antral follicles. Considering the high risk that she will have early menopause, the patient is treated with lanreotide acetate at a dose of 120 mg/months (Somatuline® Autogel® 120 mg, Beaufour Ipsen Pharma, France). The treatment is discontinued after several years when the patient wishes to conceive. A patient of approximately 35 to 40 years of age has had primary sterility for several years. Assessment of the couple produced a diagnosis of sterility of tubal origin, very probably resulting from a history of peritonitis. The menstrual cycles are ovulatory and the FSH serum level is slightly higher during the luteal-follicular transition period (for example FSH=approximately 11.4 IU/L). The ovarian ultrasound carried out by trans-vaginal route shows ovaries with a slightly reduced volume with a reduced number of antral follicles (approximately 3 per ovary). A diagnosis of reduction of the ovarian reserve is made. An in vitro fertilization treatment is recommended and the patient undergoes ovarian stimulation treatment with daily injection of 225 units of recombinant FSH. On the 6 th day of stimulation, an ovarian ultrasound shows a single growing follicle of 14 mm in the right ovary. The dose of FSH is doubled and the patient is seen again 2 days later. A single 18-mm follicle is observed, which confirms a reduction in the ovarian reserve. The treatment is discontinued. After return of a spontaneous cycle, a treatment by daily administration of a somatostatin antagonist analogue is initiated. During this treatment, the number of antral follicles present in each ovary is assessed by ultrasound at the start of each menstrual cycle. After 4 months of treatment, the number of antral follicles is on average approximately 6 per ovary and the serum FSH has been reduced. A stimulation by recombinant FSH is initiated, multiple follicular development is obtained, and a standard in vitro fertilization procedure is carried out. A patient with polycystic ovary syndrome has very irregular periods, absence of ovulation, excessive weight and cutaneous signs of androgen excess such as acne and hirsutism. When the pelvis is examined by ultrasound, the endometrium is hyperplastic, the ovaries have increased volume, an increased stroma, and more than 10 antral follicles per ovarian section. No follicle has a diameter greater than 10 mm. The patient is treated with lanreotide acetate at a dose of 120 mg/month (Somatuline® Autogel® 120 mg, Beaufour Ipsen Pharma, France). After 3 months of treatment, the patient has spontaneous periods. In the 4 th month of treatment, the ultrasound of the ovaries indicates a reduction in ovarian volume and in the number of antral follicles. One 16 mm follicle is observed. During the 5 th and 6th months of treatment, the patient has regular periods and her temperature curve is biphasic, suggesting an ovulation. In the 8 th month of treatment, the patient does not have a period and a pregnancy test is positive. The treatment with lanreotide acetate is discontinued.
Particular Abbreviations and Definitions Used in the Present Application:
The abbreviations of the common amino acids are in accordance with the IUPAC-IUB recommendations. Moreover, the definitions for certain abbreviations used in the present application are as follows:
Abu=α-aminobutyric acid; Aib=α-aminoisobutyric acid; β-Ala =β-alanine; Amp=4-aminophenylalanine; Ava=5-aminovaleric acid; Bzl=benzyl; Cha=cyclohexylalanine; Cpa=3-(4-chlorophenyl)alanine; Dab=2,4-diaminobutyric acid; Dap=2,3-diaminopropionic acid; Dip=3,3′-diphenylalanine; GABA=γ-aminobutyric acid; HSer=homoserine; 1-Nal=3-(1-naphthyl)alanine; 2-Nal=3-(2-naphthyl)alanine; Nle=norleucine; Nva=norvaline; 2-Pal=3-(2-pyridyl)alanine; 3-Pal=3-(3-pyridyl)alanine; 4-Pal=3-(4-pyridyl)alanine; Phg=—HN—CH(C 6 H 5 )—CO— Tfm=trifluoromethyl; TfmA=4-trifluoromethylphenyl-alanine; Tic=1,2,3,4-tetrahydroisoquinoline-3 -carboxylic acid.
Moreover, NMeLys represents the N-methyl-lysine, in which the nitrogen of the peptide bond is methylated (and not the nitrogen of the side chain of the lysine).
Finally, Tyr(I) represents an iodized tyrosine residue (for example 3-1-Tyr, 5-I-Tyr, 3,5-I-Tyr) in which the iodine atom can be a radioactive isotope, for example I 125 , I 127 or I 131 .
Moreover, the term “approximately” refers to an interval around the value considered. As used in the present application, “approximately X” means an interval of X less 10% of X to X plus 10% of X, and preferably an interval of X less 5% of X to X plus 5% of X.
Preparation of the Peptides of General Formula (I):
The peptides of general formulae (I) and (II) mentioned above and their synthesis are described for instance in the patent applications PCT WO 97/01579 and WO 02/10192.
The peptides of general formula (III) mentioned above and their synthesis are described in the patent application PCT WO 02/072602.
Unless they are otherwise defined, all the technical and scientific terms used here have the same meaning as that usually understood by an ordinary specialist in the field to which this invention belongs. Similarly, all the publications, patent applications, all the patents and all other references mentioned here are incorporated by way of reference.
The following examples are given in order to illustrate the above procedures and must in no event be considered to be a limit to the scope of the invention.
EXAMPLES
Example 1
Ovaries of adult ewes are collected immediately after slaughter. The ovaries are placed in an organ transport medium without serum (X-vivo, Bio Whittaker, Walkersville, Md., USA) at 10° C. and transported to the laboratory. Approximately 1 h after removal, the cortex is isolated from the medulla then fractionated into slices of 2 mm thickness (1 cm 2 , average weight of 212 mg) after rinsing in new X-vivo. The cortex fragments are cultured in an oven under 5% oxygen for 10 days in well plates in the presence of DMEM. The medium is changed every 2 days.
In the control fragments (incubated in the absence of SST) the primordial follicles gradually progress to the state of follicles at the start of growth (see FIGS. 1 and 2 ). The addition of SST14 at concentrations varying between 10 −9 M and 10 −6 M very significantly inhibits the start of growth of the primordial follicles as is shown by the maintenance over time of the number of primordial follicles (cf. FIG. 1 ) and the absence of increase in the number of primary follicles (cf. FIG. 2 ).
Example 2
The procedure used is the same as for Example 1, except that the somatostatin is replaced with one of its agonist analogues, namely the synthetic peptide of formula c[Tic-Tyr-DTrp-Lys-Abu-Phe] (hereafter AG 1 peptide).
In the control fragments (incubated in the absence of AG 1 peptide) the primordial follicles gradually progress to the state of follicles at the start of growth (cf. FIG. 3 ). The addition of AG 1 peptide at a concentration of 10 −9 M very significantly inhibits the start of growth of the primordial follicles as is shown by the maintenance over time of the number of primordial follicles and the absence of increase in the number of primary follicles (cf. FIG. 4 ).
Example 3
The procedure used is the same as for Example 1, except that the somatostatin is replaced by one of its antagonist analogues, namely the synthetic peptide of formula Cpa-c(DCys-3-Pal-DTrp-NMeLys-Thr-Cys)-2-Nal-NH 2 (hereafter ANT 1 peptide).
In the control fragments (incubated in the absence of ANT 1 peptide) the primordial follicles gradually progress to the state of follicles at the start of growth (cf. FIG. 3 ). It is observed that the addition of ANT 1 peptide at a concentration of 10 −6 M accentuates the start of growth of the primordial follicles (cf. FIG. 5 ).
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 represents the proportions of dormant follicles during a period of 10 days of culture of an ovarian cortex of a ewe in the presence or absence (control) of somatostatin (SST14). These proportions are measured for each sample tested on the day of the start of the experiment (D 0 ), on the 4 th day (D 4 ), on the 7 th day (D 7 ) and on the 10 th day (D 10 ).
FIG. 2 represents the proportions of primary follicles during a period of 10 days of culture of an ovarian cortex of a ewe in the presence or absence (control) of somatostatin (SST14). These proportions are measured for each sample tested on the day of the start of the experiment (D 0 ), on the 4 th day (D 4 ), on the 7 th day (D 7 ) and on the 10 th day (D 10 ).
FIG. 3 represents the proportions of primordial, intermediate, primary and secondary follicles during a period of 10 days of culture of an ovarian cortex of a ewe in the absence of agonist or somatostatin antagonist analogue. These proportions are measured for each sample tested on the day of the start of the experiment (D 0 ), on the 4 th day (D 4 ), on the 7 th day (D 7 ) and on the 10 th day (D 10 ).
FIG. 4 represents the proportions of primordial, intermediate, primary and secondary follicles during a period of 10 days of culture of an ovarian cortex of a ewe in the presence or absence of a somatostatin agonist analogue, the synthetic peptide of formula c[Tic-Tyr-DTrp-Lys-Abu-Phe] (AG 1 peptide). These proportions are measured for each sample tested on the day of the start of the experiment (D 0 ), on the 4 th day (D 4 ), on the 7 th day (D 7 ) and on the 10 th day (D 10 ).
FIG. 5 represents the proportions of primordial, intermediate, primary and secondary follicles during a period of 10 days of culture of an ovarian cortex of a ewe in the presence or absence of a somatostatin antagonist analogue, the synthetic peptide of formula Cpa-c(DCys-3-Pal-DTrp-NMeLys-Thr-Cys)-2-Nal-NH 2 (ANT 1 peptide). These proportions are measured for each sample tested on the day of the start of the experiment (D 0 ), on the 4 th day (D 4 ), on the 7 th day (D 7 ) and on the 10 th day (D 10 ).
TESTS FOR DETERMINATION OF THE AGONIST OR AMTAGONIST EFFECT OF A SOMATOSTATIN ANALOGUE
Inhibition of the Intracellular Production of cAMP
CHO-K1 cells expressing the sub-types of human somatostatin (SRIF-14) receptors are cultured in 24-well plates in an RPMI 1640 medium containing 10% foetal calf serum. The medium is changed the day before the experiment.
The cells at a rate of 10 5 cells/well are washed twice with 0.5 ml of new RPMI medium comprising 0.2% BSA completed with 0.5 mM of 3-isobutyl-1-methylxanthine (IBMX) and incubated for approximately 5 minutes at approximately 37° C. The production of cyclic AMP is stimulated by the addition of 1 mM of forskolin (FSK; supplier: Sigma Chemical Co., St. Louis, Mo., USA) for 15-30 minutes at approximately 37° C.
Determination of the Agonist Effect of a Somatostatin Analogue
The agonist effect of a somatostatin analogue is measured by the simultaneous addition of FSK (1 μM) and the analogue to be tested (10 −10 M to 10 −5 M).
The reaction medium is eliminated and 200 ml of HCI 0.1 N are added. The quantity of cAMP is measured by a radioimmunoassay (Kit FlashPlate SMP001A, New England Nuclear, Boston, USA).
Determination of the Antagonist Effect of a Somatostatin Analogue
The antagonist effect of a somatostatin analogue is measured by the simultaneous addition of FSK (1 μM), SRIF-14 (1 to 10 nM) (supplier: Bachem, Torrence, Calif., USA) and the analogue to be tested (10 −10 M to 10 −5 M).
The reaction medium is eliminated and 200 ml of HCI 0.1 N are added. The quantity of cAMP is measured by a radioimmunoassay (Kit FlashPlate SMP001A, New England Nuclear, Boston, USA).
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The invention primarily relates to the use of somatostatin or one of the agonistic analogs thereof for producing a medicament serving to regulate the ovarian follicular reserve and, in particular, to reduce the depletion of the ovarian follicular reserve over time in non-menopausal women or to the use of an antagonistic analog of somatostatin for producing a medicament serving to accelerate the start of growing of quiescent follicles in non-menopausal women. The invention also relates to in vitro applications of somatostatin and of agonistic and antagonistic analogs thereof.
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BACKGROUND OF THE INVENTION
This invention relates to tufting machines and more particularly to a yarn jerker system therefore for controllably applying different degrees of pull-back on the yarns of selective needles.
It is known to provide a yarn jerker system in tufting machines comprising a jerker member moveable in sychronism with the needle bar and cooperating with a fixed jerker member to tension the yarn and set the stitch in the backing when the needles are at the top of their stroke. The fixed yarn jerker member may be adjustable to vary the yarn path length between the yarn feed assembly and the needles to thereby vary the pull-back in accordance with tufting conditions and the yarn in use. For example, the greater the elasticity of the yarn, the greater the pull required for the same effect. One such adjustable system is illustrated in Parsons, U.S. Pat. No. 3,738,293.
It is sometimes desirable to thread the machine so as to tuft simultaneously with more than one type of yarn, i.e., yarns of different elasticity. For example, carpeting comprising a bulk continuous filament nylon and an acrylic or any spun yarn has aesthetic properties which may be desirable. However, since the tensioning and feeding of yarns of different elasticity are dissimilar, undesirable variations in loop levels have been produced in the product. The known yarn jerker systems have not been successful in compensating for these differences in the yarns. Moreover, the known yarn jerker systems are not by themselves capable of producing textured effects on tufting while the machine is threaded with the same yarn.
SUMMARY OF THE INVENTION
Accordingly, it is the primary object of the present invention to provide a yarn jerker system for enabling a tufting machine to produce level effects when tufting simultaneously with yarns of different elasticity.
This objective is accomplished by splitting one of the fixed or moveable jerker members so as to provide more than one such jerker member with each said member independently adjustable relative to the tufting machine frame. In the preferred form of the invention the fixed jerker is split and comprises a jerker bar adjustably positionable relative to the tufting machine frame carrying a first jerker member, and a slide member carrying a second jerker member adjustably mounted on the bar. This effects a leveling condition of the loops in the backing by compensating for the greater elasticity of one yarn relative to the other. The yarn with the greater elasticity may be given a greater pull so as to give it the same tuft height. The construction is such that patterning or texturing effects can also be obtained when tufting with a single type of yarn by back-pulling the yarn from selective needles more than from other needles by threading the selected yarns through the jerker member giving the longer yarn path length. By properly choosing the threading sequence through alternate jerkers interesting texturing effects such as stripes, corduroys and checkerboards may be possible.
It is therefore another object of the present invention to provide a yarn jerker system for a tufting machine whereby differing amounts of jerk or pull-back can be applied to the yarns selectively.
A further object of this invention is to provide a yarn jerker system for a tufting machine that can effect selective texturing by control of the pull applied to the yarn threaded through different needles.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of this invention will best be understood upon reading the following detailed description of the invention with the accompanying drawings, in which:
FIG. 1 is an end elevational view of a portion of a tufting machine having a yarn jerker system constructed in accordance with the present invention; and
FIG. 2 is a fragmentary front elevational view of the mechanism illustrated in FIG. 1 as viewed from the left side therein.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, in which like reference numerals are used for corresponding parts in the two views, there is disclosed a yarn jerker system for a tufting machine generally designated at 10 including a head 12. Mounted conventionally in the head for vertical reciprocation is a push rod 14 to the lower end of which is secured a foot 16 supporting a needle bar 18. Secured in the needle bar is a multiplicity of needles 20 longitudinally disposed across the width of the machine in a single row or in multiple rows as illustrated. The choice of the specific needle arrangement is not part of the present invention although the needle array determines the path of the yarns. In the usual manner the needles cooperate with loopers (not shown) mounted below a bed plate 22 in a bed (also not shown) to form loops in a backing fabric passing over the plate 22. For simplicity of illustration only the upper portion of the tufting machine is shown to illustrate the invention. It is to be understood that the lower portion is conventional and well-known.
Yarn Y is fed to the needles 20 by a yarn feed assembly 24 comprising a plurality of feed rollers 26 about which the yarn is wound. The yarn is positively fed to the needles with the amount each needle cycle being determined by the rotational speed of the rollers on which the yarn strands are wound. The yarn feed assembly may of course include a pattern attachment whereby the amount of yarn fed to the individual needles may be varied by driving the feed rollers selectively at different speeds determined by a pattern control.
The yarn which is positively fed from the feed roller assembly to the needles, passes through a yarn spreader guide 28 comprising a perforated plate secured to the head 12 of the tufting machine by means of a bracket 30. The spreader guide spreads or separates the individual yarns from adjacent yarns fed from the rollers 26 and guides them to the fixed yarn jerker designated generally as 32 which will be hereinafter described in detail. From the fixed jerker 32 the yarn is threaded through a moveable jerker member 34 which comprises a plate having a multiplicity of apertures 36 for receiving the individual yarn ends. The moveable jerker may be mounted on the push rod foot 16 by means of bracket 38 so as to reciprocate with the push rods and needle bar. The yarn from the moveable jerker 34 is thereafter threaded through an apertured yarn guide 40 secured to the front of the needle bar for guiding the yarn to the front row of needles. If a second row of needles is provided as illustrated, yarn ends from the guide 34 are also fed to the needles through the guide 42 mounted on the rear of the needle bar 18. A further yarn guide 44 mounted on the push rod foot 16 may be provided to guide the yarn from the moveable jerker 34 to the guide 42.
In accordance with the present invention the fixed jerker 32 is split to comprise a first jerker member 46 and a second jerker member 48. The first jerker member 46 comprises a plate having a plurality of apertures 50 supported on the lower end of a jerker support bar 52. The bar 52 is slidably received within a bracket 54 secured in conventional manner such as screws 56 to the head 12 of the tufting machine. The bar may be adjustably positioned within the bracket by conventional means, for example set screws 58 acting on a flat on the bar. The second jerker member 48 comprises a plate having apertures 60 secured to a slidable carriage 62 positioned on the bar 52 and adjustable relative thereto. Conventional means such as set screws 64 may secure the carriage 62 to the bar 52 at selected positions.
It should be understood that the first jerker member 46 is adjustable relative to the tufting machine frame and the second jerker member 48 is adjustable relative to the first jerker member and the tufting machine frame. Thus, the path length of the yarn through the second jerker member from the feed rollers to the needle can be varied independently of the path length of the yarn through the first jerker member from the feed rollers to the needle. The tension on each strand of yarn passing through the second jerker member can therefore be set as desired for that yarn independently of the tension on the yarn passing through the first jerker member. Moreover, the path length of the yarn through both jerker members can simultaneously be adjusted relative to the tufting machine frame. Since the yarn feed assembly positively feeds a fixed amount of yarn to the needles, and the moveable jerker 34 pulls yarn when the needles are at the top of the stroke to set the loop in the backing fabric, the loops formed by the yarn passing through the first jerker member can be pulled more than the loops formed by the yarn passing through the second jerker member. Hence, leveling conditions can be obtained in the loops when yarn of different elasticity are threaded through the jerker members, the yarn of greater elasticity being threaded through the first jerker member and the other yarn through the second jerker member. The relative positions of the first and second jerker members are of course adjusted in accordance with the specific yarn being used. Moreover, when the same types of yarn are threaded through the two jerker members one yarn is pulled back more than the others so that loops of different heights can be formed to create patterning effects.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. For example, the adjustable members may be on the moveable jerker rather than the fixed jerker. However, it is to be understood that the present disclosure relates to a preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.
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An adjustable yarn jerker system for a tufting machine including a movable jerker member secured to the needle bar and a split adjustable stationary jerker secured to the machine frame. The split adjustable jerker comprises a bar adjustably moveable relative to the machine frame carrying a first jerker member and a slide member adjustable relative to the bar and carrying a second jerker member. The first and second jerker members being independently adjustable the pull back on the respective yarns are selectively controlled.
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BACKGROUND
[0001] 1. Field of the Invention
[0002] The embodiments of the present invention relate generally to ink-jet printing mechanisms, and in particular to squeegees for wiping excess ink off inkjet printheads.
[0003] 2. Background of the Invention
[0004] Inkjet printheads eject controlled sprays of ink onto a page while printing. Each such printhead has very small nozzles through which drops of various colored ink are fired. To print a typical image, the printhead is moved back and forth across a page, while ejecting patterns of ink drops. Conventional printheads use piezo-electric and thermal printhead technology. For instance, thermal ink ejection mechanisms are shown in U.S. Pat. No. 5,278,584 issued to Brian J. Keefe et al on Jan. 11, 1994 and U.S. Pat. No. 4,683,481, issued to Samuel A. Johnson on Jul. 28, 1987.
[0005] A wiper assembly mechanism is typically mounted within the housing of the printing mechanism to clean and protect the printhead. The printhead can be moved over the assembly for maintenance, specifically for wiping off ink residues and any paper dust or other debris that have collected on the printhead.
[0006] A wiping sequence generally includes a forward and a backward wiping stroke. In the forward stroke, a wiper blade of the wiper assembly moves from its home position and across the printhead to scrape off ink residues from the printhead. After the forward stroke, the wiper blade moves back to its home position in the backward stroke and wipes the printhead a second time.
[0007] In the forward stroke, most ink residues on the printhead are wiped off, and such wets one side of the wiper blade. On the backward stroke, a dry wiping of the printhead occurs if no other fluids are used to moisten the wiper blade. Dry wiping of the printhead can damage the nozzles on the printhead and the wiper blade itself. What is needed is a squeegee and method that reduce or prevent such printhead wear and damage.
SUMMARY OF THE INVENTION
[0008] Briefly, a squeegee embodiment of the present invention includes a set of wiper blades that bend over easier to one side than the other. The wiper blades are arranged in conjunction with an inkjet printhead so that the direction that requires the higher force is the one used when the printhead is wet with excess ink. The easy-to-bend direction is used for the backstroke when the printhead is driest.
[0009] An advantage of embodiments of the present invention is a squeegee is provided for an inkjet printhead to clean off excess ink.
[0010] Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which description illustrates by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a perspective diagram of an inkjet printer embodiment of the present invention;
[0012] [0012]FIG. 2 is a diagram of a wiper assembly embodiment useful in the printer embodiment of FIG. 1;
[0013] [0013]FIGS. 3A and 3B are side view diagrams that illustrate the wiping of a printhead during forward and back strokes by using a squeegee embodiment of the present invention in the printer of FIGS. 1 and 2; and
[0014] [0014]FIGS. 4A and 4B are side view diagrams that partially illustrate the wiping of a printhead during forward and back strokes by using another wiper embodiment of the present invention useful in the printer embodiment of FIG. 1.
DETAILED DESCRIPTION
[0015] [0015]FIG. 1 illustrates an inkjet printer embodiment of the present invention, and is referred to herein by the general reference numeral 100 . The printer 100 is representative of the many kinds of devices that use inkjets and spittoon reservoirs, and that can therefore benefit from embodiments of the present invention. For example, some inkjet-based fax and copier machines are included in alternative embodiments of the present invention.
[0016] The typical inkjet printer 100 includes a chassis 102 surrounded by a housing or casing enclosure 104 . Sheets of paper are typically fed through a print zone 106 for printing as they pass by an inkjet and carriage assembly. Printer 100 includes an inkjet cartridge 108 , a thermal printhead 110 , a servicing region 112 , a sliding carriage guide rod 114 , a scanning axis 116 , and a printer controller 118 that receives print-job instructions from a host computer. The sliding carriage guide rod 114 mounted on chassis 102 allows an ink-jet carriage 120 to slide back and forth across the print zone 106 . The scanning axis 116 is defined by the guide rod 114 . Carriage-position information feedback can be provided to the printer controller 118 by an optical encoder reader mounted to the carriage 120 . Such typically reads an encoder strip that extends along the path of carriage travel.
[0017] The carriage 120 moves across the guide rod 114 to the servicing region 112 inside the casing 104 . Wipers and drain basins within the servicing region 112 are used to keep the inkjet cartridge clean and disposes of excess ink that is wiped off.
[0018] After arriving inside the print zone 106 , each sheet of paper is printed with ink squirted from the inkjet cartridge 108 . Such cartridge 108 is sometimes called a “pen” by artisans. The inkjet cartridge 108 includes a supply of ink, a printhead 110 with an orifice plate, and a plurality of nozzles. The printhead 110 illustrated in FIG. 1 represents a thermal inkjet printhead, although other types of printheads may be used, such as piezoelectric printheads.
[0019] The outer surface of the orifice plate of the printhead 110 preferably lies in a common printhead plane. In one embodiment, such printhead plane extends substantially horizontally.
[0020] Here, only some of the pen servicing functions are discussed, e.g., wiping of the printhead 110 . The wiping can be performed by a wiper assembly incorporated in a service station like that illustrated in U.S. Pat. No. 6,132,026, issued to Bret K. Taylor et al on Oct. 17, 2000. Alternatively, the wiper assembly can be mounted independently on the chassis.
[0021] [0021]FIG. 2 represents a wiper assembly 200 which can be separated from a service station and mounted independently on the printer chassis.
[0022] The wiper assembly 200 is mounted in the servicing region beneath the printhead in a position for wiping. It includes a pair of wiper blades 202 and 203 , e.g., made of ethylene-propylene-diene-monomer (EPDM). Each wiper blade 202 and 203 acts as a squeegee to wipe excess ink off a printhead. Each wiper blade extends vertically up to the printhead plane from a platform 204 .
[0023] A wiping of the printhead occurs when a rack 206 connected to the platform 204 moves along a slot defined within a base frame 208 of the wiper assembly. The rack 206 is driven back and forth along the slot by a wiper gear which meshes with the rack gear 210 . The wiper gear is turned by a motor in the printer through a gear train. Both the slot and the rack 206 lie parallel to the nozzles of the printhead 110 . Such is substantially parallel to the media advancement direction 212 , in which the media sheet is advanced through the print zone 106 (FIG. 1) during printing operations.
[0024] A pair of frames 214 and 215 are respectively located at two sides of the base 208 . They project up from and along the rack 206 . A pair of guide track slots 216 and 217 are defined by tops of frames 218 and 219 , and the bottom edges of frames 220 and 221 . On the other hand, the platform 204 has two projections 222 at two respective sides for fitting into the slots 216 , 217 . In this way, the platform 204 is restricted to slide along the slots during the wiping process.
[0025] Rack 206 has a support 224 , which extends upward and is mounted on the rack 206 at an end away from the rack gear 210 . A pivot arm 226 at an end of the platform 204 fits into a pivot slot 228 at an end of the support such that the platform 204 is mounted to the support 224 . In this way, when the rack 206 slides back and forth along the slot (not shown), the platform 204 moves accordingly as driven by the support 224 .
[0026] Each wiper blade 202 and 203 has a slit 234 on one of its side walls 230 , 232 . Each slit 234 extends substantially parallel to the printhead plane in a widthwise direction as shown in FIG. 2. Slit 234 on an elastic wiper blade causes the stiffness of the wiper blade to be different during the front and back strokes of the wiping action. The change in wiper blade stiffness puts less pressure on the printhead when the previous stroke has already dried it.
[0027] In one embodiment, the forward stroke is defined as being the first squeegee stroke across the printhead. The backward stroke returns it to the home position.
[0028] In the forward stroke represented in FIG. 3A, the wiper blade 302 exerts a force F 1 on the printhead 304 . This closes up slits 306 and increases the stiffness of the wiper blades 302 . As a result, the wiper blade 302 exerts maximum pressure and a maximum wiping force on the printhead 304 .
[0029] In the backward stroke represented in FIG. 3B, the force F 2 on the wiper blade 302 exerted by the printhead 304 widens the opening 308 of each slit 306 on the back wall 310 of the respective wiper blade 302 . In this direction, the wiper blades 302 are not as stiff, so each wiper blade 302 applies a minimum of wiping force on the printhead.
[0030] In one embodiment of the present invention, each slit 306 runs the full end-to-end width of its respective wiper blades 302 . The depth of each slit is about three-fifths of the thickness of its respective wiper blade. The spacing between each slit 306 and the platform is about four-sevenths of the height of its respective wiper blade. Such depths and spacings control the amount of the wiping force that will be applied on the printhead during the backward stroke. The geometry and placement of the slits and the material of the wiper itself can be used to adjust such backstroke wiping force.
[0031] [0031]FIGS. 4A and 4B represent another inkjet and wiper assembly embodiment of the present invention, and is referred to herein by the general reference numeral 400 . A printhead 402 moves back and forth in relation to a pair of wipers 404 and 405 mounted to a platform 406 . The wiper assembly embodiment 400 is similar to that of FIG. 2. Each wiper blade 404 and 405 acts as a squeegee to wipe excess ink off the printhead. A pair of rigid columns or buttresses 408 and 409 are fixedly mounted to the platform 406 . Each buttress 408 and 409 extends substantially parallel to its respective wiper blade but is shorter in height than the wiper blades 404 and 405 . Furthermore, each buttress 408 and 409 is placed behind and in close proximity to its respective wiper blade 404 and 405 in the forward wiping direction of the forward stroke as illustrated by FIG. 4A.
[0032] In the forward stroke of FIG. 4A, each wiper blade 404 and 405 is bent over by the printhead 402 and comes into contact with its respective buttress 408 and 409 due to the wiping direction and the position of the buttresses. The bottom part of each wiper blade 404 and 405 is then restricted from further bent-over by the buttresses 408 and 409 . In this way, the effective stiffness of the wiper blades 404 and 405 is increased during the forward stoke. As a result, the wiper blades 404 and 405 exert a maximum pressure and wiping force on the printhead 402 during its forward stroke.
[0033] In the backward stroke represented in FIG. 4B, each buttress 408 and 409 does nothing to restrict the flexing of wiper blades 404 and 405 in a direction opposite to the backward wiping direction 412 . Each wiper blade 404 and 405 flexes away from its corresponding buttress 408 and 409 . Therefore, during the backward stroke, the wiper blades have a relatively low effective stiffness as compared to the forward stroke. In this way, each wiper blade 404 and 405 is manipulated to apply a minimum of wiping force on the printhead 402 during the backward stroke.
[0034] Alternatives can be made. For example, the buttresses 408 and 409 can be made of flexible materials. Each buttress mainly functions to increase the effective stiffness of its respective wiper blades during the forward stroke by applying an additional force on the wiper blade.
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An inkjet printhead squeegee is split on one side so that its wiping force on a printhead is highest on the front stroke and much lighter on the backstroke when the surface is dry. Alternatively, the split can be arranged so that the front stroke is light enough to leave the printhead wet, and then the backstroke is much firmer to completely squeegee the printhead dry. The result is high pressure strokes on a dry printhead are avoided.
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RELATED APPLICATION
This application is a divisional of patent application Ser. No. 454,464 filed on Dec. 3, 1999, which is a divisional patent application of Ser. No. 09/464,545, filed Dec. 3, 1999, now U.S. Pat. No. 6,328,009, which is a continuation-in-part of patent application Ser. No. 09/203,015, filed Dec. 1, 1998, U.S. Pat. No. 6,209,498.
FIELD OF THE INVENTION
The present invention relates to a roller valve lifter having a roller at one end thereof that cooperates with a lobe of a camshaft in an internal combustion engine. More specifically, the invention relates to improving the lubrication of the valve lifter and preventing rotation of the lifter.
BACKGROUND OF THE INVENTION
Conventional camshaft or “cam”, internal combustion engines typically utilize valve lifters, push rods, and valve springs along with rocker arms to open and close the valves of the engine to allow air and fuel to enter and exhaust to exit the cylinders of the engine during combustion. These components are collectively referred to as the “valve train.”
In conventional cam engines as opposed to those of over-head design, a valve lifter with a pushrod rides on the lobes of the camshaft which is rotated by the crankshaft. As the lifter reciprocates up and down, the push rod seated in the lifter also reciprocates and communicates this up and down motion via a rocker arm to either an intake or exhaust valve. A high tension spring ranging from approximately 200 to 1000 ft·lbs, surrounds the stem of the valve and when the spring is compressed, the valve is pushed into the cylinder.
During the up stroke of the piston in the cylinder, the intake valve opens to allow fuel and air to enter the combustion chamber. Somewhere near the very top of the up stroke, both the intake and the exhaust valves close and the spark plug creates a spark to ignite the air-fuel mixture which is under compression by the piston. This results in a high temperature explosion which forces the piston downward, called the “power stroke,” thereby translating this movement via a connection rod to rotate the crankshaft which, in turn, translates this angular motion to the wheels of the vehicle via a set of gears. Near the bottom of the compression stroke, the exhaust valve opens to expel the burnt fuel mixture out of the cylinder. After the piston changes directions and begins the up stroke, the exhaust valve continues to remain open thereby forcing any remaining the spent gases out of the cylinder. However, during this same time, the intake valve begins to open to recharge the cylinder with fuel. It is not until the piston has started to travel upward that the exhaust valve closes. Thus, at various times during the compression cycle, both the intake and exhaust valves will be open and closed at the same time. The timing of the opening and closing of the valves is controlled by the physical design of the oval shaped lobes on the camshaft. As the valve lifter is pushed upward by the lobe of the camshaft, the valve lifter pushes the pushrod up which drives the rocker arm downward, causing the valve to open. Likewise, as the lifter and pushrod travel downward, the rocker arm raises and the valve closes due to the biasing action of the valve spring.
In high speed engines, measured as revolutions per minute (RPM), the valve train components are under extreme stress and high temperatures. To increase engine performance and decrease component wear which may eventually lead to failure, various valve lifter configurations have been designed. Solid and hydraulic valve lifters are the most common designs used in conventional cam engines. Hydraulic lifters are typically used in relatively low RPM engines, up to 6,500, whereas solid valve lifter designs are preferred in high RPM applications such as racing and high performance applications. Conventional hydraulic and solid lifters have a flat surface that is fixed or integral with the body of the lifter and is adapted to engage and ride on the lobes of the camshaft. The engagement between the fixed surface of the lifter body and the camshaft lobe creates high frictional forces causing the surfaces of the lobes to wear. Therefore, the higher the RPM of the engine, the greater the wear and the likelihood of material being removed. As material is removed from the surface of the lobe, the timing of the opening and closing of the valve also changes. This change in timing may hamper engine performance such as by allowing excess air-fuel mixture to enter the cylinder causing a rich condition. Conversely, improper timing may permit the air-fuel mixture to escape through the exhaust valve which results in a lean condition. Either of these conditions will affect cylinder pressure and decrease performance and may cause misfiring of the cylinder and engine damage. Furthermore, if this improper timing allows a valve to remain open when the piston is near the top of the compression stroke, the piston will strike the valve resulting in bent pushrods and valves, broken valve springs and lifters and will eventually lead to catastrophic engine failure.
To decrease lobe wear in high performance engines, a roller has been added to the body of the valve lifter for riding on the cam. The roller allows the use of a camshaft with lobes of steeper ramp angles to provide faster valve opening and closing for accommodating high RPM engines. The roller engagement between the roller and rotating cam lobe reduces the frictional forces generated therebetween. Not only does the presence of the roller decrease cam lobe and valve lifter wear, it also provides smoother transitions as the roller travels over the peak of the lobe thereby decreasing valve train noise. Likewise, various bearing and sleeve configurations have been utilized to decrease friction and wear of the shaft rotatably mounting the roller to the valve lifter. For high performance engines, needle bearings have replaced solid rollers, bushing and conventional ball bearings to decrease wear and more evening spread the load over the surface of the shaft. However, these bearings and bushings also rely upon oil to function properly.
Although the addition of the roller increases camshaft and valve train life, overall roller wear is a function of engine speed (RPM). High performance engines such as those used in drag racing applications produce extremely high engine speeds (6,000 to 13,000 RPM) over a short duration of time (i.e. less than 5 to 12 seconds). Conversely, stockcar racing engines produce relatively high engine speeds of typically 5,000 to 8,000 RPM and under racing conditions, maintain those speeds for long periods of time (2 to 3 hours). At these high engine speeds, it becomes difficult to provide oil to the valve lifter, roller and bearing assembly as well as adequate lubrication of the camshaft.
From the ground up, a typical engine is configured with an oil pan for holding oil and an oil pump which feeds the oil to various locations in the engine. Above the oil pan sits the engine block and the crankshaft, such that a portion of the crank rotates in the oil. In a typical “V”-style engine, that is, one having cylinders at an angle to the left and right sides of the block in a “V” pattern with the crankshaft positioned at the apex of the “V”, the camshaft is typically located directly above and in parallel with the crank. In straight cylinder configuration engines wherein all cylinders are aligned in a row, the crankshaft and cylinders are located in the same plane and camshaft is positioned to one side so not to interfere with the travel of the connecting rods.
The valve lifters, in an “V” style engine, are located in a lifter galley. The lifters are lubricated by oil in the engine block and receive direct lubrication from a transverse oil passageway in the engine block that intersect the bores in which the valve lifters are positioned and indirectly from oil that is sprayed into the lifter galley from the rotation of the crankshaft and connecting rods. Various methods have been employed to increase the lubrication of the valve lifters and camshaft.
One method used to increase the movement of oil to the valve lifters and camshaft is the addition of small holes to the crankshaft and the dynamic balance weights of the crank. These holes, or oil squirters, pickup oil from the pan and any oil on the surface of the crank and throw the oil to the camshaft and valve lifter as the crankshaft and rotates. This method is also employed in engines having steel connecting rods to lubricate the cylinder wall by placing a through-hole on the end that connects to the piston and to the lifters by adding a squirter to the “big end” or end that connects to the crankshaft. However, the machining of the squirter reduces the strength of the connecting and have been found to severely weaken aluminum connecting rods used in high performance, high RPM engines.
Another method of directing oil to the lifters and camshaft involves adding separate oil feed lines to the lifter galley. This is accomplished by drilling a feed hole into an oil passageway of the engine block to tap the oil pressurized by the oil pump and adding metal tubing to direct the oil to the desired location such as above the camshaft. However, adding components to the internals of engine is not always practical due to the limited amount of space. Furthermore, these added components may also fail and create shrapnel that will be run through the engine which can damage precision surfaces such as on the camshaft, crankshaft, pistons, etc.
To increase the movement of oil in the common transverse oil passageway and lifter bores, the valve lifter body has been modified. One modification includes adding a channel through the body of the lifter to increase the amount of flow of oil from one passageway to the next lifter bore. Another method of facilitating the flow of oil in the common passageway while increasing lubrication to the lifter is by adding an annular groove to the body of valve lifter. As the valve lifter reciprocates in the bore, the oil trapped between the space created by the annular groove and the bore is deposited on the walls of the bore.
With all of these methods, the higher the RPM, the greater the oiling of the valve lifter; however, at low engine speeds such as during idling, start-up, stop-and-go driving conditions, and gear shifting create inadequate lubrication conditions. Not only are these types of driving conditions prevalent on race day, but also seen during every day driving. Therefore, a method is needed to provide adequate lubrication to the roller and the bearing assembly thereof to reduce wear, maximize engine performance and avoid valve train component failure.
Another problem associated with the use of solid valve lifters with rollers in high RPM engines, is the rotation of the lifter as it reciprocates in the lifter bore of the engine. At high RPM the valve lifter has a tendency to rotate so that its axis of rotation becomes skewed or out of parallel alignment with that of the camshaft and lobes thereof. Also, the use of steep angled camshaft lobes require extremely high valve spring pressures. Any misalignment of the roller with the engaging surface of the camshaft lobe may lead to catastrophic failure of the roller causing significant damage to the camshaft and bent pushrods and valves and broken rocker arms and valve springs. Also, rotation of the lifter in the bore may prevent the oil pressure feed receiving area or groove of the valve lifter from intersecting and the common transverse oil passageway of the engine block that feeds oil to the valve lifters.
To prevent rotation in the bore, link bars are commonly used to tie the bodies of two lifters together, typically the exhaust and intake of one cylinder. These link bars may be permanently attached to the lifters or removable such as shown in U.S. Pat. No. 4,809,651. Although these prior link bars prevent rotation, they also add components and weight to the lifter assembly. Furthermore, the attachment point of the link bar to the body also wears due to the repetitive motion and may eventually fail. Furthermore, in high revolutions engines, these link bars on the valve lifters are constantly fighting rotation and under repetitive forces. Thus, in applications requiring high engine speeds over long durations of time, the link bar and the attachment devices may fatigue creating unnatural movement of the lifter which will damage the valve train.
Another method used to prevent rotation of the lifter is by adding a “U” shaped member in which the legs of the “U” are inserted into two adjacent lifter bores as illustrated in U.S. Pat. No. 5,022,356. The legs of this anti-rotation member are smaller than the diameter of the lifter bore and longer than the bore length. Once inserted in the lifter bore, the member is push to the front or rear of the bore and, thus, the member makes contact with the entire length of lifter bore on each end side of the member leg. The member is prevented from falling through the bores by a cross-member that connects the two legs. Also, a foot is added at the end of the member to prevent the member from exiting the lifter as the lifter travels upward. The valve lifter must also be modified to be used in conjunction with this member. The portion of the valve lifter which engages the member must be machined flat. Although this member and lifter assembly prevents rotation without adding components to the valve lifter body, the member presents other problems. The member edges are in contact with the full length of the lifter bore and the long flat of the valve lifter engages the member. Thus, as the lifter reciprocates, the large area of contact between the member and the lifter creates friction thereby requiring additional lubrication to prevent excessive wear and heat. Furthermore, the edges of the member may eventually wear into the lifter bore thereby removing material which is run through the engine. Also, the feet of the member extend through the lifter bore positioning themselves near the camshaft and the roller of the lifter. The height of the feet are, therefore, critical to prevent the lobes of the cam from making contact with them. In high performance engines, a specific cam design is used to create precise opening and closing of the valves for that particular engine configuration. Thus, if an engine is retrofitted with a different camshaft, the feet of the member may also have to be ground to allow clearance by the cam lobes. Therefore, an anti-rotation device which prevents rotation of the lifter but does not add weight and/or components to the valve lifter or those that may interfere with the cam lobes and does not create excess friction and heat is needed for these high performance engines.
SUMMARY OF THE INVENTION
In accordance with the presence invention, a valve lifter apparatus is provided including a body with a roller member at one end thereof for riding on one of the camshaft lobes. The body is provided with a predetermined flow path which direct lubrication in a well-defined manner directly to be end of the body at which the roller member is located. In this manner, lubrication is directed in a predetermined manner to the place it is needed most, i.e. the roller, rather than simply relying on the general undirected travel of the oil fed to the lifter bore.
In another aspect of the invention, a valve lifter assembly is provided including a lifter body which reciprocates in a bore in the engine block. A portion of body of the valve lifter has a flat exterior surface and the assembly includes an anti-rotation member including at least one short portion thereof that extends into the lifter bore adjacent the flat of the valve lifter body to prevent rotation thereof in the bore. As the length of the flat is much greater than the length of the member portion, the flat surface will only have a short section thereof that is in contact with the short member portion at any time during the reciprocation of the valve lifter body. This small area of engagement minimizes the amount of friction and wear caused by the up and down movement of the flat. In this regard, the small engagement area also advantageously requires less oil to keep the surfaces properly lubricated.
As mentioned, the invention contemplates a predetermined flow path for directing lubrication to the roller member, and specifically, the bearing assembly thereof. The predetermined flow path, which in the preferred and illustrated form includes internal oiling channels formed in the valve lifter body that extend between the oil receiving area on the lifter body and the roller member, avoids the need to add oil squirters or add direct feed oil lines. This is desirable because oil squirters are not practical for use in aluminum and high performance steel connecting rods due to the loss of strength and stress riser resulting from the addition of the hole. Furthermore, the amount of the oil thrown from the squirters decrease as engine speeds decrease and are thereby inefficient if not unreliable.
Alternatively, an external oiling channel can be provided on the surface of the lifter body. This external oiling channel is used to direct oil received by the oil receiving area, which is more preferably, an annular, circumferential groove about the lifter body that intersects the common oil passageway as the lifter reciprocates in the bore. As oil is received in the groove, the external oiling channel directs oil towards the housing portion of the lifter body where it may lubricate the roller and bearing assembly situated therein. Another advantage of using an annular groove and external oiling channel is that any oil thrown on the body of lifter may also be contained by the groove and channel and directed to the roller and bearing assembly.
The oil receiving area is in one form a transverse, through passageway that can be modified by adding of at least two round or oval shaped receiving areas on each side of the lifter body. The oil receiving areas are oriented perpendicular to the rolling direction of the roller, are ramped into the body and intersect the common transverse oil passageway in the engine block which feeds oil to the lifter galley. In the lifter body these oil receiving areas or inlets are connected by a passageway which travels through the body and parallel with the shaft of the roller. Also, additional inlets may be added to the front and back surfaces of the lifter body and connected to the internal passageway to feed additional oil into the passageway. Internal oiling channels have been added in the lifter body to direct the oil feed into the inlets and passageway. The oiling channels originate at the passageway and axially direct the oil through the body to the housing mounting the roller. To increase bearing and shaft life, at least two oiling channels are positioned to deposit oil between the housing and the outward sides of the roller to facilitate lubrication the shaft and bearing and to indirectly the surface of the roller. Additional oiling channels may be added to directly feed oil to the surface of the roller to directly lubricate the roller and camshaft lobes.
To prevent rotation of the valve lifter as it rapidly reciprocates up and down, a small guide or anti-rotation member has been added and fixed to the engine block in the lifter galley. The anti-rotation guide can span across two adjacent lifters and has a substantially flat main portion that sits on top of the engine block outside the bores. A tab extends perpendicular from the middle of the guide and in one form has a slot where a fastener may be inserted and threaded into the block of the engine to hold the guide stationary. Other methods of securing the anti-rotation guide to the block may also be employed. Each end of the guide that spans a lifter bore contains a small, crescent-shaped portion which depends from the main portion to form a shoulder therewith. The small crescent portion extends into the lifter bore with the curved portion of the crescent-shaped portion matching the curvature of the lifter bore to provide secured and flush engagement between the bore walls and the top of the block and the crescent-shaped portion of the anti-rotation member. The portion also has a planar bearing surface that mates with the front surface of the lifter for preventing rotation of the body of the lifter in the bore. To increase stability and decrease friction and wear on the valve lifter as it reciprocates, the lifter body has been modified by machining a short, planar surface on the front of the lifter. Due to the small contact surface created by the crescent-shaped portion of the anti-rotation guide and only a small portion of the lifter body need be planar. Now, as the lifter reciprocates in the bore, the front planar surface slides across the small planar surface of the anti-rotation guide containing its movement.
Thus, this guide provides an alternative to link bars which not only add excess material to the lifter assembly, but also present the potential for damage to the engine as the bars and attachment members wear due to the constant motion of the assembly. Furthermore, the small contact area created by the crescent-shaped portion minimizes friction and heat created thereof. Also, the guide also allows the mechanic to remove a single valve lifter from the engine by loosening the fastener and lifting and sliding the guide to allow the lifter to clear the guide; conventional link bars require the removal of the lifters as a pair. The capability to remove one lifter at a time is advantageous in engines where the pushrods may be of different lengths for the exhaust and intake valves. The mechanic needs to remove only one valve lifter and pushrod and thereby prevents the inadvertent switching of the pushrods during reassembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of an internal combustion engine including the valve train thereof;
FIG. 2 is an elevational partial view taken along line 2 — 2 of FIG. 1 showing a pair of valve lifters apparatuses in accordance with the present invention, the valve lifter apparatuses each including a roller member engaged with respective lobes of a camshaft;
FIG. 3 is a cross-sectional view taken along line 3 — 3 of FIG. 2 showing a bearing assembly for the roller member;
FIG. 4 is an enlarged elevational view of a body of the valve lifter showing oil passageways including an oiling channel and an opening for the bearing assembly;
FIG. 5 is a cross-sectional view taken along line 5 — 5 of FIG. 4 showing the oil passageways and oiling channels leading to a space at the lower end of the body for the rolling member;
FIG. 6 is an enlarged sectional view of the lower end of the valve lifter body as shown in FIG. 5 including the roller member and bearing assembly mounted thereto with oil being directed through the oiling channels to the roller member;
FIG. 7 is a plan view taken along line 7 — 7 of FIG. 4 showing an upper bore and depression for receiving a pushrod and an oil channel;
FIG. 8 is a plan view taken along line 8 — 8 of FIG. 4 showing oiling channels and depressions for directing oil to the opening at the lower portion of the valve lifter for the roller member;
FIG. 9 is an enlarged sectional view of an alternative embodiment of the lower end of the valve lifter body as shown in FIG. 5 including the roller member and a bushing assembly mounted thereto with oil being directed through the oiling channels to the roller member;
FIG. 10 is a cross-sectional view taken along line 3 — 3 of FIG. 2 showing the engagement between an anti-rotation guide and flat of the valve lifter;
FIG. 11 is a cross-sectional view taken along line 11 — 11 of FIG. 2 showing the anti-rotation guide and a pair of valve lifters;
FIG. 12 is an elevational view of the anti-rotation guide showing a pair of short flat surfaces for engaging the flats of the valve lifters;
FIG. 13 is a plan view of the anti-rotation guide showing a main portion thereof including an attachment slot;
FIG. 14 is a bottom plan view of the anti-rotation guide showing a pair of crescent-shaped portions including the short flat surfaces;
FIG. 15 is a front elevational view of the anti-rotation guide showing the short flat surfaces;
FIG. 16 is a side elevational of the anti-rotation guide showing a portion formed between a curved surface on the crescent portion and the main portion;
FIG. 17 is a perspective view a pair of valve lifters and the anti-rotation guide showing the portion and the short flat surfaces engaged against the respective flats of the valve lifters;
FIG. 18 is a perspective view of a valve lifter showing an external oiling channel;
FIG. 19 is an elevational view of the valve lifter showing the diagonal path of the external oiling channel and an oil receiving area.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A valve lifter as used in an internal combustion engine is used to translate the angular motion of a camshaft to reciprocating motion to open and close the intake and exhaust valves. FIG. 1 illustrates a simplified, pushrod-type internal combustion engine 2 having a crankshaft 4 which is attached to a connecting rod 6 having a piston 8 connected thereto. As fuel ignited in a cylinder, the piston 8 is driven downward from the explosion which in turn, causes the crankshaft 4 to rotate. This rotation of the crankshaft 4 is translated, in a vehicle application, to a transmission and gears which cause the drive tires to rotate. Also, the crankshaft 4 drives a camshaft 10 via a chain or a belt (not shown).
The camshaft 10 has lobes 12 , or cams, as depicted in FIG. 2. A valve lifter 14 , also known as a cam follower, rides on a lobe 12 of the camshaft 10 to translate the rotational motion of the camshaft 10 into a reciprocating motion. The valve lifter is typically machined from high strength stainless steel alloys such as 4130, 4140 or SAE 9310. In a pushrod engine, the valve lifter receives a pushrod 16 which moves up and down with the valve lifter 14 . At the opposite end of the pushrod 16 is a rocker arm 18 which acts upon a valve 20 . The valve 20 is positioned in a valve spring, not shown, which is situated in a cylinder head that has intake and exhaust openings above the cylinder in which the valves are seated. The cylinder head receives a mixture of air and fuel via an intake manifold from either a fuel injection system or carburetor. When the intake valve 20 opens, the air-fuel mixture passes through the intake port and enter the cylinder for combustion. The resulting spent gases are expelled from the combustion chamber when the exhaust valve opens. The opening and closing of the valve 20 are controlled by the movement of the camshaft 10 which is translated by the valve lifter 14 and pushrod 16 . As the valve lifter 14 and pushrod 16 move upward, the rocker arm 18 forces the valve 20 downward, or open. Conversely, as the valve lifter 14 and pushrod 16 move downward, the rocker arm 18 allows the valve 20 to travel up, or closed.
As shown in FIG. 2, the valve lifter 14 is positioned in a lifter bore 22 in the engine block 24 . The valve lifter 14 receives oil from a common oil passageway 26 in the engine block 24 that communicates with the bores 22 . The body of the valve lifter 14 has oil pressure feed receiving areas 28 which are positioned to intersect the common oil passageway 26 as the lifter 14 moves up and down in the bore 22 . The lifter 14 also has a roller 30 which rides on the surface of the lobe 12 of the camshaft 10 . As seen in FIG. 3, the roller 30 may have a bearing assembly 32 containing needle bearings 34 or alternatively a bushing 35 . The roller 30 is rotatively mounted to the valve lifter 14 by a shaft 36 . The oil receiving areas 28 positioned on the sides of the valve lifter 14 are connected by a common passageway 38 as seen in FIGS. 3 and 5. The oil passageway 38 may also receive oil from two additional receiving areas 40 on the front and back surfaces of valve lifter 14 that is thrown from the rotating components of the engine. The pushrod 16 which extends into an upper cylindrical bore 42 in the body of the valve lifter 14 and rests in a depression 44 also requires lubrication to reduction friction. An oil passageway 46 traveling through the valve lifter 14 body from the front and back surfaces supplies oil to the pushrod 16 via a vertical channel 47 that connects the oil passageway 46 and the depression 44 , as illustrated in FIGS. 4, 5 , and 7 .
In high performance engines, especially those which maintain high engine speeds for long durations, a common area of wear and failure of a valve lifter 14 is at the bearing assembly 32 or bushing 35 of the roller 30 . Excessive wear or friction may be the result from inadequate oiling of the roller 30 or in extreme cases, the complete lack of oil to the bearing assembly 32 or bushing 35 . To facilitate the movement of lubrication to this area, oiling channels 48 have been added which connect the oil passageway 38 to the housing portion 50 for the roller 30 formed at the lower end of the lifter body. Here, the oil is pressure feed from the common transverse oil passage 26 in the engine block 24 into the oil receiving areas 28 and through the oil channels 48 to the edges of the roller 30 . To provide for this increased in flow of oil, a semi-circular depression 52 about the width of the opening for the shaft 36 is milled running axially the length of the housing 50 . The depression 52 also facilitates the movement of oil from the surface of the lobe 12 of the camshaft 10 to the shaft 36 , bearing assembly 32 or bushing 35 . FIG. 8 depicts the oil channels 48 and depression 52 as seen from the bottom of valve lifter 14 with the roller 30 removed. As oil exists the oil channels 48 , the oil flows down the depression 52 of the housing 50 and lubricates the roller 30 , the needle bearings 34 or bushing 35 , and the shaft 36 as illustrated in FIGS. 6 and 9.
Valve lifters in high performance engines have a tendency to rotate in the lifter bores 22 due to the high engine speeds and mechanical vibrations. To prevent rotation, a link bar which connects two lifters, typically the lifter for exhaust and intake valve is commonly used. However, the bar adds additional moving components to the valve lifter 14 and thereby increasing the likelihood of fatigue. Also, attachment buttons or fasteners must be added to the lifter to attach the link bar. Furthermore, to remove a lifter from the engine when the two lifters are attached together, both lifters must be removed as a pair. This may result in the inadvertent switching of pushrods during reassembly when different length exhaust and intake pushrods are used.
Turning to FIGS. 10-16, to prevent movement of the valve lifter 14 , the present invention uses a guide 54 which mounts to the engine block 24 . The lifter guide 54 includes a main flat guide portion 55 sized to span the distance between two adjacent lifter bores 22 as seen in FIGS. 2 and 11. To physically secure the lifter guide 54 to the top of the engine block 24 , a fastener 56 , typically a threaded type fastener, is placed through a slot 58 in a tab portion 59 projecting from an intermediate position along the length of the main flat guide portion 55 away from the bores 22 . The lifter guide 54 also has two small crescent-shaped portions 60 that depend from the flat portion 55 out of the plane thereof for extending into the lifter bores 22 as shown in FIGS. 10 and 11. The curvature of curved surface 60 a the crescent-shaped portion 60 mates with the curvature of the lifter bore 22 . Thus the curved surface 60 a and the guide member portion 55 form a tight fitting shoulder 61 that securely engages against the corner 63 at the junction of the upper end of the bore 22 and the top of the engine block. In this manner, as the guide member encounters torquing forces that want to twist it out of position and loosen its connection to the block, the tight mating engagement between the shoulder 61 and corner will resist these forces to keep the guide member in proper position for guiding and resisting rotation of the lifter body as it reciprocates in the bore 22 .
To this end, a short flat surface 60 b is provided extending between the ends of the curved surfaces 60 a and faces towards the center of bore 22 . A short flat 62 is machined on the front surface of the valve lifter 14 to provide clearance for fitting the crescent-shaped portion 60 of the lifter guide 54 in the bore 22 with the short flat surface 60 b thereof in confronting relation with the lifter body flat 62 as shown in FIG. 10 . Also, the flat 62 must continue axially down the body of the valve lifter 14 for a length that is equal to or greater than the distance the valve lifter 14 travels up and down in the lifter bore 22 . However, because the guide flat surfaces 60 b only extend into the bore 22 a short distance, the flat 62 need not extend the entire axial length of the lifter body. FIG. 17 illustrates the portion 60 of the lifter guide 54 engaging the flat 62 of the lifter 14 as it would inside the lifter bore 22 . With the crescent-shaped portion 60 in the lifter bore, all movement of the valve lifter 14 is limited to up and down travel, thereby preventing rotation.
Another method of providing lubrication to the roller 30 and bearing assembly 32 is by adding an external oiling channels 64 to the lower portion of on front and back surfaces of the lifter body as illustrated in FIGS. 18 and 19. To collect the oil from the transverse oil passageway 26 of the engine block 24 , the oil receiving location has been modified by machining an annular grove on the surface of the body above the external oiling channel 64 . This annular groove, or annular oil receiving area 66 collects oil as the receiving area 66 passes the transverse oil passageway 26 of the engine block 24 . The external oiling channel 64 then directs the oil from the annular oil receiving area 66 to the housing portion 50 of the lifter 14 . Here, the depressions 52 in the internal sides of the housing portion 50 , as shown in FIGS. 4 and 8, further facilitate the movement of oil to the bearings 34 or alternatively, a bushing 35 and the shaft 36 . One advantage of utilizing an the external oiling channels 64 is that less machining is required than that of the internal oil passageways and oiling channels used in the first method. The body of the lifter 14 may be cylindrical as shown in FIG. 18 and used with a link bar to prevent rotation in the lifter bore 22 . Alternatively, the lifter may also incorporate the flat 62 as shown in FIG. 19 and utilized with the anti-rotation lifter guide 54 .
The external oiling channel 64 is positioned diagonally across the surface of the lifter 14 , however, alterative orientations may also be used to achieve the desired results. For example, the external oiling channel 64 could travel axially from the annular oil receiving area 66 to the housing portion 50 . However, for ease of manufacturing, the diagonal position is preferred to prevent external oiling channel 64 from catching the tooling during machining and polishing of the lifter body.
The invention described in the above detailed description is not intended to be limited to the specific form set forth herein, but on the contrary it is intended to cover such alternatives, modifications and equivalents as can reasonably be included in within the spirit and scope of the appended claims.
The invention described in the above detailed description is not intended to be limited to the specific form set forth herein, but on the contrary it is intended to cover such alternatives, modifications and equivalents as can reasonably be included in within the spirit and scope of the appended claims.
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A valve lifter apparatus is provided including a valve lifter body with predetermined oil paths for increase lubrication to a rolling member for engaging a lobe of a camshaft. An anti-rotation member for prevent rotation of the valve lifter in the lifter bore of the engine block as the valve lifter reciprocates is also provided. The valve lifter apparatus may be employed in high revolutions per minute engines to decrease valve lifter wear and increase performance.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to European Patent Application 14189908.8 filed Oct. 22, 2014, the contents of which are hereby incorporated in its entirety.
TECHNICAL FIELD
[0002] The present disclosure relates generally to multi stage turbines, including steam turbines and gas turbines and more specifically to means to reduce efficiency loss caused by leakage flow through seals of shrouded rotating blades.
BACKGROUND INFORMATION
[0003] An axial flow turbine, for example a steam turbine, comprises a casing and a rotor which is rotatably supported within the casing. The rotor comprises a shaft and a plurality of rotor blade rings which are attached behind one another to the shaft. During operation of the turbine working fluid is expanded progressively by the blade rings to bring about driving the shaft.
[0004] Each rotor blade ring is formed by a plurality of rotor blades being circumferentially arranged, wherein two adjacent rotor blades form a blade passage. The rotor blades are aerodynamically profiled such that, when the working fluid passes the blade passages, the flow is turned and thereby a circumferential force on the rotor blades is generated. The circumferential forces on each blade of the rotor blade ring effect turning the rotor thereby generating shaft power.
[0005] The rotor blades are fixed to the shaft and extend therefrom towards the casing. The lateral ends of the rotor blades at the casing are formed into blade tips, wherein at the blade tips the rotor blade ring is shrouded by a shroud. The shroud is fixed to the blade tips and spaced apart from the casing thereby forming a tip clearance. The height of the tip clearance is dimensioned such that during operation of the turbine it is prevented that the shroud scrubs at the casing. Due to the fact that static pressure of the flow upstream of the rotor blade ring is higher than static pressure of the flow downstream of the rotor blade ring, during operation of the turbine a leakage flow passes the tip clearance.
[0006] The main flow passes the blade passages for shaft power generation, whereas the leakage flow bypasses the rotor blade ring via the tip clearance. Therefore, the leakage flow does not participate to the shaft power generation and does not flow through the blade passage. Further, the leakage flow after being re-entrained into the main flow path interferes with the main flow. Therefore, the main flow is locally inhomogeneous resulting in a mismatched flow. Furthermore, the tip clearance flow mixes with the main flow and generates disadvantageous dissipation. As consequence of this, the presence of the tip clearance flow affects the turbine efficiency.
[0007] In particular in high pressure turbines with low aspect ratio blades, the loss caused by the tip clearance flow is significantly high compared with the total losses of the turbine.
[0008] A remedy to reduce this negative effect of the tip clearance flow on the aerodynamic efficiency of the turbine is to take measurements reducing the tip clearance flow. A measurement, for example, is to provide a labyrinth seal on the outer circumference of the shroud within the tip clearance in order to reduce the mass flow of the tip clearance flow. As an alternative, a sealing element is fixed at the casing in the tip clearance. For fixing the sealing element to the casing, in the casing a circumferential groove is provided into which the sealing element is mortised.
[0009] Each of the solutions reduces tip leakage but does not eliminate the flow. As a result there is a continuing need to address turbine efficiency losses resulting from blade tip leakage.
SUMMARY
[0010] A turbine is disclosed that is configured to address the problem of rotating blade leakage flow reducing turbine efficiency by creating turbulence in the main working fluid flow passage.
[0011] It attempts to addresses this problem by means of the subject matter of the independent claim. Advantageous embodiments are given in the dependent claims.
[0012] The disclosure is based on the general idea of providing a bypass around the stationary vanes in order to at least reduce the re-entry flow of the leakage fluid passing between shrouded rotating blade tips and the casing.
[0013] One general aspect includes a turbine comprising a rotor with a rotational axis, a casing enclosing a rotor to form a flow passage therebetween having first and second sealing means. The turbine also includes a first rotating blade row in the flow passage having a plurality of circumferentially distributed first blades each with a first root connected to the rotor and a first shroud adjacent the first sealing means. The turbine additionally has a stationary vane row, each that with vane airfoil that extends into the flow passage. The stationary vane row is axially adjacent and downstream of the first rotating blade row having a plurality of circumferential distributed stationary vanes. Each of the stationary vanes has a base member connected to the casing. A second rotating blade row is located in the flow passage axially adjacent and downstream of the stationary vane row. This second rotating blade row has a plurality of circumferentially distributed second rotating blades each with a second root connected to the rotor and a second shroud adjacent the second sealing means. A first cavity is formed by the first shroud, the first sealing means and the base member while a second cavity is formed by the second shroud, base member and the second sealing means.
[0014] Further aspects may include one or more of the following features. The turbine wherein each stationary vane has a leading edge wherein the first end of the bypass-passage is located at a point of the first cavity circumferentially between the leading edges of two circumferentially adjacent stationary vanes. The turbine wherein the bypass-passage is radially displaced from the rotor rotational axis. The turbine wherein the bypass-passage is parallel to the rotor rotational axis. The turbine wherein the bypass-passage is angled from the rotational axis in a direction to the normal operating rotation of the rotor of between −30 degrees and 30 degrees, preferably between 0 degrees and 10 degrees. The turbine wherein the bypass-passage has a uniform cross sectional area along its length. The turbine configured as a gas turbine, or impulse type steam turbine. The turbine wherein the base member is a steam turbine diaphragm.
[0015] In a general aspect the turbine of claim comprising a plurality of bypass-passages.
[0016] Other aspects and advantages of the present disclosure will become apparent from the following description, taken in connection with the accompanying drawings which by way of example illustrate exemplary embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] By way of example, an embodiment of the present disclosure is described more fully hereinafter with reference to the accompanying drawings, in which:
[0018] FIG. 1 is a perspective view of a turbine section with a bypass-passage according to an exemplary preferred embodiment of the disclosure;
[0019] FIG. 2 is a top sectional view of the turbine section of FIG. 1 ;
[0020] FIG. 3 is a sectional view of steam turbine with a diaphragm and bypass-passage of an exemplary embodiment around the diaphragm; and
[0021] FIG. 4 is an expanded view of the base member of FIG. 1 showing a bypass-passage of non-uniform cross sectional area.
DETAILED DESCRIPTION
[0022] Exemplary embodiments of the present disclosure are now described with references to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of the disclosure. However, the present disclosure may be practiced without these specific details, and is not limited to the exemplary embodiments disclosed herein.
[0023] Pitch is the distance in the direction of rotation between corresponding points on adjacent blades. In this description, the points correspond to the leading edge of circumferentially adjacent stationary blades wherein 0% pitch corresponds to the leading edge of the upstream blade as taken from the circumferential direction of rotation of the rotating blades of the turbine and 100% pitch corresponds to the leading edge of the downstream blade as taken from the circumferential direction of rotation of the rotating blades of the turbine.
[0024] An exemplary embodiment of a turbine shown in FIG. 1 includes a rotor 10 and a casing 15 enclosing the rotor 10 so as to form a flow passage 19 therebetween. A plurality airfoils 20 a , 30 a of circumferentially distributed rotating blades 20 and stationary vanes 30 are located in the flow passage 19 . The rotating blades 20 and stationary vanes 30 are arranged such that there is an upstream row of rotating blades 20 adjacent a downstream row of stationary vanes 30 which are in turn adjacent a further row of rotating blades 21 . The number of rotating blades 20 and stationary vanes 30 shown in FIG. 1 is only limited in order to explain an exemplary embodiment and therefore is not a limiting example of a turbine to which exemplary embodiments of this disclosure can be applied.
[0025] The turbine includes sealing means 16 , 17 that provide a seal between the stationary casing 15 and the shrouds 22 , 23 of the rotating blades 20 , 21 . Depending on the configuration of the turbine, the sealing means 16 , 17 could be mounted on the casing 15 , as shown in FIG. 2 , or else mounted on an extension ring 18 a, 18 b such that each of the seal means 16 , 17 are in a first cavity 40 and a second cavity 42 respectively that are both located outside the flow path 19 . In an exemplary embodiment shown in FIG. 3 an extension ring 18 a, 18 b is mounted to a downstream base member 32 . In an exemplary embodiment shown in FIG. 3 an extension ring 18 a is mounted to the base member 32 and an extension ring 18 b is mounted to a downstream base member 32 . In a not shown exemplary embodiment an extension ring 18 a is mounted to an upstream base member 32 .
[0026] Each of the rotating blades 20 , 21 includes a blade root 24 that fixes the rotating blade 20 , 21 to the rotor 10 . At a distal end of each rotating blade 20 , 21 , that is, at an end nearest the casing 15 , the rotating blades 20 , 21 have a shroud 22 , 23 . The shroud 22 , 23 is configured such that there is a leakage flow of working fluid that passes between the shroud 22 , 23 and the casing 15 . A sealing means, typically located between the casing 15 and the shroud 22 , 23 , limits the leakage flow.
[0027] The stationary vanes 30 , located between the rows of rotating blades 20 , 21 , each have a base member 32 that supports or connects the stationary vane 30 to the casing 15 . The form of the base member 32 is dependent on the configuration of turbine. For example, in an exemplary embodiment applied to an impulse type steam turbine, the base member 32 is a diaphragm 32 configured as a ring to support the stationary vanes 30 of the stationary vane row. In another not shown exemplary embodiment, the base member 32 is a vane root 32 connecting each stationary vane 30 to the casing 15 . In another not shown exemplary embodiment, the base member is a combination of the casing 15 and a vane attachment means.
[0028] The first cavity 40 is formed by the first shroud 22 , the first sealing means 16 and the base member 32 while the second cavity 42 is formed by the second shroud 23 , base member 32 and the second sealing means 17 .
[0029] An exemplary embodiment shown in FIG. 1 further includes a bypass-passage 44 that extends from a first end at the first cavity 40 through the base member 32 to a second end at the second cavity 42 wherein both the first end and the second are located outside of the flow passage 19 . The purpose of the bypass-passage 44 is to direct leakage flow flowing over the shroud 22 of the upstream rotating blades 20 to the downstream row of rotating blades 21 by bypassing the flow passage 19 all together and thus bypass the airfoil 30 a of the vane 30 . As little or no leakage fluid from the first cavity 40 returns to the flow passage 19 a source of turbulence in the flow passage 19 , and thus efficiency lost, is thus eliminated or at least reduced.
[0030] In an exemplary embodiment the bypass-passage 44 has a first end located at a point of the first cavity 40 circumferentially between the leading edges 34 of two circumferentially adjacent stationary vanes 30 . In this exemplary embodiment circumferential between includes a point axially and/or radially displaced from a point on a line projected between leading edges 34 of two circumferentially adjacent stationary vanes 30 . That is, the first end of the bypass-passage 44 may be at any point in the first cavity upstream of the projected line.
[0031] The configuration of the bypass-passage 44 is dependent on the type of turbine and whether or not the bypass-passage 44 is retrofitted to the turbine or else configured as part of the original design. As such it may be straight or else include at least one non-linear section, such as a curve or corner.
[0032] In an exemplary embodiment shown in FIG. 3 the turbine is an impulse type steam turbine with a diaphragm 32 configured as a ring to encircle and support stationary vanes 30 of the stationary blade row. In this exemplary embodiment, the bypass-passage 44 is formed through the diaphragm 32 .
[0033] In an exemplary embodiment shown in FIG. 4 , the bypass-passage 44 has different cross sectional areas along its length. In a first portion the bypass-passage 44 has a larger cross-sectional area while at an end region the bypass-passage 44 has a reduced cross-sectional area. This exemplary embodiment may be applicable for retrofits where it may be easier to drill long passages with a larger drill bit. This is enabled by the presence of a smaller pilot hole formed by the smaller cross-sectional area of the bypass-passage 44 that defines the flow capacity of the bypass-passage 44 .
[0034] In an exemplary embodiment shown in FIG. 1 the flow passage 19 is skewed from the rotational axis 12 to preferably follow an expansion of the flow passage 19 . In a not shown exemplary embodiment the flow passage 19 is parallel to the rotational axis 12 .
[0035] In an exemplary embodiment shown in FIG. 2 the bypass-passage 44 forms an angle 46 with the rotational axis 12 that angles the bypass-passage 44 in the direction of rotational direction 14 of the rotating blades 20 . In an exemplary embodiment shown in FIG. 2 the first end of the bypass-passage 44 is located along a pitch of the stationary vanes 30 .
[0036] In an exemplary embodiment shown in FIG. 3 the turbine is an impulse type steam turbine with diaphragm 32 configured as a ring to support stationary vanes 30 of the a stationary blade row. In this exemplary embodiment, the bypass-passage 44 is formed around the diaphragm 32 . When this exemplary embodiment is retrofitted to a steam turbine it may be necessary to ensure that steam does not further bypass the sealing means. Where the sealing means includes extension rings 18 a, 18 b each of which is itself mounted on the diaphragm 32 of this row of stationary vanes 30 or an adjacent row, additional casing seals 48 spanning between either or both of the extension rings 18 a, 18 b and the casing 15 may be required.
[0037] Although the disclosure has been herein shown and described in what is conceived to be the most practical exemplary embodiment, it can be embodied in other specific forms. For example, exemplary embodiments may equally be applied to gas turbines and all types of steam turbines including high pressure steam turbines, intermediate pressure steam turbines, reaction bladed steam turbines and impulse bladed steam turbines. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restricted. The scope of the disclosure is indicated by the appended claims rather that the foregoing description and all changes that come within the meaning and range and equivalences thereof are intended to be embraced therein.
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The invention relates to a turbine in which a bypass-passage extends through a base member of a stationary vane to join seal cavities of adjacent rotating blade rows so that seal flow passing between a casing and shrouds of the rotating blades at least partially bypasses the turbine main flow passage.
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FIELD OF THE INVENTION
[0001] The present invention relates to aeration of liquid systems.
BACKGROUND
[0002] Aeration of liquids is important in many process applications. In waste water treatment for example, various processes require effective aeration to perform efficiently. Typically, blower/diffuser systems are employed. Such systems operate at low efficiencies, and thus require air to be supplied in great excess to produce adequate aeration. There is a need for a system and process to more efficiently provide aeration to liquid systems.
SUMMARY OF THE INVENTION
[0003] The present invention relates to a device for dissolving a gas in a liquid. The device includes a pressure vessel having an inlet disposed on the pressure vessel for receiving a gas-liquid mixture. A riser is disposed in the pressure vessel and connected to the inlet. The riser extends into a head space of the pressure vessel. The riser is adapted to receive the gas-liquid mixture from the inlet and inject the mixture into the head space. An opening is disposed in an upper end of the riser below an interior surface of the pressure vessel. Disposed in an upper portion of the pressure vessel is a flow director that forms a swirling flow path. An outlet is disposed on the pressure vessel for directing the liquid from the pressure vessel.
[0004] The present invention provides a method of dissolving a gas into a liquid. The method includes mixing a gas into the liquid to form a gas-liquid mixture. The method also includes directing the mixture into a pressure vessel and into a vessel riser extending within the pressure vessel. In addition, the method includes discharging the mixture under pressure into the pressure vessel and directing the mixture along a swirling flow path and towards an outlet. The method also includes discharging the liquid under pressure from the pressure vessel. The method may further include discharging pressurized liquid with gas dissolved therein into a tank containing a liquid and forming micro bubbles in the tank.
[0005] Other objects and advantages of the present invention will become apparent and obvious from a study of the following description and the accompanying drawings which are merely illustrative of such invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic of an embodiment of the system for producing micro bubbles in a liquid held in a tank.
[0007] FIG. 2 is a cross-sectional view of one embodiment of the pressure column of the present invention.
[0008] FIG. 3 is a cross-sectional view of a second embodiment of the pressure column of the present invention.
[0009] FIG. 4 is a cross-sectional view of a third embodiment of the pressure column of the present invention.
DETAILED DESCRIPTION
[0010] With particular reference to the drawings, a micro bubble forming system, indicated generally by the numeral 100 , is provided. Micro bubble forming system 100 includes a liquid source contained in a tank 40 . Connected to an outlet 46 of tank 40 is a pump 10 . Pump 10 is connected to a venturi device 20 to cause liquid from tank 40 to flow therethrough. Venturi device 20 includes an air inlet 22 to entrain a gas, such as air, into the liquid flow. To direct the flow of gas-entrained liquid from venturi device 20 , the venturi device is connected to inlet 32 of a pressure column, indicated generally by the numeral 30 . Outlet 34 of pressure column 30 is connected to inlet 42 of tank 40 to return the flow of liquid to the tank. It is appreciated that system 100 provides a generally closed circuit in which liquid may flow from tank 40 and be returned to the tank. In circuit, the liquid passes through venturi 20 where a gas is entrained with the liquid, transits pressure column 30 where the liquid becomes highly saturated with the gas, and returns to tank 40 where micro bubbles are formed. System 100 has utility in such areas as aerating waste water prior to treatment and enriching other fluids with oxygen.
[0011] It is appreciated that micro bubble forming system 100 may, in an operable state, include any of various liquid sources. As illustrated in FIG. 1 , the liquid source contained in tank 40 , and the tank holds a volume of liquid from which liquid is withdrawn, pumped through venturi device 20 and pressure column 30 , and returned to the tank. Alternatively, for example, the liquid source may be contained in a pipe through which a liquid is conducted under influence of a separate motive force. A portion of the liquid flowing in the pipe may be withdrawn by means of a first tap or side outlet, pumped through venture device 20 and pressure column 30 , and returned to the pipe at a second tap or side inlet.
[0012] Turning now to a detailed description of pressure column 30 , and referring particularly to FIG. 2 , the pressure column comprises generally a pressure vessel capable of withstanding operating pressures. Pressure column or vessel 30 includes a riser 36 that is fluidly connected to inlet 32 . Vessel riser 36 extends upward within pressure column 30 and has an opening disposed near an inner surface 38 of the top of the vessel. In one embodiment riser 36 extends to a height such that the upper open end is disposed a short distance down from the inner surface 38 of the top of the vessel forming a gap there between. An open upper end of riser 36 forms the opening, which faces inner surface 38 across the gap. The gap is generally about one inch or smaller.
[0013] Inlet 32 to pressure column 30 is disposed at the top of inlet riser 31 , and outlet 34 is disposed at the top of outlet riser 33 . Generally, inlet riser 31 extends upwardly to about 50% of the height of vessel riser 36 while outlet riser 33 extends upwardly to about 40% of the height of the vessel riser.
[0014] In a second embodiment, pressure column 30 includes a helical baffle 39 disposed in an upper portion of the pressure vessel at least partially below head space 37 near the surface of liquid pool 35 . See FIG. 3 . Helical baffle 39 comprises about one revolution or more of a helical or screw flight and forms a helical flow path in an upper portion of liquid pool 35 . In a third embodiment, illustrated in FIG. 4 , one or more revolutions of helical baffle 39 are disposed at least partially in head space 37 , and one or more revolutions are disposed at least partially in liquid pool 35 . Baffle 39 serves as a flow director to encourage a swirling and generally downward flow within pressure column 30 .
[0015] Micro bubble forming system 100 functions as follows. The liquid is pumped through venturi device 20 where a gas is entrained. As illustrated in FIG. 1 , environmental air may be entrained via venturi device 20 . However, a gas, such as oxygen, from a gas source or generator may be entrained alternatively or in addition to environmental air. A gas-liquid mixture is formed in venturi device 20 and directed to inlet 32 of pressure column 30 as a gas-entrained liquid flow. In response to the pump driving force, the gas-liquid mixture is directed up vessel riser 36 and injected under pressure into head space 37 . In one embodiment, the mixture is ejected under pressure from an opening in riser 36 against interior surface 38 . The ejection of the mixture against surface 38 tends to spray the mixture into head space 37 . The gas-liquid mixture is incorporated into liquid pool 35 such that the gas becomes dissolved in the liquid at a highly saturated level.
[0016] In one embodiment, the apparatus for which is illustrated in FIG. 2 , the gas-liquid mixture sprayed into head space 37 descends into liquid pool 35 where the gas dissolves in the liquid. In one embodiment, apparatus illustrated in FIG. 3 , a swirling and generally downward movement of the mixture and the liquid in pool 35 is encouraged by helical baffle 36 disposed in an upper portion of liquid pool 35 . In one embodiment, apparatus shown in FIG. 4 , the gas-liquid mixture descends along helical baffle 38 that is disposed at least partially in head space 37 and at least partially in liquid pool 35 . A swirling and generally downward movement of gas and liquid in pressure column 30 at least partially facilitates the gas becoming dissolved in the liquid.
[0017] Sufficient pressure is maintained in pressure column 30 further encourage dissolution of the gas and to force liquid with gas dissolved therein from pool 35 through outlet 34 and thence to tank 40 . Generally, the pressure within head space 37 ranges from about 35 psi to about 60 psi. Due to the pressure drop between liquid leaving pressure column 30 and liquid in tank 40 , gas will come out of solution and form micro bubbles 44 as the liquid returns to the tank. The pressure drop preferably ranges between about 8 psi and about 10 psi. Micro bubbles formed range in diameter from about 1 micron to about 10 microns and generally less than about 5 microns. Continued operation of system 100 for a sufficient time results in a cloudy or milky appearance of the liquid in tank 40 . This cloudiness evidences extensive dispersion of micro bubbles throughout the liquid.
[0018] By way of example two functional scale models are described here below. In both cases, the liquid is water and the gas is environmental air. These scale models illustrate the utility of system 100 in aerating water.
[0019] Model I includes tank 40 holding 55 gallons of water. Pressure column 30 is 46½″ high formed from 8⅝″ OD×¼″ wall thickness steel tube capped on each end by a 1″ steel plate welded there to and having a capacity of 10 gallons. Risers 31 , 33 , and 36 are formed from ¾″ schedule 40 S steel pipe. The gap between the upper end of riser 36 and surface 38 is 1″. Venturi device 20 is a Mazzei® Injector Model NK PVDF 784 (Mazzei Injector Corp. 500 Rooster Dr. Bakersfield, Calif. 93307). A 1 hp pump 30 is used and a flow rate of 10 gpm is maintained through venturi device 20 .
[0020] Model II includes tank 40 holding 5 gallons of water. Pressure column 30 is 18″ high formed from 2½″ OD×¼″ wall thickness steel tube capped on each end by a 3/16″ steel plate welded there to and having a capacity of 0.24 gallons. Risers 31 , 33 , and 36 are formed from ¼″ schedule 80 S steel pipe. The gap between the upper end of riser 36 and surface 38 is ⅜″. Venturi device 20 is a Mazzei® Injector Model NK PVDF 287. A ¼ hp pump 30 is used and a flow rate of 1 gpm is maintained through venturi device 20 .
[0021] The responses of the two models are summarized in Table I.
[0000]
TABLE I
Model
Time to Cloud
I
4 minutes
II
2 minutes
[0022] A utility of the present invention is to enhance, for example, oxygen-requiring reactions in a reservoir such as tank 40 . Tank 40 may be a water treatment tank, for example, where aerobic degradation of pollutants is desired. The distribution of micro bubbles of air, for example, in such a treatment tank may enhance and accelerate the removal of such pollutants. The enhancement may result in a reduction in treatment time and/or tank size.
[0023] The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the scope and the essential characteristics of the invention. The present embodiments are therefore to be construed in all aspects as illustrative and not restrictive.
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A device for dissolving a gas in a liquid. The device comprises a pressure vessel or column for receiving a gas-entrained liquid via an inlet and for injecting the gas-entrained liquid via a riser into a headspace of the vessel. A flow director is disposed in an upper portion of the vessel or column to form a swirling flow path extending into a liquid pool in a lower portion of the vessel or column. An outlet is provided to direct the liquid away from the vessel or column.
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[0001] This application claims priority of U.S. provisional patent application No. 60/786,738, Ventilation chimney section and method, to John Waldner, filed 29 Mar. 2006, which is incorporated herein by reference.
[0002] This invention is directed to a method of manufacture of ventilation chimney sections and ventilation chimney sections, also called exhaust fan flues.
BACKGROUND AND PRIOR ART
[0003] Ventilation is important in livestock raising barns in general and hog barns in particular. Ventilation chimneys typically with an associated fan are used to exhaust air from the barns. Generally these chimneys are assembled from prefabricated sections.
[0004] Currently sections are made from rotary molded “rotomolded” plastic tubes, and from a plastic sheet welded longitudinally to form a tube. As the chimneys ventilate to the outside air, they tend to ice up in winter. Sometimes chimneys are insulated after installation in the barn attic to overcome the icing problem. Some sections are formed from inner and outer tubes welded longitudinally from plastic sheets, and spaced at the ends by a circular spacer typically ¼ inch thick.
[0005] None of these solutions are particularly satisfactory, although better than no ventilation.
[0006] The invention is directed to a method of forming an insulated chimney section by forming inner and outer tubes by welding plastic sheets to form tubes, inserting a sheet of insulation formed into a tube between inner and outer tubes, and attaching a male coupling at one end and a female coupling at the other. The male and female couplings are adapted to engage matingly. The invention is also directed to chimney sections manufactured by the method and chimneys constructed from the sections.
[0007] Although the invention is described with respect to methods of manufacture of chimney section by welding plastic sheets into inner and outer tubes and inserting a sheet of insulation between the inner and outer tubes and attaching male and female coupling s at the ends, sections manufactured by the method and chimneys constructed from the sections, it will be apparent to those skilled in the art that the invention is not limited to the method of manufacture, sections and chimneys, but extend to similar methods, sections and chimneys.
[0008] It is a principal object of the invention to provide a chimney section having plastic inner and outer tubes separated by insulation. It is a subsidiary object of the invention to provide a chimney section having male and female couplings fitted into the space between the inner and outer tubes. It is a further principal object of the invention to form a chimney section by welding a plastic sheet to form an outer tube and welding another plastic sheet to form an inner tube, and to insert the inner tube inside the outer tube and slide a sheet of insulation material having touching edges between the inner and outer tubes. It is a further object of the invention to insert a male coupling at one end of the section fitting between the inner and outer tubes and to insert a female coupling at the other end of the section fitting between the inner and outer tubes. Other objects will be apparent to those skilled in the art from the following specification, accompanying drawings and appended claims.
DESCRIPTION OF THE INVENTION
[0009] The invention in one broad aspect is directed to a method of manufacture of a ventilation chimney section comprising welding plastic sheets to form inner and outer cylindrical tubes placing the inner tube within the outer tube and sliding a sheet of insulation between the inner and outer tube. Preferably the plastic sheets are cut to the desired length, and the desired width, that is π times the desired diameter of the tubes, which are then edge welded to form the inner and outer tubes. The sheet of insulation is similarly cut, most preferably slightly shorter in length to allow for the coupling elements. The thickness of the sheet of insulation is set to be slidable within the space between the inner and outer tubes. The sheet of insulation is preferably cut into a plurality into a plurality of segments, alignable parallel to the common axis of the tubes, before sliding the sheet between the inner and outer tubes. Each segment fills a longitudinal portion of space between the inner and outer tubes. Preferably the sheet of insulation is cut into four quarter cylindrical segments, alignable parallel to the common axis of the tubes. Most preferably the sheet fits snugly between the inner and outer tubes. Preferably the collar of a male coupling element is inserted into one end of the section between the inner and outer tubes and secured therein. Preferably the collar of a female coupling element is inserted into the other end of the section between the inner and outer tubes and secured therein. The male coupling element is adapted to matingly engage a female coupling identical to the female coupling element and vice versa. Preferably the collars are secured between the inner and outer tubes by fasteners, which are preferably screws, although plastic rivets may also be used, extending through the outer tube and into the collar.
[0010] In another broad aspect the invention is directed to a chimney ventilation section comprising coaxial inner and outer plastic tubes separated by a sheet of insulation in the space between the inner and outer tubes. Preferably the sheet of insulation fits snugly between the inner and outer tubes. Preferably the sheet of insulation has four quarter cylindrical segments aligned parallel to the common axis of the tubes. Conveniently the collar of a male coupling element is inserted into one end of the section between the inner and outer tubes and secured therein. Conveniently the collar of a female coupling element is inserted into the other end of the section between the inner and outer tubes and secured therein. The male coupling element is adapted to matingly engage a female coupling identical to the female coupling element and vice versa. Usually the collars are secured between inner and outer tubes by fasteners. Preferably the fasteners are screws extending through outer tubes and into the collars. A preferred form of male coupling element has a first circumferential wall abutting the collar of the male coupling element projecting outward, a first inner cylindrical sleeve at the inner edge of the first circumferential wall. The first sleeve forms a plug to engage a socket of a female coupling element. The preferred form of the female coupling element has a second circumferential wall abutting its collar projecting outward, a second outer cylindrical sleeve at the outer edge of the second circumferential wall. The second sleeve and second wall form a socket to engage a plug of a male coupling element. Both circumferential walls surround a central fluid passage communicating with the fluid passage of the section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a cross sectional elevational view of a ventilation chimney section of the invention.
[0012] FIG. 2 shows a cross sectional plan view of the embodiment of claim 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] The invention is now illustrated by reference to preferred embodiments thereof. Numeral 10 indicates a ventilation chimney section of the invention. Section 10 includes cylindrical tube 12 , male end coupling 14 and female end coupling 16 . Tube 12 has outer cylindrical tube 18 , inner cylindrical tube 20 , separated by cylindrical insulation 22 filling space 50 between tubes 18 and 20 . Tubes 18 and 20 are made by welding opposed edges of a plastic sheet to form a cylindrical tube. Typically the sections are 2, 3 and 4 feet long (approximately 60, 90 and 120 cm) and 16, 18, 22 or 25 inches inner diameter (approximately 40, 45, 60 and 63 cm), these dimensions are those requested and preferred by purchasers although other lengths and diameters may be used, and custom supplied. Typically the plastic sheets are polyethylene and about ⅛ inch thick (approximately 3 mm, although other plastics of similar properties can be used instead, and the thickness can be similarly varied, as known by those skilled in the art. Inner tube 20 when placed within outer tube 18 is spaced apart about 1⅛ inch (approximately 2.8 or 2.9 cm) forming space 50 . This gap is filled by a 1 inch thick (approximately 2½ cm) insulating polystyrene sheet 22 , which may be cut into four quarter cylinders, and is typically foamed, other insulating plastics of similar properties can be used instead. In manufacture polyethylene sheets are cut to size, as is a polystyrene sheet. The polyethylene sheets are edge welded to form cylindrical tubes 18 and 20 placed concentrically within each other and polystyrene 22 slid between them preferably as four quarter cylinders 24 . Male coupling 14 and female coupling 16 are inserted into ends 26 and 28 of tube 12 and secured by screws 30 passing through outer tube 18 into couplings 14 and 16 , plastic rivets may be used instead of screws 30 . Male coupling 14 has collar 32 to engage space 50 between inner tube 20 and outer tube 18 , collar 32 joins circumferential wall 34 at the inner edge of which is sleeve 36 , the inner surface of wall 34 and sleeve 36 are aligned with the inner surface of inner tube 20 to form fluid passage 38 . The outer surface of sleeve 36 forms plug 40 . Female coupling 16 has collar 42 to engage space 50 , collar 42 joins circumferential wall 44 at the outer edge of which is sleeve 46 . the inner surface of wall 44 is aligned with the inner surface of inner tube 20 to form fluid passage 48 . Wall 44 and sleeve 46 together form socket or plug insertion port or plug receiving hole 52 , with edge recess 54 . Plug 40 and socket 52 are dimensioned to matingly engage similar elements on other sections. Couplings 14 and 16 are typically polyurethane foam, although other suitable materials of like properties may be used as known to those skilled in the art. Collars 32 and 42 are typically about 1½ inch deep (approximately 3.8 cm) and 1 inch wide (approximately 2½ cm) to fit into space 50 , itself about 1⅛ inch across (approximately 2.8 or 2.9 cm), wall 34 and sleeve 36 together extend about 2½ inch (approximately 6.3 or 6.4 cm) from the end of tube 12 , as do wall 44 and sleeve 46 . Sleeve 36 is about 1 inch (approximately 2⅛ cm) thick, as is edge recess 54 . Sections 10 are joined together at installation by a suitable compatible plastic adhesive applied between plug 40 and socket 52 . In general tolerances throughout are of the order of ⅛ inch.
[0014] Although the terms “polyethylene,” “polystyrene,” “foam polystyrene,” and “polyurethane” are used, these are illustrative only, as is well understood by those skilled in the art, each of these substances has equivalents of similar properties that can be used instead, and the invention is not restricted to the particular named conventional substances.
[0015] As those skilled in the art would realize these preferred described details and materials and components can be subjected to substantial variation, modification, change, alteration, and substitution without affecting or modifying the function of the described embodiments.
[0016] Although embodiments of the invention have been described above, it is not limited thereto, and it will be apparent to persons skilled in the art that numerous modifications and variations form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention.
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A ventilation chimney or exhaust fan flue section for hog barns has inner and outer plastic tubes formed by edge welding plastic sheets. An snug fitting insulation sheet is slid between the tubes. Collars of male and female coupling elements are inserted into the ends of the section between the inner and outer tubes and secured by screws passing through the outer tube and into the collars. The chimney can be installed by combining sections using a suitable adhesive.
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BACKGROUND OF THE INVENTION
[0001] The existing pressure sensitive ink jet media for various commercial ink jet printers and inks, such as sold by Apple, Hewlett Packard, Canon, Epson and the like, work under the mechanism in which the ink absorption relies principally or partially on the absorption of the ink into voids of substrate fiber and/or silica gel pigment particles, and/or heavy coating thickness. It dries slowly. The print feathers, bleeds, and has low color saturation and poor resolution. The print smears readily, smudges easily, and requires immediate interleaving. The print also has a high water sensitivity and will be washed off upon contact with water such as under outdoor display conditions where it is subject to rain.
[0002] The current market does not offer waterproof aluminum foil/plastic film self-adhesive ink jet media. Due to the fact that these substrates are absolutely non-porous, non-absorbing, non-penetrating to ink jet inks, normal approaches are to increase the coating thickness (e.g., 17 g/m2), using significant loading of porous micro-absorbing white pigment (e.g., silica to resin=63.37), which result in opaqueness and poor resolution.
[0003] The present composition for forming an ink jet receptive coating to a base substrate overcomes the aforesaid problems of the prior art.
BRIEF DESCRIPTION OF THE PRESENT INVENTION
[0004] The present invention provides a water proof ink jet ink-receiving media with a pressure sensitive adhesive (PSA) applied to the back side for sticking to a receiving surface. While it comprises several coating layers applied to conventional substrate (as will be made more clear in FIG. 1), principal inventiveness resides in the composition of pressure sensitive ink jet receptive media. Its component elements provide a medium of excellent receptivity to ink jet printing and generate photorealistic output. The printed ink is fast drying (within a minute). The resulting image has a high resolution, relatively high gloss and exhibits bright, vivid and saturated color gamut. The printed image is free of feathering and bleeding and is resistant to abrasion and scratching as well as being water proof and outdoor weatherproof.
[0005] The ink jet receptive coating (top coating) of the present invention comprises the following components:
[0006] (1) Binder
[0007] The binder's function is to bond pigment particles to one another and to the surface of the plastic or foil substrate stock. The binder determines the viscosity of the coating mix and its drying characteristics. The binder has a great deal to do with the ink acceptance (hence the printability), the smoothing or calendaring properties, water and oil resistance, and the pick strength and foldability of the coated substrate.
[0008] (2) Charge Control Agent
[0009] Conductive polymers are selected to interact with the dye molecules on the ink receptive layer. Hydrophilic cationic homo-polymers or co-polymers having positive charges that are capable of electrically absorbing negatively charged ink jet ink ions are used. The positive charge carried by the conductive polymer attracts the anionic dye ions in the ink and thus functions to localize and fix the dye.
[0010] (3) Cross-Linking Agent
[0011] Inorganic and organic compounds capable of reacting with the primary polymer matrix by forming chemical or hydrogen bonds with its hydroxyl, carboxyl, NH or other functional groups to form a strong linkage are employed. They serve to increase melting point, reduce swelling after immersion in water, waterproof the network and provide abrasion, scratch and smudge/scuff resistance.
[0012] The composition can be self-crosslinking where it has hydroxyl functional groups; or other cross-linking agents such as epoxy, formaldehyde, or glyoxal can be incorporated.
[0013] (4) Adhesion Enhancing Agent
[0014] Gelatin, alpha-olefin such as polyethylene polypropylene, ethylene acrylic acid and poly-acrylic acid may be incorporated in the present composition.
[0015] (5) Dispersant
[0016] Surfactant or wetting agents are employed to reduce the surface tension of the substrate so that the normal coating can be uniformly spread without streaking or other undesirable coating defects. Examples of surfactants include anionic polymers (polyacrylic, lignosulfonate, naphthalene sulfonate), alkali silicates, nonionic polymers (fatty alcohols, ethylene oxide), and various fluorinated surfactants.
[0017] (6) Porous Ink-Absorptive Pigment
[0018] Such pigments may optionally be present where a non-glossy product is desired. In such cases, various fine-grained, micro-porous, negatively or positively charged pigments such as silica gels are preferred.
[0019] The relative proportions of elements in the compositions of the present invention are set forth in Table 1 below with all percentages being on weight basis.
TABLE 1 INK JET RECEPTIVE COATING ESPECIALLY BROAD PREFERRED PREFERRED COMPONENT RANGE RANGE RANGE (1) BINDER 5-40% 10-30% 15-25% (2) CHARGING 20-50% 25-45% 30-40% CONTROL AGENT (3) CROSS- 0.05-3% 0.1-2% 0.2-1% LINKING AGENT (4) ADHESIVE 0.1-5% 0.5-3% 1-2% ENHANCING AGENT (5) DISPERSANT 0.05-3% 0.1-2% 0.5-1% (6) POROUS INK- 0-3% 0.8-2% 0.6%-1% ABSORPTIVE PIGMENT
[0020] The present ink jet receptive coating particularly resolves the difficulty of using non-permeable, non-porous, non-penetrating substrates which are non-absorptive to ink jet inks, such as polyester, styrene, vinyl, polypropylene films, aluminum foil, or metalized plain or holographic plastic films coated on the other side with pressure sensitive substrates. The resulting product is a digital printing medium which is pressure sensitive, self adhesive, and easy to apply.
[0021] The coating of the present invention specifically provides electrical attraction to ink jet ink and maximizes its absorption to the specific substrates utilized. The balance of the composition of the ink-receptive coating attracts and fixes ink. The polymers being utilized exhibit hydrophilic properties and are electrically positive charged and thus have the ability to absorb water and negatively charged ink. The polymers contribute excellent physical properties to the product. They have hydroxyl and/or carboxyl functional groups and can be either self-cross-linked or cross-linked by the addition of epoxy or other hardening agents to obtain necessary water-resistance and anti-abrasion properties.
DRAWINGS
[0022] [0022]FIG. 1 illustrates the overall structure comprising the ink jet receptive product according to the invention which comprises from the top down as illustrated:
[0023] (1) an ink jet receptive coating,
[0024] (2) a primer coating,
[0025] (3) a substrate,
[0026] (4) a pressure sensitive adhesive (hereinafter denoted as PSA) coating,
[0027] (5) a silicone coating, and
[0028] (6) a backer substrate.
DETAILED DESCRIPTION
[0029] Primer Coating
[0030] Before applying the ink jet receptive coating, the substrate surface is coated with a primer coating, which is called a subbing layer in the literature. The primer coating allows the ink receptive coating to form an integral bond with it and to the substrate, thus giving enhanced physical properties (adhesion; scuffing, rubbing and scratch resistance; etc.). These properties are obtained by the addition of an alpha-olefin polymer having 2-10 carbon atoms, e.g., polyethylene, polypropylene, polyethylene acrylic acid, polyacrylic acid, and/or natural polymers, e.g., cow bone gelatin, pigskin gelatin, fish gelatin, with or without cross-linking agents.
[0031] The following provides a further description of the key elements of the ink jet receptive coating:
[0032] 1. Binder
[0033] The binder serves to hold the final coating together after the final coating has been applied to the substrate and dried. Suitable binders include, but are not limited to, gelatin (GEL), gelatin extenders, gelatin derivatives, graft polymers of gelatin, other natural polymers and synthetic hydrophilic colloidal homo-polymer and co-polymer, and aqueous dispersions of hydrophobic homo-polymer and co-polymer. Gelatin includes acid or base treated cow bone gelatin, pigskin gelatin and fish gelatin. Other natural polymers include albumin and casein, sugar derivatives such as cellulose (CEL) derivatives (e.g., hydroxyethyl cellulose, carboxymethyl cellulose, cellulose sulfate and cellulose acetate butyrate), sodium alginate, and starch derivatives. Synthetic polymers include polyvinyl acetate butyrate), sodium alginate, and starch derivatives. Synthetic polymers include polyvinyl alcohol (PVOH), polyvinyl alcohol partial acetal, polyethylene glycol (PEG), poly (2-ethyl-2-oxazoline) (PEOX), polyamides, acrylate derivatives (e.g., polyacrylic acid, polymethacrylic acid, polyacrylamide), polyvinyl imidazole, and polyvinylpyrazole and positively charged polyurethane. Dispersions using hydrophobic polymers such as polyvinylidone chloride, polyethlacrylate, or a hard thermoplastic acrylic co-polymers are applicable, as well. The binder is needed to support and keep the coating from cracking and being frail. As little binder as possible must be used, since the binder takes up space and lowers the micro pore ratio. In addition, to avoid hindering ink absorption, a non-swelling polymer must be selected. If the binder swells, it will block the penetration of ink. The supporting binder is at 20-45% solids. The weight percentage of binder is between 5-40%.
[0034] 2. Charge Control Agent
[0035] The charge control agent refers to electrically conductive compounds, which are mainly focused on ionic polymers and electronically conductive polymers including electrically positively charged conductive homo-polymer or co-polymer. The charge control agents may also be called dye mordants, which are used to fix dyes. Commonly used charge control agents are cationic molecules such as cationic polyamide, polymeric quaternary ammonium compounds and amines, sodium cellulose sulfate, quaternary polyelectrolyte polymers. Hydrophilic cationic homo-polymers or co-polymers, having positive charges are capable of electrically absorbing negatively charged ink-jet ink ions. The positive charge carried by the conductive polymer attracts the anionic dye ions in ink and thus functions to localize and fix the dyes. To perform this function efficiently, the type of the polymer carrying positive charge must be carefully selected to interact with the dye molecules on the ink receptive coating. The use of conductive polymers is disclosed in many patents, such as, for example, U.S. Pat. Nos. 2,882,157, 2,972,535, 6,615,531, 3,938,999, 4,460,679 and 4,960,687 which are incorporated by reference. Poly (vinyl benzyltrimethyl ammonium chloride)(PVBTMAC) and poly (diallyidimethyl ammonium chloride)(PDADMAC), and an aqueous dispersions of positively charged urethane resin are three examples of suitable conductive polymers. The weight percentage of charge control agent is between 20-50%.
[0036] 3. Cross-Linking Agent
[0037] The cross-linking agents of the present invention refer to inorganic and organic compounds which are capable of reacting with the prime polymer matrix by forming a chemical bond or hydrogen bond with its hydroxyl, carboxyl, NH or other functional groups to form strong linkage to increase its melting point, reduce its swell after immersion in water, and to enable the network become water-proof as well as an, abrasion/scratch/smuggler resistant material. Inorganic compounds include aluminum sulfate, potassium and ammonium alums, and zinc ammonium carbonate. Organic compounds serving as a cross-linking agent include activated esters, aldehydes, including formaldehyde, glyoxal, N-methylol, and other blocked aldehyde, aziridines, carbodimides, isoxazolium salts (unsubstituted in the 3 position of the ring), carbonic acid derivatives, carboxylic and carbamic acid derivatives, epoxides, active halogen compounds, ketones, active olefins, blocked active olefins, polymeric compounds such as dialdehyde derivatives of starch and other polysaccharides, quinones, sulfonate esters, sulfonyl halides, s-trizines, and their mixtures. The weight percentage of crosslinking agent ranges from 0.05 to 3%.
[0038] 4. Adhesion Enhancing Agent
[0039] A specific adhesion-enhancing agent is added to the ink jet composition. The agent can be a primer or resin, which is a polymer dispersion exhibiting good affinity for unprimed polyester, styrene, vinyl, polypropylene, aluminum foil or other non-porous, non-ink penetrating substrates. Suitable polymers include, but are not limited to, natural polymers and synthetic hydrophilic colloidal homo-polymers and co-polymer, selected from gelatin (GEL), and aqueous dispersions of hydrophobic homo-polymer and co-polymer. For instance, alpha-olefin polymer, e.g., polyethylene, polypropylene, ethylene acrylic acid, and poly-acrylic acid, are useful in this invention. Gelatin includes acid or base treated cow bone gelatin, pigskin gelatin and fish gelatin. Other natural polymers include albumin and casein, sugar derivatives such as cellulose (CEL) derivatives (e.g., hydroxyethyl cellulose, carboxymethyl cellulose, cellulose sulfate, and cellulose acetate butyrate), sodium alginate, and starch derivatives. Synthetic polymers include polyvinyl include polyvinyl alcohol (PVOH), polyvinyl alcohol partial acetal, polyethylene glycol (PEG), poly (N-vinyl) pyrrolidone (PVP), polyvinyl acetate (PVA), polyethylene oxide (PEO), poly (2-ethyl-2-oxazoline) (PEOX), polyamides, acrylate derivatives (e.g., polyacrylic acid, polymethacrylic acid, polyacrylamide), polyvinyl imidazole, and polyvinyl pyrazole. Dispersions using hydrophobic polymer such as polyvinylidone chloride, polyethlacrylate, or a hard thermoplastic acrylic co-polymer are applicable, as well. The adhesion enhancing agent comprises 0.1 to 5 wt % of the composition.
[0040] 5. Dispersant
[0041] Suitable dispersants are a specific group of surfactants or wetting agents, which reduce the surface tension of the substrates so that the novel coating can be uniformly spread, and well carried out on the specific substrate surface without streaks, pinholes, fish eyes, comet, and other undesirable coating defects (a condition which is termed “mottle”). Ionic and non-ionic surfactants as well as fluorinated surfactants ar disclosed in many patents, such as, for example, U.S. Pat. Nos. 2,600,831, 2,719,087, 2,982,651, 3,026,202, 3,428,456, 3,457,076, 3,454,625, 4,267,265, 4,510,233, 4,847,186 and 4,916,054 and European Patents 245,090 and 319,951, which are incorporated by reference.
[0042] Examples of applicable surfactant include Ninol 96 SL, methyl ester of lauramide DEA, Makon 10, alkoxylate from Stepan Maplofix 563, sodium lauryl sulfonate from Onyx Hostapur SAS 93, secondary alkanesulfonate, sodium salt, from American Hoechst Daxad 11, sodium naphthalenesulfonate-formaldehyde dispersant from Hampshire Igepal, nonyl phenoxy poly(ethyleneoxy)ethanol, Mona-70E, sodium dioctyl sulfosuccinate, Monateric CAB-LC, cocamidopropyl betaine, Monamid 716, lauramide DEA, linear alkylbenzene sulfonate from Mona, Triton X-100, octyl phenoxy polyethoxy ethanol, Triton X-200, alkylaryl polyether sulfonate from Rohm & Haas, Surfynol 104, acetylenic diol (2,4,7,9 tetramethyl-5-decyne-4,7 diol) from Air Products, FC-170C, fluorochemical from 3M, Bio-Soft D-40, sodium dodecyl benzene sulfonate, Slip-Ayd SL-530, polyethylene in 2-butoxythanol from Daniel Products, and Pluronic L-61, polyoxyethylene-polyoxypropylene glycol from BASF.
[0043] The dispersant will comprise 0.05 to 3 wt % of the composition.
[0044] 6. Porous. Ink-Absorptive Pigment
[0045] The component is used where a non-glossy product is desired. Aluminum oxide, alumina hydrate, boehmite, precipitated calcium carbonate, titanium dioxide, fumed silica, precipitated silica, polymethylmeth-acrylate (PMMA), starch, polyterefluoro-ethylene (PTFE) can be used. Better results can be obtained with fine-grained, micro-porous, neutrally or positively charged pigments, for instance, silica gels. Silica gel consists of primary particles of 2-20 nm, which from agglomerates of 2-10 microns; specifically, the grades with higher absorption capacities and cationic serve better. Silica is the only one of the white pigments which available in grade with oil absorption value greater than 100 g oil/100 g pigment. Silica gel is preferred to the other types of silica because of its availability in particular particle sizes, which give a more open coating structure per particle volume, and because the silica gel particles do not break down under shear during mixing operations. Submicron silica gels, average particle size no more than 0.3 micron, with positive zeta potential in aqueous solution or slurry, are preferred. The pigment comprises 0 to 3 wt % of the present coating. When producing a non-glossy product, it typically will comprise 0.8-2 wt % of the composition.
[0046] Base Substrates
[0047] The base substrates can be chosen from a variety of flexible material including the following:
[0048] a. Resin coated papers, for instance, alpha-olefin polymer having 2 to 10 carbon atoms, such as, polyethylene, polypropylene, ethylene-butene co-polymer, etc.
[0049] b. Board.
[0050] c. Fabric.
[0051] d. Supported and non-supported plastic films and tapes, such as cellulose nitrate, cellulose acetate, cellulose acetate butyrate, cellulose acetate propionate, polypropylene, polystyrene, polycarbonate, polyvinyl acetyl, polyethylene, polyvinyl alcohol, terephthalate, with application including gloss, matte, transparent, projectable, holographic, fluorescent, metalized golden, silvery, chrome colored films.
[0052] e. Laminated gold, silver, chrome aluminum foil products may also be used.
[0053] The base substrate is laminated with pressure-sensitive adhesives (PSA) before or after ink jet receptive layer coating is applied.
[0054] Method of Application
[0055] To apply the new coating, various coating methodologies can be utilized. For instance, Meyer rod, bar dipping, slot, air-knife curtain, roll, direct gravure, reverse gravure, three or four roll reverse roll gravure, micro-gravure, spray . . . etc, are applicable. The preferred coating weight is 4-5 grams/m 2 .
[0056] Cross-linking agents or hardeners are added and well mixed into the final solution just before the coating. If gelatin is used, an on-line mixer can be used as a manner of continuous hardener addition with the final solution. The jacket temperature needs to be precisely controlled so that the solution final is maintained at 37-43 degrees C., or 99-110 degrees F., during the entire coating operation.
[0057] Where gelatin is used as a binder, the moving web travels into a chiller and then into a dryer. The chiller causes the gelatin-based coating to gel or solidify. In this manner, the coating is prevented from intermixing during the drying thereof in the dryer. In the dryer, ink jet composition is dried (i.e., the solvent is removed). More precisely, all but residual solvent is removed from the coating, residual solvent is that solvent which is chemically or physically bound to the binder or is otherwise not removable by drying under ambient conditions. In other words, when substantially dry, the solvent content of the binder tends to be in a nearly steady state equilibrium with the environment at ambient temperature, pressure, and humidity. For example, when gelatin is used as the binder, water is normally used as the solvent/carrier fluid for the coating. Depending upon the particular type of gelatin used, the coating is dried in dryer for a period of about 1.5 to 9 minutes, at a temperature of about 60 degrees to 130 degrees F. Residual water typically amounts to between 5% and 20% water, by weight, in substantially dried gelatin, again depending upon the particular type of gelatin used. If synthetic polymer binders are used instead of gelatin, a chiller is not needed. The preferred oven temperature is 170-180° F. (80-85° C.) for 4-5 minutes or equivalent. After the initial drying, the coated roll should be left to stay overnight at room temperature to receive a natural incubation before it can be used for ink jet printing. Coating weight is measured by “cut and weight” technique.
Pressure Sensitive Coating and Silicone Release Liner
[0058] The novel ink jet coated substrate (plastic film, foil, fabric and paper media) described above can be coated directly or indirectly with a pressure sensitive adhesive (PSA) and laminated with a protective silicone coated release backer. Such protective silicone coating backers are well known in the prior art. The resultant product is pressure sensitive.
[0059] The PSA can be applied directly to the backside of the ink jet media or indirectly over the silicone coating on the backer sheet and laminated together, creating a sandwich type construction with the ink jet film on top, the PSA in the middle, and the protective silicone coated backer on the bottom. The overall media construction has previously been described relative to FIG. 1.
[0060] The PSA is formulated from polymers, either in water or solvent based vehicles or radiation curable systems. Polymers useful in formulating water base PSAs are acrylic, vinyl acrylic, styrene acrylic, urethane acrylic and butyl acrylate. Peel adhesion, tack level, creep and shear resistance, viscosity, age resistance, crosslinking, hardness, and softness can be adjusted to a desired end point by selecting the appropriate additives. Similar chemistry is true for solvent based and radiation curable PSA systems.
[0061] Solvent based PSAs offer the greatest variety of formulating opportunities, resulting in a greater variety of possible adhesives. Radiation curable systems are the most limited in variety, and the water base systems are somewhere in between.
Backer and Silicone Coating
[0062] The backer substrate can be polyethylene coated bleached kraft, clay coated kraft, polyester film, polypropylene film, polyethylene film, and polystyrene film, which are coated with a cured silicone resin system. The silicone systems are catalyzed and cross-linked to prevent the silicone from migrating to the adhesive and contaminating its properties. The surface of the backer substrate must have good hold-out properties to prevent absorption of the silicone before drying and curing. The backer substrate and silicone coating are protective layers protecting the PSA and carrying the substrate through the ink jet printer.
Pressure Sensitive Adhesive (PSA)
[0063] The pressure sensitive adhesive is placed on the non-coated side of the substrate. The PSA will allow the ink jet printed copy to be mounted and/or adhered to almost any receiving surface like a wall, window, sign, craft, tile, etc.
[0064] Waterbased, solvent based and radiation curable systems may be use in the present invention. Examples thereof are set forth below.
Waterbased Acrylic Polymer Emulsion, PN-3579-1 H.B Fuller 1530 Lexington Avenue, St. Paul, MN (800) 468-6358 Acrylic Polymer Emulsion, Gelva GME 2234 Solutia, 10300 Olive Blvd, St. Louis, MI Acrylic Polymer Emulsion, 72-9292, National Starch & Chemical Co., 10 Finderne Avenue, Bridgewater, NJ Acrylic Polymer Emulsion, Covinax 222, Franklin International, 2020 Bruck Street, Columbus, OH Acrylic Polymer Emulsion, Phoplex N-500, Rohm & Haas Co. 100 Independence Mall West, Philadelphia, PA Solvent Based Acrylic Polymer Solution, SCC-134B H.B. Fuller, 3530 Lexington Avenue, St. Paul, MN Acrylic Polymer Solution, Gelva GMS 1753, Solutia, 10300 Olive Blvd., St. Luis, MI Acrylic Polymer Solution, Durotak 80-1058, National Starch & Chemical, 10 Finderne Avenue, Bridgewater, NJ Radiation Cured Urethane/Acrylic Polymer 100% Uninax 347-54-3A, manufactured by Solid, Franklin International, 2020 Bruck Street, Columbus, OH
[0065] Coating of PSA
[0066] Water based and solvent based PSAs are commonly coated by the following coating methods:
[0067] a. Meyer rod
[0068] b. Direct and indirect gravure
[0069] c. Knife over-roll
[0070] d. 3 and 4-roll reverse roll coaters
[0071] These coating methods are designed to meter and apply liquid PSAs onto a moving web in a continuous, smooth defect-free matrix. The viscosity of the PSA will vary depending on the coating method. The viscosities for Meyer rod and gravure coatings preferably will be in the range of 100-1500 cps, while that of knife-over-roll and reverse-roll methods are 300-50,000 cps. In most of the cases, the Meyer rod is applied PSA is near 300-1000 cps and reverse-roll at 5,000-8,000 cps. Radiation cured PSAs can also be applied to a moving substrate with various coating methods selecting of which will depend on the rheology of the PSA.
[0072] Drying
[0073] The most common method for drying water and solvent base PSAs on moving substrate is to pass the web through a high efficiency convection drying oven designed with high velocity nozzles and exhaust systems. Length of the oven will depend on the coating weight, temperature, web speed, and evaporation rate of the vehicle's, solvents, and/or water used in the PSA formula. The temperature will vary. However, usually a temperature of 52-93 degrees C. (125 -200 degrees F.) is used at the first stage of the oven and is being gradually and eventually increased to 93-150 degrees C. (200-300 degrees F.) at the last stage of the oven. The final temperature or the temperature of last stage of the oven is dependent on the formula. If the vehicle (or solvent) in the formula has large and bulky molecules, the evaporation rate will be higher, which requires higher drying temperatures. In addition to evaporation of the vehicles, many adhesives require cross-linking where they form a covalent bond between the polymer molecules, improving the cohesive strength and creep resistance. This is an important property for adhesives used in ink jet PSA products. For water based PSA systems, the adhesive polymers take the form of tiny spheres, approximately 10,000 Armstrong in diameter, dispersed in water. The water acts as a vehicle to keep the spheres separated in the dispersion. As the water is evaporated, the spheres begin to come together and coalesce forming a film when the water is completely evaporated. For solvent based systems, as the solvent diffuses through the adhesive polymers, the adhesive forms a film when the solvents are completely evaporated. In either case the drying must provide the heat source to vaporize and remove the vehicle.
[0074] Radiation cured PSAs do not depend on evaporation of vehicles to form a film. Radiation cured adhesives are 100% solid containing monomers, oligomers, photo initiators, and other additives. After they are coated onto a moving substrate and exposed to radiation, the energy causes them to crosslink and polymerize, forming a film.
[0075] Laminating
[0076] After the dried and cured adhesive exits the oven, it goes directly to a lamination station where the ink jet coated media substrate is laminated to a silicone release liner between a rubber and steel roll. In the case where the PSA is coated directly on to the backside of the media substrate, the adhesive stays where it is. In the case where the PSA is coated over the silicone coating of the backer substrate, the adhesive will transfer to the back of the media substrate upon lamination. In both cases, it will form a final structure where the media coating stays on the top, a PSA coating bonded to the backside of the media substrate and is in the middle, and a silicone coated backer protecting the PSA is on the bottom. In application, the backer substrate will be removed to expose the PSA when the printed media is applied and adhered to a receiving surface.
Testing
[0077] The following test procedures were employed in evaluating the product of the present invention.
[0078] (1) Printing
[0079] Print the media with Apple, IIP, Canon, or Epson Ink Jet printers with test patterns containing colored blocks (cyan, magenta, yellow, red, green, blue and black). The black ink may be composite or separate component, the setting is photo quality ink jet paper or transparencies, at 1440 dpi or lower.
[0080] Drying time: record ink drying time right after the printing.
[0081] Waterproof test: leave under running tap water for two hours.
[0082] Smudge test: under tap water, smudge the image using a finger.
[0083] (2) Coating Adhesion: Use 3M 601-tape to perform adhesion test between ink receptive coating and the substrate.
[0084] Pressure Sensitive Peel Adhesion (180 degree angle):
[0085] Use a Tensile Tester for example an Instron Model 1011 to measure. Peel adhesion measures the force to remove a pressure sensitive adhesive from a stainless steel panel at a specific width, angle and speed. The adhesive is applied at a standard 4 pound pressure to a stainless steel panel as a 1″ wide strip. The force to peel the strip away at 900 or 1800 angle from the stainless steel panel is expressed in grams per inch or grams/cm.
[0086] Release Properties PSTC #4: A Tensile Tester is used to measure the force required to peel the pressure senstitive adhesive away from the silicone coated backer (PSTC #4). The PSTC #4 test is performed the same as the PSTC #1 and the results are expressed the same.
[0087] The Pressure Sensitive Tape Council (PSTC), a manufacturers' trade association, has several tests for measuring peel, e.g., peel adhesion (PSTC #1) at 180° degree angle, Adhesion to Liner (PSTC #4) of Pressure Sensitive Tapes at 180° angle.
EXAMPLES
Example 1
[0088] The following components were mixed at room temperature to form the ink jet receptive composition. 1 gram of slurry or aqueous dispersed silica gel, average size at 0.3 micron with a positive zeta potential, (commercially available from Grace Division), was added to 6 grams of OF-280, a cationic co-polymer, dimethyl-diallyl-ammonium chloride/acrylic acid with 80/20 ratio and 35% activity molecular weight 250-400K, commercially available from Calgon Company), under agitation. 32 grams of IJ-2, positively charged polyurethane (commercially available from Esprit Company) were then added and well mixed. 35 grams of tap water were added. 8 grams of 10% aqueous solution of Daxad 11, Sodium napthalenesulfonate-formaldehyde dispersants (commercially available from Hampshire Corporation) were added afterwards.
[0089] Two grams of Lucidene 901 polyethylene acrylic acid (commercially available from Morton Corporation) were then added to the mixture. 2.2 grams of Carboset GA-33, acrylic dispersion having less carboxyl function group in the molecule, (available from BF Goodrich) were then mixed in. 20 grams of second tap water were finally added to the mixture. Right before coating, 0.2 grams of CR-5L a cross-linking agent from Esprit Company, were added and mixed. Then 19.51 grams of 0.4% Glyoxal HCOCHO dialdehyde, (commercially available from Aldrich Fine Chemicals Company) were added to the final composition. The pot life was about 24 hours. A #18 Meyer rod was used to hand-coat the mixture. The substrate was Fasson pressure sensitive laminated foil, 55# bright gold no score/no black-print with super permanent adhesive. The coating was oven dried at 170° F. for 4 minutes and then incubated at room temperature overnight. The coating was printed in the Epson stylus color 850 under the setting of “Photo Quality Ink Jet Paper with microwave on, and HT (Error Diffusion), then at the resolution of 1440 dpi. A custom setting with auto adjustment to maximum contrasting and saturation was used. Testing results showed that the image was dried in less than 1 minute. The print was placed under the running tap water for 2 hours; no washout was observed. The print was tested for finger smudging. It was not damaged in any way. It was proven to be water-fast, smudge, scrub, and scratch resistant. The adhesion between the ink receptive coating and the substrate was tested as acceptable.
[0090] Release properties were measured at:
[0091] Liner to Foil/Film:
[0092] PSTC-4=8.33 grams/2″
[0093] PSTC-4 (24 HR)=11.33 grams/2″
[0094] The results were within the specifications.
Example 2
[0095] Part A:
[0096] 600 grams of poly (diallyldimethylammonium chloride), commercially available from Aldrich, 20% by weight in water, average molecular weight 400-500K, under vigorous agitation were mixed with 3200 grams of IJ-2 (commercially available from Esprit Company), 3500 grams of distilled water were then added after 800 grams of 10% by weight aqueous solution of Triton X-100, Polyoxyethylene-polyoxypropylene glycol, a wetting agent, (commercially available from Rohm & Haas Company), were added afterwards. 20 grams of Pruronic L-61, Octylphenoxypolyethoxyethanol nonionic surfactant, a defoamer, (commercially available from BASF Corporation), were added to the mixture. 200 grams of Carboset CR-761 (commercially available from BF Goodrich Company), were added to the mixture 20 grams of CR-5L, an aliphatic epoxy compound (commercially available from Esprit), were added.
[0097] Part B:
[0098] 600 grams of pigskin pharmaceutical grade gelatin, 11337 Type 56, (commercially available from SKW Biosystems), was soaked in 2000 grams of cold distilled water for 30 minutes. The temperature was raised to 40 degrees C. or 104 degrees F. and the solution was agitated for another 30 minutes.
[0099] Coating Final: at 40 degrees C. or 104 degrees F., part A was mixed with part B.
[0100] In-line Mix: using a stationary mixer at weight ratio =60 mL/min of coating final to 11 mL/min of 10% aqueous solution of GXL-100, pyridinium, 1-[(dimethylamino)-carbonyl]-4-(2-sufoethyl); inner salt (commercially available from Esprint). A slot coating station was used. The coating speed was 300 fpm. The coating temperature was maintained at 37-43 degrees C. (99-110 degrees F.). The drying paths included a chill zone, several low temperature zones, medium temperature zones, high temperature zones (up to 77 degrees C. or 170 degrees F.), and a balance zone (see the drying description in the ink receptive coating part of this application) with a total length of 100 meters (328 feet).
[0101] The substrate was VA bright silver 80#, ½ mil aluminum foil with a vinyl acrylic lacquer coating laminated to bleached kraft, commercially available from Alufoil Products Company. The substrate was a pre-coated using a slide coating station with water base sulphonated polyester dispersion to give ⅓ mil dry thickness.
[0102] UV curable pressure sensitive adhesive, Uninax 347-54-3A, a 100% solids UV curable urethane acrylate polymer, containing 36.2% by weight urethane acrylate oligomer, and 30.5% acrylic monomers, (commercially available from Franklin International) was coated by the same methodology to give a thickness of 0.4 mil on the backer substrate. A radiation curing device with two 200 Watt UV lamps at vertical distance of one inch above the web was used for the polymerization. The cured adhesive was carried directly to a lamination station where the ink jet substrate was coated and laminated to a silicone release liner between a rubber and steel roll. It formed a final structure where the media coating stayed on the top, a PSA coating bonded to the backside of the media was in the middle, and a silicone coated backer, protecting the PSA, was on the bottom.
[0103] The dried coating roll was incubated at room temperature for 1 week. The coating was printed in an HP ink jet printer 895 Cse, under the setting of “Ink Jet Transparencies” at the resolution of 700 dpi. The print was placed under running tap water for two hours. No washout was observed. The image was tested for finger smudging. The print was not damaged in any way. It was proven to be water-fast, smudge, scrub, and scratch resistant.
[0104] The adhesion between the ink receptive coating and the substrate was tested acceptable.
[0105] Peel adhesion properties were measured at PSTC #1=1000-1200 grams/in.
[0106] Release properties were measured at:
[0107] PSTC-4=7.8 grams/2″
[0108] PSTC-4 (24 Hr)=12.3 grams/2″
[0109] The results were within the specifications.
[0110] As indicated above, the present invention provides a medium for receiving ink jet printing which offers excellent receptivity and photorealistic output. The resulting image has high resolution, bright color and is free of feathering and bleeding as well as resistant to water and can be adhered to almost any receiving surface like an outside poster or sign.
[0111] Various modifications can be made by those skilled in the art without departing from the spirit of the present invention. Accordingly, reference would be made to the following claims to determine the full scope of the invention.
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The problems of applying ink jet inks to various known coating surfaces so as to overcome smearing, poor resolution and attack by water etc., is overcome by the use of the new ink jet receptive media. The media comprises in combination: (1) a waterproof ink jet receptive coating, (2) a primer coating, (3) a non-porous substrate, (4) a pressure sensitive adhesive coating, (5) a silicone coating and (6) a backer layer. The receptive coating comprises the combination of: (1) binder, (2) charge control agent, (3) cross-linking agent, (4) adhesion enhancing agent and (5) dispersant. The absorption of the ink jet ink to the substrate is maximized, thus attracting and fixing the ink and providing a waterproofing effect.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2013-0096456, filed on Aug. 14, 2013, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The following disclosure relates to an impeller for a fuel pump of a vehicle. More particularly, the following disclosure relates to an impeller for a fuel pump of a vehicle capable of decreasing a magnitude of high frequency fluid noise due to high speed rotation of the impeller by improving shapes of impeller blades positioned between upper and lower casings of the fuel pump and coupled to a shaft of a driving motor to deliver a fuel by rotational force in sucking the fuel from a fuel tank and supplying the fuel to an engine of an internal combustion engine.
BACKGROUND
[0003] Generally, a fuel pump of a vehicle is mounted in a fuel tank of the vehicle and serves to suck a fuel and forward the fuel to a fuel injection device mounted in an engine.
[0004] In addition, the fuel pump of the vehicle is classified into a mechanical fuel pump and an electrical fuel pump, and a turbine type fuel pump 10 , which is a kind of electrical fuel pump, is mainly used in an engine using gasoline as the fuel.
[0005] The turbine type fuel pump 10 is configured to include a driving motor 20 disposed in a motor housing 60 thereof, upper and lower casings 30 and 40 disposed at a lower end portion of the motor housing 60 and closely adhered to each other, and an impeller 50 disposed between the upper and lower casings 30 and 40 , as shown in FIG. 1 . In addition, the impeller 50 is coupled to a shaft 21 of the driving motor 20 to thereby be rotated together with the driving motor 20 .
[0006] That is, as the impeller 50 is rotated, a pressure difference is generated, such that a fuel is sucked in the impeller 50 , and pressure of the fuel rises by a rotational flow generated by continuous rotation of the impeller 50 , such that the fuel is discharged.
[0007] Therefore, the fuel is introduced into a fuel inlet 41 of the lower casing 40 and then passes through the rotating impeller 50 , such that pressure of the fuel is raised. Then, the fuel flows to a check valve 70 formed at an upper portion of the motor housing 60 along an inner portion of the motor housing 60 through a fuel outlet 31 of the upper casing 30 and is then supplied to a fuel injection device mounted in an engine of a vehicle.
[0008] Here, the impeller 50 includes several blades 51 formed in a disk shape in an outward direction of a circumferential surface thereof along the circumferential surface thereof and blade chambers 52 formed between the respective blades 51 so as to penetrate through both surfaces of the impeller 50 as shown in FIG. 2 , and the fuel is introduced into the fuel inlet 41 of the lower casing 40 , such that a rotational flow is generated in a space between the blade chamber 52 and a lower flow passage groove 42 formed in the lower casing 40 and an upper flow passage groove 32 formed in the upper casing 30 and a circulation process in which the fuel is introduced into a blade chamber 52 adjacent to the blade chamber 52 to generate the rotational flow is repeated to convert kinetic energy due to the rotation of the impeller 50 into pressure energy of the fuel, such that the fuel is delivered to the fuel outlet 31 of the upper casing 30 , as shown in FIG. 3 .
[0009] Further, the impeller 50 according to the prior art includes a circumference center guider 53 formed at the center of the circumferential surface thereof along the circumferential surface thereof, thereby making it possible to efficiently generate the rotational flow formed in a space between the blade chamber 52 and the lower flow passage groove 42 and the rotational flow formed in a space between the blade chamber 52 and the upper flow passage groove 32 .
[0010] However, the fuel introduced into the fuel inlet 41 flows along the lower flow passage groove 42 of the lower casing 40 and then flows the upper flow passage groove 32 of the upper casing 30 through the blade chamber 52 at an end of the lower flow passage groove 42 . In this case, impact of a fluid is generated in the blade chamber 52 due to the fuel passing through the blade chamber 52 , such that high frequency noise is generated.
[0011] As the prior art related to this, Korean Patent Laid-Open Publication No. 2012-0113332 entitled “Impeller for Fuel Pump of Vehicle” has been disclosed.
PRIOR ART DOCUMENT
Patent Document
KR 2012-0113332 A (2012 Oct. 15)
SUMMARY
[0012] An embodiment of the present invention is directed to providing an impeller for a fuel pump of a vehicle capable of decreasing a magnitude of high frequency fluid noise due to high speed rotation of the impeller by forming upper and lower blades of impeller blades positioned between upper and lower casings of the fuel pump and coupled to a shaft of a driving motor to deliver a fuel by rotational force so as to have asymmetrical angles based on the center of a thickness of an impeller body.
[0013] In one general aspect, an impeller 1000 for a fuel pump of a vehicle includes: an impeller body 100 having a disk shape and having a shaft fixing hole 120 at the center thereof so as to penetrate therethrough so that a shaft of a driving motor is inserted thereinto and coupled thereto; and a plurality of blades 200 formed at predetermined intervals along an outer circumferential surface of the impeller body 100 and formed in an outward direction of the circumferential surface, wherein each of the blades 200 includes an upper blade 200 a formed at an upper side of the impeller body 100 in a thickness direction and a lower blade 200 b formed at a lower side of the impeller body 100 in the thickness direction, and an angle a of the upper blade 200 a is larger than an angle b of the lower blade 200 b.
[0014] The angle a of the upper blade 200 a may be larger than the angle b of the lower blade 200 b by 3 to 5 degrees.
[0015] A sum of the angle a of the upper blade 200 a and the angle b of the lower blade 200 b may be 90 to 100 degrees.
[0016] A height h1 of the upper blade 200 a may be the same as a height h2 of the lower blade 200 b.
[0017] The impeller for a fuel pump of a vehicle may further include a side ring 300 formed on outer circumferential surfaces of the plurality of blades 200 so as to form blade chambers 210 allowing discharge and introduction of a fuel to be made at upper and lower sides of the blade 200 , respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a cross-sectional view showing a schematic configuration of a fuel pump of a vehicle according to the prior art.
[0019] FIG. 2 is a perspective view showing a structure of an impeller according to the prior art.
[0020] FIG. 3 is a partial cross-sectional view showing an impeller and upper and lower casings according to the prior art.
[0021] FIG. 4 and FIGS. 5A and 5B are, respectively, a perspective view and a partially enlarged view showing an impeller for a fuel pump of a vehicle according to the present invention.
[0022] FIGS. 6A and 6B are front views showing a cross section of an impeller blade according to the present invention.
[0023] FIGS. 7 and 8 are experimental graphs and data showing a comparison result between noise and pump efficiency of an example of an impeller in which an angle of an upper blade is the same as that of a lower blade according to the prior art and noise and pump efficiency of an example of an impeller in which an angle of an upper blade is larger than that of a lower blade according to the present invention.
[0024]
[0000]
[Detailed Description of Main Elements]
1000: Impeller for fuel pump of vehicle
100: Impeller body
110: Circumference center guider
120: Shaft fixing hole
200: Blade
200a: Upper blade
200b: Lower blade
210: Blade chamber
220: Blade center guider
300: Side ring
400: Lower flow passage groove
500: Upper flow passage groove
DETAILED DESCRIPTION OF EMBODIMENTS
[0025] Hereinafter, an impeller for a fuel pump of a vehicle according to the present invention as described above will be described in detail with reference to the accompanying drawings.
[0026] FIG. 4 and FIGS. 5A and 5B are, respectively, a perspective view and a partially enlarged view showing an impeller for a fuel pump of a vehicle according to the present invention, and FIGS. 6A and 6B are front views showing a cross section of an impeller blade according to the present invention.
[0027] FIGS. 4 to 6B , an impeller 1000 for a fuel pump of a vehicle according to the present invention is configured to include an impeller body 100 having a disk shape and having a shaft fixing hole 120 at the center thereof so as to penetrate therethrough so that a shaft of a driving motor is inserted thereinto and coupled thereto; and a plurality of blades 200 formed at predetermined intervals along an outer circumferential surface of the impeller body 100 and formed in an outward direction of the circumferential surface, wherein each of the blades 200 includes an upper blade 200 a formed at an upper side of the impeller body 100 in a thickness direction and a lower blade 200 b formed at a lower side of the impeller body 100 in the thickness direction, and an angle a of the upper blade 200 a is larger than an angle b of the lower blade 200 b.
[0028] The impeller body 100 is formed in the disk shape and has the shaft fixing hole 120 formed at the center thereof.
[0029] In addition, the plurality of blades 200 are formed in the outward direction of the circumferential surface of the impeller body 100 at predetermined intervals along the circumferential surface of the impeller body 100 and have blade chambers 210 formed therebetween. That is, the blade chamber 210 is a space formed between two adjacent blades 200 .
[0030] Here, the blade chamber 210 has a fuel introduced thereinto when the impeller is rotated to generate rotational flows between upper and lower flow passages grooves 500 and 400 each formed in upper and lower casings formed at upper and lower sides of the impeller so as to correspond to positions of the blade chamber 210 , such that pressure of the fuel is raised.
[0031] Here, the respective blades 200 are formed in the thickness direction of the impeller body 100 and has a shape of “<”. Here, each of the blades 200 includes the upper blade 200 a formed at the upper side of the impeller body 100 in the thickness direction and the lower blade 200 b formed at the lower side of the impeller body 100 in the thickness direction, and the angle a of the upper blade 200 a is larger than the angle b of the lower blade 200 b.
[0032] That is, as shown in FIGS. 6A and 6B , an inclined angle a of the upper blade 200 a formed at an upper side based on a reference line SL is different from an inclined angle b of the lower blade 200 b formed at a lower side based on the reference line SL, such that the upper blade 200 a has a form in which it relatively slightly stands and the lower blade 200 b has a form in which it relatively slightly lies.
[0033] Therefore, the fuel introduced into a fuel inlet of the lower casing flows along the lower flow passage groove 400 of the lower casing and then flows to the upper flow passage groove 500 of the upper casing through the blade chamber 210 at an end of the lower flow passage groove 400 . Here, impact of a fluid due to the fuel passing through the blade chamber 210 is decreased by the inclined angles of the upper and lower blades 200 a and 200 b , such that high frequency noise is decreased.
[0034] In addition, flow energy loss of the fluid is decreased due to the decrease in the impact of the fluid, such that pumping efficiency is improved.
[0035] In addition, FIGS. 7 and 8 are experimental graphs and data showing a comparison result between an example of an impeller in which an angle of an upper blade is the same as that of a lower blade according to the prior art and an example of an impeller in which an angle of an upper blade is larger than that of a lower blade according to the present invention. As shown in FIGS. 7 and 8 , it may be appreciated that in the impeller according to the present invention, high frequency noise is decreased as compared with an impeller according to the prior art, and pump efficiency is increased as compared with an impeller according to the prior art.
[0036] Here, it is preferable that the angle a of the upper blade 200 a is larger than the angle b of the lower blade 200 b by 3 to 5 degrees.
[0037] That is, when a difference between the inclined angles is excessively small, an impact decrease effect of the fluid may be decreased, and when the difference between the inclined angles is excessively large, a flow resistance of the fluid is increased, such that pumping efficiency may be decreased. Therefore, the upper and lower blades need to be formed in a range of a predetermined angle difference.
[0038] In addition, it is preferable that the sum of the angle a of the upper blade 200 a and the angle b of the lower blade 200 b is 90 to 100 degrees.
[0039] That is, when the sum c of the angles formed by the upper and lower blades 200 a and 200 b based on the reference line SL is excessive small or large, pumping performance and efficiency may be deteriorated. Therefore, the upper and lower blades also need to be formed at an appropriate angle.
[0040] In addition, a height h1 of the upper blade 200 a may be the same as a height h2 of the lower blade 200 b.
[0041] Since a circumference center guider 110 may be formed in a protrusion form along the center of the circumferential surface in the impeller body 100 , the upper blade 200 a formed at an upper side based on the circumference center guider 110 formed at the center of a thickness of the impeller body 100 and the lower blade 200 b formed at a lower side based on the circumference center guider 110 may have the same height as each other.
[0042] In addition, each of the plurality of blades 200 may include a blade center guider 220 formed in a protrusion form at the center thereof in a radial direction on a surface thereof in a direction in which the impeller is rotated, wherein the blade center guider 220 may be connected to the circumference center guider 110 . The fuel introduced into the blade chamber 210 more efficiently generates rotational flows at each of upper and lower portions of the blade chamber 210 by the circumference center guider 110 and the blade center guider 220 as described above, thereby making it possible to improve the pumping performance. At the same time, the impact of the fluid passing through the blade chamber 210 is decreased, thereby making it possible to decrease the high frequency noise.
[0043] Here, the impeller as described above is an impeller applied to an open channel type vehicle fuel pump in which several blades 200 are formed at the impeller body 100 , such that all of an upper side, a lower side, and an outer side of the blade chamber 210 are opened. That is, in the open channel type vehicle fuel pump, the fuel introduced into the blade chamber 210 is pushed in the outward direction of the circumferential surface of the impeller body 100 by the rotation of the impeller, such that the rotational flow is formed.
[0044] Here, the impeller 1000 for a fuel pump of a vehicle according to the present invention may further include a side ring 300 formed on outer circumferential surfaces of the plurality of blades 200 so as to form the blade chambers 210 allowing discharge and introduction of the fuel to be made and allowing the rotational flows to be formed at the upper and lower sides of the blade 200 , respectively.
[0045] That is, the impeller 1000 for a fuel pump of a vehicle according to the present invention may be applied to a side channel type vehicle fuel pump in which the upper and lower sides of the blade chamber 210 are opened and the outer side thereof is closed by the side ring 300 , such that the discharge and the introduction of the fuel are made at only the upper and lower sides of the blade chamber 210 .
[0046] Therefore, in the side channel type impeller in which an entire introduced fuel passes through the blade chamber 210 and is then discharged, when the upper and lower blades 200 a and 200 b are formed at different angles to decrease the impact of the fluid, the high frequency noise may be further decreased.
[0047] In addition, the side ring 300 includes a guider formed in a protrusion form at the center thereof along an inner circumferential surface thereof and corresponding to the circumference center guider 110 formed on the outer circumferential surface of the impeller body 100 , thereby making it possible to allow the rotational flow of the fuel to be more efficiently generated in the blade chamber 210 .
[0048] In the impeller for a fuel pump of a vehicle according to the present invention, a magnitude of high frequency fluid noise due to high speed rotation of the impeller may be decreased.
[0049] In addition, the flow energy loss of the fluid is decreased due to the decrease in the impact of the fluid, such that pumping efficiency is improved.
[0050] The present invention is not limited to the above-mentioned exemplary embodiments but may be variously applied, and may be variously modified by those skilled in the art to which the present invention pertains without departing from the gist of the present invention claimed in the claims.
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Provided is an impeller for a fuel pump of a vehicle capable of decreasing a magnitude of high frequency fluid noise due to high speed rotation of the impeller by upper and lower blades of impeller blades positioned between upper and lower casings of the fuel pump and coupled to a shaft of a driving motor to deliver a fuel by rotational force so as to have asymmetrical angles based on the center of a thickness of an impeller body in sucking the fuel from a fuel tank and supplying the fuel to an engine of an internal combustion engine.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to apparatus and methods for testing the depth of structures such as foundations using parallel seismic testing with a cone penetrometer to house the receiving element.
[0003] 2. Description of the Prior Art
[0004] Parallel Seismic (PS) testing has been employed for such uses as determining the depth of an unknown foundation when the foundation top is not accessible or when the piles are too long and slender to be tested by echo techniques. Typically a borehole is drilled into the soil adjacent to the foundation, and the borehole is cased. In the case where the receiver is a hydrophone, the cased borehole is filled with water. In the case where the receiver is a geophone, several geophone receiver components are spaced apart in the borehole.
[0005] An exposed portion of the foundation is then impacted with a hammer or the like, and compression or flexural waves travel down the foundation and are transmitted into the surrounding soil. The receiver detects the transmitted signals. The depth of the foundation is indicated by a weaker and slower signal arrival below the tip of the foundation.
[0006] Parallel seismic testing is expensive and time consuming because the borehole must be drilled and cased (or at least braced in the case of a geophone receiver).
[0007] Cone penetrometers have been used to test soil conditions. For example, Hogentogler & Co., Inc. builds a variety of commercially available cone penetrometer testers (CPTs) such as their Electronic Subtraction Cone CPTs. These units include cone tips each housing a strain gauge transducer and electronics for computing the detected strain and providing it to the user. Tips housing other transducers are also available. The CPT is mounted on a truck or track system, which includes, for example, hydraulic cylinders for driving the CPT cones into the earth.
[0008] A need remains in the art for apparatus and methods for doing parallel seismic testing in a quicker, more convenient manner.
SUMMARY
[0009] The present invention comprises three important elements:
(1) a cone penetrometer which houses a receiver; (2) an impactor to impact the structure; and (3) data gathering and analyzing equipment.
[0013] In the case where the receiver is a hydrophone, the hydrophone is embedded in the cone penetrometer head, and is exposed to water by a retractable sleeve or openings in the penetrometer casing prior to running tests. In the case where the receiver is a geophone or accelerometers, the retracting or perforated outer casing is not required.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 (prior art) is a side schematic view of a conventional parallel seismic testing device.
[0015] FIG. 2 (prior art) is a side schematic view of a conventional cone penetrometer.
[0016] FIG. 3 is a side schematic view of a parallel seismic testing device utilizing a cone penetrometer according to the present invention.
[0017] FIGS. 4A-4C show preferred embodiments of the tester of FIG. 3 , with a variety of receivers.
[0018] FIG. 5A is a plot of sample data received by the processor of the tester of FIG. 3 . FIGS. 5B and 5C illustrate two data points in the plot of FIG. 5A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] FIG. 1 (prior art) is a side schematic view of a conventional parallel seismic testing device. Foundation 101 (or some element connected to the top of the foundation, such as a pile cap) is impacted by impactor 102 (a hammer or the like). Impact hammer 102 is typically an instrumented three pound hammer producing 2000-5000 pounds of force. The instruments record (among other things) the impact time (T 0 ) of the impactor, so that the propagation time of waves 110 can be measured. An alternative hammer 102 might comprise a steel sledge hammer, three to eight pounds, with an accelerometer mounted next to the impact location to record the impact time.
[0020] Compressional, shear, or flexural waves 110 travel down through foundation 101 and are transmitted into the surrounding soil 112 . Borehole 104 is drilled out and the drill bit removed. Borehole 104 may be cased or braced. Receiver 103 is lowered into borehole 104 . Borehole 104 must be cased if receiver 103 is a hydrophone, because it is filled with water. It may be cased or otherwise braced if receiver 103 is a geophone, to prevent soil from caving in. The transmitted signals are received by receiver 103 and provided to a processor 105 .
[0021] Processor 105 analyses the signals in the time domain and identifies direct arrival times of compression and shear waves, as well as their amplitudes. Generally the tests are performed every one to three feet within bore hole 104 . Parallel seismic tests can be performed on concrete, wood, masonry, and steel foundations. Processor 105 is typically a computerized data collection system capable of collecting time domain waveforms at a sample rate of 20 microseconds per point or faster. Typical data traces are 1000-4000 points long, with one set of traces collected per hammer impact.
[0022] Typically, a sets of tests are performed at each probe depth, with all waveforms averaged together (about two to eight waveforms) to complete one test set per probe depth. A test set would consist of an averaged impact time trace (for the signal start time) and an averaged receiver time trace.
[0023] FIG. 2 (prior art) is a side schematic view of a conventional cone penetrometer tester (CPT) 201 . CPT unit 204 is a van which houses and transports the CPT equipment 201 , including hydraulic cylinders, mounted on a framework, driving push rods 203 , which are threaded together as needed to achieve the desired depth. Push rods 203 drive the CPT cones (probe tips) 202 into the earth 112 . Instrumented cone 202 is driven into the soil 112 to be tested. The instruments might determine pore pressure, tip resistance, and sleeve resistance for bearing and skin friction value determination. CPT 201 can also be used in a seismic piezocone test, wherein the earth is impacted and compressional and shear wave energy is measured by accelerometers or geophones in the cone. A plastic casing can be installed by pushing a dummy tip to the desired location, and then leaving the internal casing in the ground as the rods 203 are withdrawn.
[0024] FIG. 3 is a side schematic view of a parallel seismic testing device utilizing a cone penetrometer 301 according to the present invention. Rather than drilling a borehole and casing or bracing it, the cone penetrometer directly delivers the receiver 302 to the right depth. The cone 310 housing receiver 302 is steadily driven into the soil generally parallel to the shaft 303 to be measured. In this patent, the terms “shaft” and “foundation” are used interchangeably, and are defined to include foundations, piles, piers, caissons, footings, or other element of which the depth is to be measured. The shaft to be measured is typically formed of concrete, timber, steel, and/or masonry.
[0025] In one specific embodiment which has been implemented, a Hogentogler & Co. Electronic Subtraction Cone including a Seismic Electronic Cone Penetrometer was pushed into soil adjacent to a foundation element to be tested with a Hogentogler CPT unit mounted on Caterpillar tracks. The CPT used two double acting hydraulic cylinders coupled by a platen that pushed and pulled the push rods connected to the cone.
[0026] Periodically, as the cone 310 is being driven downward into the soil, foundation 303 is impacted by impactor 304 (a hammer or the like). Compressional, shear, or flexural waves 110 travel down through foundation 303 and are transmitted into the surrounding soil 305 . The transmitted signals are received by receiver 302 and provided to a processor 306 . Processor 306 analyses the signals in the time domain and identifies direct arrival times of compression and shear waves, as well as their amplitudes.
[0027] FIG. 4A shows a side schematic drawing illustrating one preferred embodiment of testing device 301 , which utilizes a hydrophone 302 A for receiver 302 . Periodically during the time cone 310 is being driven into the soil, the pushing element pauses and allows metal cone penetrometer tip 307 A to open and withdraw slightly to uncover plastic inner casing 308 . Inner casing 308 is filled with water surrounding hydrophone 302 A. Shaft 303 is impacted and hydrophone 302 A measures the arrival time of the generated waves in the soil. Then tip 307 A lowers and surrounds casing 308 and cone 310 continues its journey into the soil.
[0028] FIG. 4B shows a second embodiment which utilizes a geophone 302 B as the tip transducer to act as the receiver. A geophone measures movement or vibrations of the surrounding earth, for example by using the motion of a spring supported coil in the field of a permanent magnet to generate an output signal. FIG. 4C illustrates a third embodiment of the present invention which includes an accelerometer 302 C as a receiver. An accelerometer measures acceleration, for example by measuring the displacement of a mass connected to a spring. In the case where a geophone or an accelerometer is used, tip 307 B, 307 C does not generally need to be retracted while the measurement is made. The movement (pushing) of cone 310 may be paused while each measurement is made, or the measurements may be taken while the cone is moving.
[0029] In all cases, receiver 302 is detecting the arrival of waves 110 which have travelled down shaft 303 and transmitted through the soil. The amount of time between the impact and the detection of the wave is used to detect where the shaft ends, as is shown in FIG. 5 .
[0030] FIG. 5A is a plot of sample data received by processor 306 . Arrival time T increases slowly with depth until the end of foundation 303 is reached. Then arrival time increases much more quickly. As shown in FIG. 5B , time T 1 is measured before the end of the shaft is reached, so it is on the shallow part of the curve. As shown in FIG. 5C , time T 2 is measured after tip 302 has extended beyond the end of the shaft, so it is on the steep part of the the curve. Other analysis may also be performed, including amplitude and phase of signals sensed above, at and below the foundation bottom to determine its depth.
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A parallel seismic tester utilizing a cone penetrometer to test the depth of a foundation or the like comprises three important elements: the cone penetrometer which houses a receiver, an impactor to impact the structure, and data gathering and analyzing equipment. The receiver may comprise a hydrophone, a geophone, or accelerometers. In the case where the receiver is a hydrophone, the hydrophone is embedded in a plastic, water filled container within the cone penetrometer head, and the head retracts prior to running tests.
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BACKGROUND
The present invention relates to semiconductor integrated circuits, and in particular, to a semiconductor integrated circuit that incorporates a phase-locked loop (PLL) circuit and a plurality of clock and data recovery (CDR) circuits for synchronization of clocks used in a plurality of serial transmission channels.
In the network field, a transmission technology based on serial transmission has been developed. Currently, serial transmission in the network field mainly uses a technique of embedding clock information (encoded data) in a series of data, transmitting the data at the transmitting side and decoding a clock from the transmitted data at the receiving side for synchronization between transceivers.
Network devices usually include PLL circuits and CDR circuits in order to synchronize clocks between remote places connected over a network.
FIG. 7 is a block diagram of a known conventional PLL circuit. A PLL circuit 70 includes a phase-frequency detector (PFD) 71 , a charge pump (CP) 72 , a loop filter (LF) 73 , a voltage-to-current converter (V-I) 74 , an oscillator (OSC) 75 , and a frequency divider (DIV) 76 . When a reference clock REFCLK is externally input to the PLL circuit 70 , the phase frequency detector 71 compares the reference clock REFCLK to a divided signal DIVCLK into which the frequency of an oscillation output signal GCLK from the oscillator 75 is divided to detect the phase and frequency differences therebetween. The phase frequency detector 71 outputs an up pulse signal UP or a down pulse signal DOWN to the charge pump 72 , depending on the phase difference and frequency difference. The charge pump 72 charges or discharges the loop filter 73 on the basis of the up pulse signal UP or the down pulse signal DOWN. A control voltage VTUNE determined by an electric charge stored in a capacitance of the loop filter 73 is converted into a frequency control current ICTRL in the voltage-to-current converter 74 . The frequency control current ICTRL is used to control an oscillation frequency of the oscillator 75 .
In this way, the phase difference and the frequency difference between the reference clock REFCLK and the oscillation output signal GCLK from the oscillator 75 are detected, and in accordance with the detected values, the oscillation frequency of the oscillator 75 is repeatedly changed, so that the phase and frequency of the reference clock REFCLK and the phase and frequency of the oscillation output signal GCLK are synchronized with each other.
FIG. 8 is a block diagram of a conventional serial-to-parallel converter (S/P) for converting serial data into parallel data by using a CDR circuit. As shown in FIG. 8 , a serial-to-parallel converter 80 includes a deserializer 84 and a CDR circuit 81 having a phase detector (PD) 82 and a phase control block 83 . The phase detector 82 detects the leading edge and the trailing edge of serial data signals RXP and RXN (which are differential data), and transmits to the phase control block 83 phase differences between the serial data signals RXP and RXN and clocks GCLKI, GCLKQ, GCLKIB, and GCLKQB. The clocks GCLKI, GCLKQ, GCLKIB, and GCLKQB are generated by a PLL circuit and 90 are degrees out of phase with the adjacent clock. The phase control block 83 shifts the phases of the clocks GCLKI, GCLKQ, GCLKIB, and GCLKQB such that the phases of these clocks are synchronized with the phases of the serial data signals RXP and RXN. Clocks FCLKI and FCLKIB, whose phases have been adjusted by the phase control block 83 , are transmitted to the deserializer 84 . The deserializer 84 converts the serial data into parallel data in synchronism with the clocks transmitted from the phase control block 83 .
FIG. 9 is a block diagram of another conventional serial-to-parallel converter (S/P). A serial-to-parallel converter 90 includes, instead of the phase control block 83 shown in FIG. 8 , a coarse loop 92 , which is similar to a PLL circuit, and a fine loop 91 for performing control from a phase detector, and a deserializer 93 . The coarse loop 92 operates in the same manner as the PLL circuit described above, i.e., compares a low-frequency reference clock REFCLK and a divided signal DIVCLK into which the frequency of an oscillation output signal generated in an oscillator 915 is divided to detect a phase difference therebetween and controls an oscillation frequency of the oscillator 915 . If the frequency of the reference clock REFCLK is equal to the frequency of serial data signals RXP and RXN, the fine loop 91 performs an adjustment such that the phases of high-speed clocks GCLKI, GCLKQ, GCLKIB, and GCLKQB which are generated in the oscillator 915 , are coincident with the phases of the serial data signals. The high-speed clocks GCLKI and GCLKIB, whose phases have been adjusted in the fine loop 91 , are transmitted to the deserializer 93 . The deserializer 93 then converts the serial data into parallel data in synchronism with the high-speed clocks GCLKI and GCLKIB from the fine loop 91 .
With increases in the amount of traffic on networks in recent years, a technique of binding a plurality of serial transmission channels is used. In this case, it is necessary to perform data communications while the frequencies of clocks in the plurality of serial transmission channels are coincident with each other. The technique is broadly classified into two methods described below.
A first method is a method of supplying a clock from a single PLL circuit to each of the plurality of channels. FIG. 10 is a schematic diagram illustrating this method. Serial-to-parallel converters 80 in FIG. 10 are similar to the serial-to-parallel converter 80 shown in FIG. 8 . This method has the advantage of being capable of entirely synchronizing the frequencies of clocks in the channels.
However, as the line becomes finer in semiconductor process technology, line widths and spaces between lines are reduced, and therefore, line resistance and capacitance between lines tend to increase. As a result, as the clock frequency increases its speed from several gigabytes to several tens of gigabytes, deterioration of signal quality, such as a decrease in clock amplitude, an occurrence of jitter, and the like, tends to occur in channels that are remote from each other in layout. To address this problem, a buffer inserted into a path of clock wiring or a shielding of wire is required. This imposes limitations on layout of clock wiring on a semiconductor chip.
A second method is a method of arranging a serial-to-parallel converter such as the one shown in FIG. 9 in each channel, and providing commonality among reference clocks of the serial-to-parallel converters. FIG. 11 is a schematic diagram illustrating this method. This second method can reduce clock deterioration dependent on the position on layout more than the first method because high-speed clocks are generated in each channel.
However, since a reference clock is shared in the second method, the influence of driven load capacitance is not avoided. Therefore, limitations on layout of clock wiring are still present, although not as much as in the high-speed clock described above. Additionally, both the layout area and power consumption are increased because a coarse loop and a fine loop are disposed in each channel. Moreover, since each coarse loop uses a low-frequency reference clock for synchronization, it is necessary to increase a frequency gain of an oscillator, which results in the occurrence of jitter.
As the second method, various techniques are discussed. For example, Japanese Unexamined Patent Application Publication No. 2000-243939 discloses a technique that allows layout of wiring for a reference clock merely by embedding a reference-clock transmission block in each channel and arranging the channels in a different sequence.
Japanese Unexamined Patent Application Publication No. 2004-015032 discloses a technique that suppresses noise within a chip by arranging a line for a reference clock in a dedicated area on an outermost section of the chip and also reduces the length of the line for the reference clock.
Japanese Unexamined Patent Application Publication No. 11-205133 discloses a technique that reduces variations in the frequency of an oscillator by providing a PLL circuit in a receiver with two loops, one loop functioning to compare a reference clock and a feedback clock and the other functioning to compare serial data and the feedback clock, switching between the two loops at start-up and at which data synchronization is performed, and suppressing a current in a tuning-current generating circuit in an oscillator when synchronization with serial data is performed.
The techniques described in Japanese Unexamined Patent Application Publication Nos. 2000-243939 and 2004-015032 can reduce limitations on layout and suppress the influence of noise caused by a circuit adjacent to a clock line, but do not solve a problem of the increase in the layout area and power consumption because a clock itself is supplied to each channel. Additionally, the problem of the occurrence of jitter remains unsolved because it is necessary to increase the gain of a voltage-controlled oscillator.
The technique described in Japanese Unexamined Patent Application Publication No. 11-205133 suppresses variations in the frequency of the oscillator and thus reduces the occurrence of jitter by not using a reference clock and reducing a tuning current when synchronization with serial data is performed. However, in a state where no serial data is input over a fixed period of time, the first loop for the reference clock is temporarily switched on and, upon receipt of serial data, the second loop is switched on again. Therefore, it is necessary to use a reference clock whose jitter is low. As a result, the problem of the limitations on layout of wiring for the reference clock, and the increase in power consumption caused by a buffer arranged in a path of distribution of the reference clock remains unsolved.
SUMMARY
It is an object of the present invention to provide a semiconductor integrated circuit that solves the above-described problems in the known art, avoids limitations on layout of clock wiring from a PLL circuit to CDR circuits when clocks used in a plurality of serial transmission channels are synchronized with each other, and reduces the occurrence of jitter.
According to an exemplary aspect of the present invention, a semiconductor integrated circuit includes a phase-locked loop (PLL) circuit and a plurality of clock and data recovery (CDR) circuits. The PLL circuit is configured to generate an oscillation output signal synchronized with a reference clock and includes a phase-frequency detector, a loop filter, an oscillator, and a voltage-to-current converter configured to convert a control voltage output from the loop filter and used for controlling an oscillation frequency of the oscillator into a current. The CDR circuits are configured to adjust a phase of the oscillation output signal with respect to a phase of serial data. The semiconductor integrated circuit also includes a path for distributing the converted current to the plurality of CDR circuits.
According to various exemplary embodiments, each of the CDR circuits may include an oscillator whose oscillation frequency is controlled on the basis of the distributed current.
According to various exemplary embodiments, each of the CDR circuits may include a current-to-voltage converter configured to convert the distributed current into a voltage, and a voltage-controlled oscillator whose oscillation frequency is controlled on the basis of the converted voltage.
As described above, a semiconductor integrated circuit according to an exemplary aspect of the present invention distributes to each channel a current for controlling an oscillation frequency (center frequency) of an oscillator in a PLL circuit, instead of distributing a clock. Therefore, no consideration is required for layout of clock wiring, which is to be considered in the known art. In other words, since a control current is not subjected to the influence of noise on wiring, such as crosstalk, no signal deterioration is present in even a CDR circuit that is remote from the PLL circuit. As a result, a line for shielding and a buffer in a path of wiring are not required. Power consumption can be reduced accordingly. Furthermore, since an oscillator in each CDR circuit may control its oscillation frequency (may adjust the phase of the oscillation frequency with respect to that of serial data) by using a mirrored current from a PLL circuit, a circuit with a reduced frequency gain can be designed, and therefore, the occurrence of jitter can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a semiconductor integrated circuit according to an exemplary embodiment of the present invention;
FIG. 2 is a schematic diagram of a PLL circuit used in the semiconductor integrated circuit according to an exemplary embodiment of the present invention;
FIG. 3 is a schematic diagram of a voltage-to-current converter shown in FIG. 2 according to an exemplary embodiment;
FIG. 4 is a schematic diagram of another voltage-to-current converter according to an exemplary embodiment;
FIG. 5 is a schematic diagram of a serial-to-parallel converter included in the semiconductor integrated circuit according to an exemplary embodiment;
FIG. 6 is a schematic diagram of another serial-to-parallel converter included in the semiconductor integrated circuit according to an exemplary embodiment;
FIG. 7 is a schematic diagram of a conventional typical PLL circuit;
FIG. 8 is a schematic diagram of a conventional typical serial-to-parallel converter;
FIG. 9 is a schematic diagram of another conventional typical serial-to-parallel converter;
FIG. 10 is a diagram illustrating a conventional method of supplying clocks to a plurality of channels; and
FIG. 11 is a diagram illustrating a conventional method of providing commonality among reference clocks in serial links.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
A semiconductor integrated circuit according to various exemplary embodiments of the present invention is described below with reference to the attached drawings.
FIG. 1 is a schematic diagram showing an exemplary embodiment of a semiconductor integrated circuit. According to various exemplary embodiments, a semiconductor integrated circuit 10 shown in FIG. 1 includes a PLL circuit (PLL) 11 and a plurality of serial-to-parallel converters (S/Ps) 12 to which CDR circuits are applied.
According to various exemplary embodiments, the PLL circuit 11 shown in FIG. 1 receives a reference clock REFCLK and outputs a plurality of frequency control currents ICTRL_PLL having the same current value. The serial-to-parallel converters 12 (S/P< 0 >, . . . , S/P<N>) receive the frequency control currents ICTRL_PLL from the PLL circuit 11 and serial data signals RXP (RXP< 0 >, . . . , RXP<N>) and RXN (RXN< 0 >, . . . , RXN<N>), respectively. According to various exemplary embodiments and as described later, each of the frequency control currents ICTRL_PLL is a mirrored current of a frequency control current ICTRL_PLL into which an output voltage of a loop filter in the PLL circuit 11 is converted by a voltage-current converter, the frequency of control current being used for controlling an oscillation frequency of an oscillator. The number of the mirrored frequency control currents may be the same as that of the serial-to-parallel converters 12 .
FIG. 2 is a schematic diagram of a PLL circuit used in the semiconductor integrated circuit according to an exemplary embodiment of the present invention. According to various exemplary embodiments, a PLL circuit 20 (the PLL circuit 11 in FIG. 1 ) includes a phase-frequency detector (PFD) 21 , a charge pump (CP) 22 , a loop filter (LF) 23 , a voltage-to-current converter (V-I) 24 , an oscillator (OSC) 25 , and a frequency divider (DIV) 26 . The oscillator 25 is a current-controlled oscillator whose oscillation frequency is controlled on the basis of the frequency control current ICTRL_PLL.
According to various exemplary embodiments, the phase-frequency detector 21 receives a reference clock REFCLK from the outside and a divided signal DIVCLK into which the frequency of an oscillation output signal of the oscillator 25 is divided by the frequency divider 26 . The phase-frequency detector 21 may then compare the reference clock REFCLK and the divided signal DIVCLK to detect the difference in phase and frequency therebetween, and may output an up pulse signal UP or a down pulse signal DOWN on the basis of the phase and frequency differences. According to various exemplary embodiments, the charge pump 22 charges or discharges a capacitance (not illustrated) in the loop filter 23 on the basis of the up pulse signal UP or the down pulse signal DOWN. Also, the loop filter 23 may generate a control voltage VTUNE for controlling the oscillator 25 from the electric charge stored in the capacitance, and the control voltage VTUNE is converted into the frequency control current ICTRL_PLL by the voltage-to-current converter 24 . The oscillation frequency of the oscillator 25 is controlled on the basis of the frequency control current ICTRL_PLL.
FIG. 3 is a schematic diagram showing an exemplary embodiment of the voltage-to-current converter shown in FIG. 2 . According to various exemplary embodiments, a voltage-to-current converter 30 includes a comparator 31 , a counter 32 , and a current distribution circuit 33 . The current distribution circuit 33 may include a plurality of constant-current power supplies 34 . As shown in FIG. 3 , each of the constant-current power supplies 34 has a plurality of current elements 35 that may flow relative amounts of currents equal to 1, ½, ¼, ⅛, 1/16, 1/32, and 1/64, and switches 36 for switching on and off the current elements 35 .
According to various exemplary embodiments, when the comparator 31 receives predetermined reference voltages VTHH and VTHL and a control voltage VTUNE, the comparator 31 then compares the reference voltages to the control voltage. If the control voltage VTUNE is larger than the reference voltage VTHH, the comparator 31 may output a count up signal. COUNT_UP; if the control voltage VTUNE is smaller than the reference voltage VTHL, the comparator 31 may output a count down signal COUNT_DOWN.
The counter 32 may output control signals 1ON, ½ON, . . . , 1/64ON for switching the current elements 35 included in the constant-current power supplies 34 on or off on the basis of the count up signal COUNT_UP or the count down signal COUNT_DOWN from the comparator 31 .
According to various exemplary embodiments, the current elements 35 generate currents by being switched on by the corresponding switches 36 receiving the control signals 1ON, ½ON, . . . , 1/64ON from the counter 32 , and the currents generated from the current elements 35 are then summed. The total current is output as the frequency control currents ICTRL_PLL for controlling the oscillator 25 from the constant-current power supplies 34 . The number of constant-current power supplies 34 may be the same as that of CDR circuits. All the constant-current power supplies 34 may be controlled by the single counter 32 . The current distribution circuit 33 delivers the frequency control currents ICTRL_PLL, which are controlled by the counter 32 and have the same current value, to the CDR circuits.
FIG. 4 is a schematic diagram showing another exemplary embodiment of the voltage-to-current converter. According to various exemplary embodiments, a voltage-to-current converter 40 shown in FIG. 4 includes a differential amplifier 41 and a current mirror 42 for delivering the currents to the CDR circuits. The differential amplifier 41 may generate voltages VH and VL on the basis of the difference between a predetermined reference voltage VTH and a control voltage VTUNE. For example, if the control voltage VTUNE is larger than the reference voltage VTH, a current that passes through a p-channel metal-oxide semiconductor transistor (hereinafter referred to as PMOS) 412 , an n-channel metal-oxide semiconductor transistor (hereinafter referred to as NMOS) 417 , and an NMOS 419 is larger than a current that passes through a PMOS 414 , an NMOS 418 , and the NMOS 419 , and therefore, the levels of the voltages VH and VL increase. In contrast to this, if the control voltage VTUNE is smaller than the reference voltage VTH, the levels of the voltages VH and VL decrease. In FIG. 4 , VB 1 , VB 2 , and VB 3 represent bias voltages.
According to various exemplary embodiments, the current mirror 42 includes a plurality of constant-current power supplies having the same shape. Each of the constant-current power supplies includes a PMOS 421 , a PMOS 422 , an NMOS 423 , and an NMOS 424 connected in series between a power supply VDD and a ground GND. The voltage VH may be input to a gate of the PMOS 421 , and the voltage VL may be input to a gate of the NMOS 424 . In accordance with the levels of the voltages VH and VL, a frequency control current ICTRL_PLL may be output from an output terminal in which a drain of the PMOS 422 and a drain of the NMOS 423 are connected to each other. As described above, in the current mirror 42 , the frequency control current may be controlled on the basis of the voltages VH and VL input from the differential amplifier 41 , and the frequency control currents ICTRL_PLL, which have the same current value as each other and are of the same number as the CDR circuits, are generated and delivered.
In the exemplary embodiments described above, the oscillator (OSC) in the PLL circuit is a known current-controlled oscillator (ICO). However, the oscillator in the PLL circuit may be a voltage-controlled oscillator (VCO) that is controlled on the basis of the control voltage VTUNE. In the case of the voltage-controlled oscillator, the control voltage VTUNE shown in FIG. 2 may be input directly to the voltage-controlled oscillator and also input to the voltage-to-current converter. The voltage-to-current converter may generate the frequency control currents ICTRL_PLL, which have the same current value as each other and are of the same number as the CDR circuits.
Each of the phase-frequency detector, the charge pump, the loop filter, and the frequency divider may be a known device. The voltage-to-current converter may be a combination of the exemplary embodiments described above, and may be a combination of a known device and current mirrors which are of the same number as the CDR circuits.
FIG. 5 is a schematic diagram showing an exemplary embodiment of a serial-to-parallel converter included in the semiconductor integrated circuit. According to various exemplary embodiments, a serial-to-parallel converter (S/P) 50 includes a deserializer 57 and a CDR circuit 51 having a phase detector (PD) 52 , a charge pump (CP) 53 , a loop filter (LF) 54 , a voltage-to-current converter (V-I) 55 , and an oscillator (OSC) 56 .
The phase detector 52 may compare the phases of clocks GCLKI, GCLKQ, GCLKIB, and GCLKQB with the phases of serial data signals RXP and RXN. If the phases of the clock signals are earlier, the phase detector 52 outputs an early signal EARLY; if the phases of the clock signals are later, the phase detector 52 outputs a late signal LATE. The charge pump 53 outputs a control voltage VTUNE_FINE on the basis of the early signal EARLY or the late signal LATE. The control voltage VTUNE_FINE may be smoothed in the loop filter 54 and then converted into a frequency control current ICTRL_FINE in the voltage-to-current converter 55 . The oscillator 56 may then receive a total current of the frequency control current ICTRL_FINE and the frequency control current ICTRL_PLL, which is supplied from the PLL circuit as a mirrored current. The high-speed clocks GCLKI and GCLKIB, whose phases have been adjusted in this way, may be transmitted to the deserializer 57 . The deserializer 57 may convert serial data into parallel data in synchronism with the high-speed clocks GCLKI and GCLKIB.
Whereas a known CDR circuit includes a coarse loop and a fine loop, the CDR circuit in various exemplary embodiments requires no circuit for such a coarse loop. Therefore, both the layout area and power consumption can be reduced. Additionally, the frequency gain of the oscillator 56 can be smaller than that in the oscillator used in the PLL circuit. In this case, the occurrence of jitter can be reduced.
FIG. 6 is a schematic diagram showing another exemplary embodiment of the serial-to-parallel converter included in the semiconductor integrated circuit. According to various exemplary embodiments, a serial-to-parallel converter (S/P) 60 shown in FIG. 6 includes a deserializer 65 and a CDR circuit 61 having an oscillator (OSC) 64 , a phase detector (PD) 62 , and a phase control block 63 . Since the oscillator 64 receives the frequency control current ICTRL_PLL from the PLL circuit, the oscillator 64 oscillates with the same frequency with which the oscillator in the PLL circuit oscillates. The phase control block 63 may perform an adjustment on the basis of an early signal EARLY and a late signal LATE input from the phase detector 62 such that the phases of clocks GCLKI, GCLKQ, GCLKIB, and GCLKQB become coincident with the phases of serial data signals RXP and RXN. High-speed clocks FCLKI and FCLKIB, whose phases have been adjusted in this way, may be transmitted to the deserializer 65 . The deserializer 65 may convert serial data into parallel data in synchronism with the high-speed clock signals FCLKI and FCLKIB.
The oscillator 64 may be a general current-controlled oscillator. Alternatively, the oscillator 64 may be an oscillator whose frequency gain is smaller than that in the oscillator used in the PLL circuit. In this case, the occurrence of jitter can be reduced. Each of the phase control block 63 and the phase detector 62 can be a known device.
The CDR circuit may be of any type as long as the CDR circuit controls the frequency of the oscillator on the basis of the frequency control current ICTRL_PLL received from the PLL circuit. For example, the CDR circuit may be a combination of the two exemplary embodiments described above or may be a known device. Additionally, the CDR circuit may include a current-to-voltage converter configured to convert the supplied frequency control current ICTRL_PLL into a control voltage, so that the oscillator can be a voltage-controlled circuit.
While the semiconductor integrated circuit according to various exemplary embodiments of the present invention has been described with reference to these embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. It is apparent that changes and modifications may be made without departing from the sprit and scope of the claimed invention.
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A semiconductor integrated circuit includes a phase-locked loop (PLL) circuit configured to generate an oscillation output signal synchronized with a reference clock and a plurality of clock and data recovery (CDR) circuits configured to adjust a phase of the oscillation output signal and a phase of serial data. The PLL circuit converts a voltage output from a loop filter, the voltage functioning to control an oscillation frequency of an oscillator, into a current and delivers the converted current to the plurality of CDR circuits. Therefore, in a case where clock signals used in a plurality of serial transmission channels are synchronized with one another, limitations on layout of clock wiring from the PLL circuit to the CDR circuits and the occurrence of jitter are reduced.
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BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates generally to toilet paper holders and more specifically to an attachment therefor for holding the free end of a roll of toilet paper in a position such that ready access thereto is provided the user.
Conventional toilet paper holders that are routinely installed in residential and commercial buildings typically provide no mechanism for giving the user ready access to the free end of a roll of toilet paper held thereby. Rather, the user is required to turn the roll of toilet paper in search of the free end, often times under subdued lighting conditions. Such searching is frequently annoying to the user, particularly when the free end has adhered itself to the remainder of the roll as the result of the previous use of a length of paper from the roll.
In accordance with one of the illustrated preferred embodiments of the present invention, a toilet paper unrolling fixture is provided which may be quickly and simply attached to a conventional recessed toilet paper holder. In accordance with another illustrated preferred embodiment of the invention, the toilet paper unrolling fixture is adapted for attachment to a flush mounted type of toilet paper holder. Each of the illustrated embodiments of the invention includes a frame member, a paper guide over which the free end of a roll of toilet paper passes, and a tear bar for supporting the free end of the roll in a position that enables the user to quickly tear a desired length of paper from the roll.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial illustration of the way in which a toilet paper unrolling fixture constructed in accordance with one embodiment of the present invention is positioned within a conventional recessed type of toilet paper holder.
FIG. 2 is a perspective view of the toilet paper unrolling fixture of FIG. 1.
FIG. 3 is a pictorial illustration of the way in which a toilet paper unrolling fixture constructed in accordance with another embodiment of the present invention is positioned within a conventional flush mounted type of toilet paper holder.
FIG. 4 is a perspective view of the toilet paper unrolling fixture of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, there is shown a typical recessed toilet paper holder 10 that is positioned within a recess in wall section 12. Paper holder 10 includes a spindle 14 that extends between a pair of side members 16 to hold a roll of toilet paper 18 in position for the user.
In accordance with one embodiment of the present invention illustrated in FIGS. 1 and 2, a toilet paper unrolling fixture 20 is provided for simple attachment to recessed toilet paper holder 10. Toilet paper unrolling fixture 20 comprises a pair of symmetrical parallel side members 22 that are spaced apart a distance slightly greater than the width of toilet paper roll 18 but slightly less than the distance between side members 16 of recessed paper holder 10. Each one of the side members 22 of the toilet paper unrolling fixture 20 is shaped to include a generally semicircular notch area 28 along the forward edge thereof that is formed to fit behind spindle 14 and thus hold the toilet paper unrolling fixture 20 in place within paper holder 10. The rearward edge of each of the side members 22 includes a vertical top portion 21 that fits flush against an upper lip 23 of paper holder 10 and further includes a vertical bottom portion 23 that fits flush against a bottom lip 25 of paper holder 10 when the unrolling fixture is positioned within the paper holder 10. A generally flat paper guide 24 is fixedly positioned between and near the top of side members 22. The bottom ends of side members 22 are supported by means of a lower support member 26 that extends there between. A tear bar 30 is horizontally positioned between side members 22 adjacent the forward edge of paper guide 24. A top edge of tear bar 30 may, if desired, be slightly serated to aid the user in tearing a length of paper from roll 18. An upper support member 34 extends between side members 22 to provide support for the top, rearward area of side members 22. A horizontally positioned flap 36 is hingedly attached, by means of a pin 38, between side members 22 and adjacent upper support member 34. Flap 36 is positioned such that a forward edge 40 thereof rests on paper guide 24.
The toilet paper unrolling fixture 20 may be fabricated of separate metallic parts that are attached to each other by means of any of a number of commonly used techniques. In the alternative, it may be fabricated of any of plastic like materials using molding technology that is well known and understood by those persons skilled in the art.
In operation, toilet paper unrolling fixture 20 is positioned behind spindle 14 and within recessed paper holder 10, as illustrated in FIG. 1. As further illustrated in FIG. 1, the free end 40 of paper roll 18 is placed on top of paper guide 24, under flap 36, and over tear bar 30. Thus, the free end 40 of paper roll 18 is held away from the bulk of the paper roll to prevent frictional attachment thereto and is in a position of ready accessibility to the user.
In accordance with another embodiment of the present invention illustrated in FIGS. 3 and 4, a toilet paper unrolling fixture 60 is provided for simple attachment to a conventional flush mounted type of toilet paper holder that includes a pair of side brackets 62 and a spindle 64. Paper unrolling fixture 60 comprises a housing that includes a pair of symmetrical side members 66, a vertical rear member 67, and a top member 68. A paper guide 70 is positioned between side members 66. A flap 72 is hingedly attached by means of pin 74 to rest on paper guide 70 in a manner similar to that in which flap 36 is attached between side members 22 of paper unrolling fixture 20 illustrated in FIGS. 1 and 2. A tear bar 76 is attached between side members 66 just forward of paper guide 70. Side members 66 are spaced a part to fit outside of paper roll 78 within side brackets 66. Side members 66 are each formed to include a generally hemispherical notch area 80 to fit behind spindle 64. Rear member 67 of paper unrolling fixture 60 is arranged to fit flush against a wall 69 when the unrolling fixture is positioned within the paper holder behind spindle 64, as illustrated in FIG. 3. Operation of the toilet paper unrolling fixture 60 is similar to that of unrolling fixture 20 described hereinabove.
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A toilet paper unrolling fixture adapted for simple attachment to a conventional toilet paper holder includes a frame, a paper guide over which the free end of a roll of toilet paper passes, and a tear bar for enabling the user to quickly tear a length of paper from the roll.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application No. 60/337,183 titled “BATTERY MONITORING SYSTEM AND METHOD” filed Dec. 6, 2001, which is hereby incorporated by reference.
FIELD
The present invention relates to a battery monitoring system. The present invention more specifically relates to a system for predicting whether the battery will perform in certain applications as expected in the future.
BACKGROUND
It is generally known to provide for a system for determining when to replace a battery of a vehicle. According to such known systems, a determination is made to replace the battery at a pre-selected time such as five years after installation of the battery. According to such known systems, a determination is also made to replace the battery when the perceived time required for the battery to crank the engine (cranking time) is longer than expected. However, such known systems have several disadvantages including that the battery may require replacement before such pre-selected time, and any perceived increase in the cranking time may be due to other factors unrelated to the battery (such as a faulty starter).
It is also generally known to provide for a system for determining when to replace a battery of a vehicle based on the voltage of the battery. According to such known systems, a determination is made to replace the battery when the voltage of the battery falls below a pre-selected value. However, such known systems have several disadvantages, including that they do not record the “history” of the battery during its use as would allow for a more accurate prediction of the capacity of the battery, notwithstanding the measured voltage.
Accordingly, it would be advantageous to provide a battery monitoring system for predicting whether the battery will perform in certain applications as expected in the future. It would also be advantageous to provide a system for determining when a battery for a vehicle should be replaced which accounts for the history of the battery during its use. It would be desirable to provide for a battery monitoring system having one or more of these or other advantageous features.
SUMMARY OF THE INVENTION
The present invention relates to a system for monitoring a battery for a vehicle. The system comprises a means for acquiring a value representative of a first period of time during which the battery will deliver a sufficient amount of power. The system also comprises a means for measuring a set of parameters comprising a voltage of the battery and a temperature of the battery during a second period of time. The system also comprises a means for predicting whether the battery will deliver the sufficient amount of power during a third period of time less than the first period of time. An output signal is provided if the means for predicting determines that the battery will deliver the sufficient amount of power during the third period of time.
The present invention also relates to a system for determining whether a battery for a vehicle will deliver a sufficient amount of power for a sufficient amount of time. The system also comprises a sensor configured to provide an input signal representative of a voltage of the battery during at least one of a first period over which the starter is disconnected from the battery, a second period over which the starter cranks the engine, and a third period over which the engine is started. The system also comprises a controller configured to determine a voltage of the battery during at least one of the first period, a minimum voltage of the battery during the second period, and a maximum voltage of the battery during the second period. The controller is configured to provide an output signal if the voltage of the battery is outside a range of pre-determined values during at least one of the first period, the second period, and the third period.
The present invention also relates to a system for determining whether a battery for a vehicle will deliver a sufficient amount of power for a sufficient amount of time. The system also comprises a means for providing a first input signal representative of a temperature of the battery during a period. The system also comprises a means for providing a second input signal representative of a voltage of the battery during the period. The system also comprises a means for providing a third input signal representative of a duration of the period. The system also comprises a means for determining an amount of life lost by the battery during the period corresponding to the first input signal, the second input signal, and the third input signal. The means for determining the amount of life lost by the battery during the period provides an output signal if the amount of life lost by the battery during the period is outside a range of pre-determined values.
DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic block diagram of a battery monitoring system according to an exemplary embodiment.
FIG. 2 is a schematic block diagram the battery monitoring system according to an alternative embodiment.
FIG. 3 is a flow diagram of a routine for predicting whether a battery may deliver a sufficient amount of power for a sufficient amount of time according to an exemplary embodiment.
FIG. 4 is a graph showing the history of a battery according to an exemplary embodiment.
FIG. 5 is a graph of voltage versus time of a battery during the starting of an engine of a vehicle according to an exemplary embodiment.
FIG. 6 is a flow diagram of a routine for predicting whether a battery may deliver a sufficient amount of power for a sufficient amount of time according to an alternative embodiment.
FIG. 7 is a graph of the voltage drop of a battery during the starting of an engine of a vehicle versus temperature according to an exemplary embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A battery monitoring system 10 as shown in FIG. 1 measures and records a set of parameters of a battery system 20 periodically during use over time. The parameters such as the voltage, temperature, state of charge and cycling of the battery may be acquired by a battery management system 30 from battery system 20 , a vehicle electrical system 22 , and an environment 24 according to a preferred embodiment, or may be otherwise acquired according to alternative embodiments.
System 10 predicts the ability of battery system 20 to perform in certain applications as expected in the future. Specifically, system 10 predicts whether battery system 20 has a sufficient remaining amount of “life” (i.e. may deliver a sufficient amount of power to the vehicle for a sufficient amount of time). In other words, system 10 predicts whether battery system 20 will likely be able to start the engine of the vehicle and power the loads of the vehicle.
A new, fully charged battery of battery system 10 has a fixed amount of “life.” A certain amount of life is “lost” from battery system 20 during its use. For example, the cold cranking capability, reserve capacity and cycling capability of battery system 20 is reduced during its use of battery system 20 . The extent to which the amount of life is lost from the battery depends on a variety of parameters, including the voltage, temperature, resistance, and state of charge of the battery system. An output signal 26 (such as a warning signal) that battery system 20 should be replaced is provided when system 10 predicts that battery system 20 will not likely perform for the intended use. (According to an alternative embodiment, another output signal comprises a signal to close a switch 40 (or switches) to connect the loads of an electrical system 22 to battery system 20 to “manage” operation of the battery system 20 .)
One way system 10 predicts the amount of life remaining in battery system 20 is based on the monitored history or use of battery system 20 . In general, the battery monitoring system sets a parameter intended to be representative of a battery “life.” As the battery is in use over time, the battery monitoring system then subtracts a certain amount from the “life” based on the nature of the use. For example, a greater amount of life is subtracted if the battery undergoes a high voltage or temperature. The system also subtracts a greater amount of life if the battery is discharged to a great extent before it is recharged. Other uses may affect the extent to which the “life” is reduced.
Another way system 10 predicts the amount of life remaining in battery system 20 is based on a parameter monitored during cranking of the engine. In general, the battery monitoring system subtracts a greater amount of life if the battery takes a greater time to deliver a sufficient amount of power to crank the engine, or if the voltage of the battery drops dramatically during cranking of the engine.
FIG. 2 shows system 10 according to an alternative embodiment. An input signal 28 representative of a condition or state of battery system 20 is provided to battery management system 30 by a sensor according to a preferred embodiment. Input signal 28 may also be provided to battery management system 30 by other devices 36 (such as a controller of a computing device for the vehicle as shown in FIG. 2) according to an alternative embodiment. Input signal 28 may also be provided to battery management system 30 by a network (shown as a CAN bus 34 in FIG. 2) according to another alternative embodiment. Input signal 28 may also be provided to battery management system 30 by a user interface 32 as shown in FIG. 2 according to a preferred embodiment.
A routine 50 for predicting whether a battery of a battery system may deliver a sufficient amount of power for a sufficient amount of time is shown in FIG. 3 . Routine 50 uses an input signal from a sensor (or otherwise acquired) representative of the voltage and temperature of the battery during use according to a preferred embodiment. The voltage and temperature of a battery is monitored and recorded over time according to a particularly preferred embodiment. The history of the voltage and temperature of a battery during use is shown in FIG. 4 according to an exemplary embodiment. As shown in FIG. 4 the battery is at about 50 degrees and about 13.5 volts for about 100 hours of use, and is at about 35 degrees and about 12.6 volts for about 5 hours of use.
Referring to FIG. 3, the amount of time a new, fully charged battery will deliver a sufficient amount of power for a sufficient amount of time is obtained as an input signal representative of the amount of “life” of the battery (step 52 ). This input signal is a pre-selected value such as 3300 days according to a preferred embodiment. Other input signals relating to parameters of the battery are also obtained from monitoring the battery (step 54 ). These input signals may relate to the voltage, temperature, time, cycling, state of charge, etc. of the battery according to alternative embodiments. The time the battery is at the specified voltage and temperature is summed (step 56 ).
The amount of life lost from the battery is determined based on the monitored parameters. If the battery undergoes at a high voltage or temperature during use, the amount of life lost from the battery is accelerated. An acceleration factor based on the voltage and temperature of the battery is pre-determined according to a preferred embodiment. The time the battery is at the voltage and temperature is multiplied by the acceleration factor based on voltage and temperature (step 58 ), resulting in a prediction of the amount of life lost of the battery due to voltage and temperature.
The amount of life lost from the battery is also determined based on the state of charge of the battery. If the battery undergoes a low state of charge, the amount of life lost from the battery is accelerated. An acceleration factor for each state of charge of the battery is pre-determined according to a preferred embodiment. The time the battery is at the state of charge is divided by the acceleration factor based on the state of charge (step 60 ), resulting in a prediction of the amount of life lost of the battery due to state of charge.
The time the battery is at the specified voltage and temperature (adjusted by the acceleration factors) is subtracted from the initial estimate of time the new, fully charged battery will deliver a sufficient amount of power for a sufficient amount of time (step 62 ). The result is a prediction of the amount of time (e.g. days) the battery may deliver a sufficient amount of power is then made (step 64 ).
Referring further to FIG. 3, the number of cycles a new, fully charged battery will deliver a sufficient amount of power is obtained as an input signal representative of the amount of “life” of the battery (step 66 ). A “cycle” is one discharge from 100 percent state of charge to complete discharge, plus one recharge to 100 percent state of charge. This input signal is a pre-selected value such as 1000 cycle counts according to a preferred embodiment. Other input signals relating to parameters of the battery are also obtained from monitoring the battery (step 54 ). The number of cycles of the battery is summed (step 66 ). If the battery undergoes a great discharge before it is recharged, the amount of life lost from the battery is accelerated. An acceleration factor based on the extent of cycling of the battery is pre-determined according to a preferred embodiment. The number of cycles of the battery is adjusted by the acceleration factor based on cycling (step 68 ). The number of cycles of the battery (adjusted by the acceleration factor) is subtracted from the initial estimate of the number of cycles of the new, fully charged battery (step 70 ) such as 1000 cycles or “counts.” The result is a prediction of the number of cycle counts (or time) for which the battery may deliver a sufficient amount of power (step 72 ).
The steps for predicting whether a battery may deliver a sufficient amount of power for a sufficient amount of time is shown in TABLES 1-4 according to an exemplary embodiment. The time the battery is at a specified voltage, temperature and state of charge is continuously monitored during use of the battery in a vehicle according to a preferred embodiment. Over a 3.5 hour period, the battery is at the parameters shown in TABLE 1:
TABLE 1
Temperature
Percent State of
(degrees C)
Voltage (V)
Charge (SOC %)
Time (hours)
50
14
90%
2
40
13
50%
1
30
12
10%
0.5
Sum = 3.5 hours
The acceleration factor based on the voltage and temperature of the battery is determined (e.g. pre-determined from a lookup table stored in memory of the battery management system) according to a preferred embodiment as shown in TABLE 2:
TABLE 2
12V
13V
14V
50° C.
7
9
10
40° C.
4
5
8
30° C.
1
2
6
The acceleration factor based on the state of charge of the battery is also determined (e.g. from a lookup table) according to a preferred embodiment as shown in TABLE 3:
TABLE 3
State of
Charge
Acceleration
(%)
Factor
90%
0.9
50%
0.5
10%
0.1
The amount of life or time lost from the battery during use is obtained by multiplying the time the battery was at the voltage and temperature (from TABLE 1) by the acceleration factor based factor voltage and temperature (from TABLE 2) and dividing by the acceleration factor based on the state of charge of the battery (from TABLE 3) as shown in TABLE 4:
TABLE 4
Acceleration
Acceleration
Factor Based on
Factor
Voltage and
Based on
Time (hours)
Temperature
State of Charge
Time Lost (hours)
2
10
0.9
22.2
1
5
0.5
10
0.5
1
0.1
5
Sum = 3.5 hours
Sum = 37.2 hours
The time the battery is at the specified voltage and temperature (adjusted by the acceleration factors) is subtracted from the initial estimate of time the new, fully charged battery will deliver a sufficient amount of power for a sufficient amount of time. Note the battery with parameters listed in TABLE 4 is used for 3.5 hours, but 37.2 hours are predicted to be lost from the battery (due to the acceleration factors).
The steps for predicting whether a battery may deliver a sufficient amount of power for a sufficient amount of time is shown in TABLES 5-7 according to an alternative embodiment. The cycling of the battery during discharge is continuously monitored during use of the battery in a vehicle according to a preferred embodiment. The battery is cycled the following amounts as shown in TABLE 5:
TABLE 5
Period
Percentage of One Cycle
1
61%
2
50%
3
10%
The acceleration factor based on the cycling of the battery is determined (e.g. from a lookup table) according to a preferred embodiment) as shown in TABLE 6:
TABLE 6
Percentage of One Cycle
Acceleration Factor Based on Cycling
10%
0.2
20%
0.5
40%
4
60%
10
The amount of cycling (from TABLE 5) is adjusted by the acceleration factor based on cycling (from TABLE 6) for each period of use of the battery as shown in TABLE 7:
TABLE 7
Period
Amount of Cycle (%)
Adjusted Cycle Counts
1
61%
10
2
50%
4
3
10%
0.2
Sum = 14.2 counts
The sum of the adjusted cycling counts is subtracted from the initial estimate of the number of cycling counts of the new, fully charged battery.
Referring to FIG. 5, the voltage of a battery (at 100 percent state of charge and room temperature) during various times of use in a vehicle is shown according to an exemplary embodiment. The times comprise: a period 74 a during which the voltage of the battery is not delivering or receiving power and all loads (including the starter) are disconnected from the battery—commonly referred to as “open circuit voltage”; a relatively short, subsequent period 74 b during which the voltage of the battery initially drops (due to connection of the starter to the battery); a subsequent period 74 c during which the voltage of the battery recovers; a subsequent period 74 d during which the starter cranks the engine of the vehicle; a subsequent period 74 e during which the engine of the vehicle is started (and the starter remains connected to the battery); and a subsequent period 74 f during which the engine is started (and the starter is disconnected from the battery).
During period 74 a (about time 0.0 seconds) the open circuit voltage of the battery is about 12.6 V. During period 704 b (about time 0.01 seconds) a relatively large drop from the voltage of the battery occurs (to about 9.0 V). This drop corresponds to the connection of the starter to the battery and a resulting initial high current draw by the starter. During period 74 c (about time 0.01 to 0.05 seconds) the voltage of the battery recovers to about 11.1 V.
Referring further to FIG. 5, the voltage of the battery “ripples” or oscillates during period 74 d (about time 0.05 to 1.2 seconds)—referred to as a “ripple interval.” A minimum voltage value 76 during the ripple interval corresponds to the compression of gas by a piston of the engine. A maximum voltage value 78 during the ripple interval corresponds to the expansion of the gas in the engine. According to a particularly preferred embodiment, the ripple interval is defined by a period of 100 milliseconds to 480 milliseconds after the starter is connected to the battery. The difference between each minimum voltage value 76 and each maximum voltage value 78 during period 74 d may be averaged to provide an average amplitude of the voltage during the ripple interval.
Referring further to FIG. 5, the engine starts at the beginning of period 74 e (about time 1.2 to 1.4 seconds). Without intending to be limited to any particular theory, it is believed that the amplitude of the voltage during the ripple interval decreases relative to the amplitude of the voltage during period 74 e because the starter is no longer cranking the engine.
Referring further to FIG. 5, the starter is disconnected from the battery at the beginning of period 74 f (at about time 1.4 to 2.0 seconds). Without intending to be limited to any particular theory, it is believed that a relatively steep rise in voltage occurs during period 74 f due to disconnection of the starter from the battery and from charging of the battery by the alternator of the vehicle.
A routine 80 for predicting whether a battery may deliver a sufficient amount of power for a sufficient amount of time (based on a weak crank of the engine) is shown in FIG. 6 according to an alternative embodiment. Routine 80 uses an input signal obtained from sensors (or otherwise acquired) representative of the voltage of the battery (step 82 ) during at least one of periods 74 a - 74 f (see FIG. 5 ). The battery monitoring system makes a determination whether the monitored drop in voltage of the battery from open circuit voltage (period 74 a in FIG. 5) to the voltage during the ripple interval (period 74 d in FIG. 5) is within a range of pre-determined values (step 84 ). According to a preferred embodiment, the routine compares the average open circuit voltage to the average voltage during the ripple interval (over a pre-determined number of starts of the engine with reference to a new, fully charged battery) to determine an “average voltage drop.” This average voltage drop is set as a range of pre-determined values according to a preferred embodiment, or some other range of pre-determined values (e.g. about 1.4 volts plus 20 percent, i.e. about 1.4 V to 1.7 V) according to an alternative embodiment. If the monitored drop in voltage of the battery from open circuit voltage to the voltage during the ripple interval is outside the range of pre-determined values, then a count is recorded representative of a weak crank of the engine (step 96 ). If the sum of the counts is not outside a range of pre-determined values (e.g. 9 counts in the last 12 attempts to start the engine) (step 98 ), then routine 80 continues to obtain inputs (step 82 ). If the sum of the counts is outside the range of pre-determined values (step 98 ), then an output signal is provided representative of a warning that the battery may not deliver a sufficient amount of power for a sufficient amount of time.
The monitored drop in voltage of the battery from open circuit voltage to the voltage of the ripple interval may be adjusted due to the temperature of the battery according to an alternative embodiment. Without intending to be limited to any particular theory, it is believed that the drop in voltage of the battery from open circuit voltage to the voltage of the ripple interval may increase as temperature decreases. The drop in voltage of the battery from open circuit voltage to the voltage of the ripple interval at various temperatures is shown in FIG. 7 according to an exemplary embodiment. As shown in FIG. 7, the drop in voltage of the battery at 40 degrees Celsius from open circuit voltage to the voltage of the ripple interval is about 1.4 V. A pre-determined range of drops in voltage of the battery from open circuit voltage to the voltage of the ripple interval may be set (e.g. about 1.4 V-1.7 V, i.e. about 20 percent greater than the average drop in voltage of the battery from open circuit voltage to the voltage of the ripple interval at that temperature) according to another alternative embodiment.
Referring further to FIG. 6, the battery monitoring system makes a determination whether the monitored open circuit voltage of the battery (period 74 a in FIG. 5) is within a range of pre-determined values (step 86 ). According to a preferred embodiment, the routine determines an average open circuit voltage over a pre-determined number of starts of the engine with reference to a new, fully charged battery (e.g. about 12.6 V plus or minus 20 percent, i.e. 10.1-15.1 V). If the monitored open circuit voltage of the battery is outside the range of pre-determined values, then a count is recorded representative of a weak crank of the engine (step 96 ). Without intending to be limited to any particular theory, it is believed that a severe increase from the open circuit voltage of the battery (e.g. from about 12.6 V-12.8 V to about 13.3 V-13.5 V) over time (e.g. days, months, etc.) may indicate that the battery is experiencing water and electrolyte loss. If the sum of the counts is not outside a range of pre-determined values (e.g. 9 counts in the last 12 attempts to start the vehicle) (step 98 ), then routine 80 continues to obtain inputs (step 82 ). If the sum of the counts is outside the range of pre-determined values (step 98 ), then an output signal is provided representative of a warning that the battery may not deliver a sufficient amount of power for a sufficient amount of time.
Referring further to FIG. 6, the battery monitoring system makes a determination whether the monitored amplitude of the voltage of the battery during the ripple interval (period 74 d in FIG. 5) is within a range of pre-determined values (step 88 ). According to a preferred embodiment, the routine determines an average amplitude of the voltage during the ripple interval over a pre-determined number of starts of the engine with reference to a new, fully charged battery (e.g. about 0.1 V plus or minus 20 percent, i.e. about 0.08 V to 1.02 V). If the monitored amplitude of the voltage of the battery during the ripple interval is outside the range of pre-determined values, then a count is recorded representative of a weak crank of the engine (step 96 ). If the sum of the counts is not outside a range of pre-determined values (e.g. 9 counts in the last 12 attempts to start the vehicle) (step 98 ), then routine 80 continues to obtain inputs (step 82 ). If the sum of the counts is outside the range of pre-determined values (step 98 ), then an output signal is provided representative of a warning that the battery may not deliver a sufficient amount of power for a sufficient amount of time.
Referring further to FIG. 6, the battery monitoring system makes a determination whether the monitored “period” of the voltage of the battery during the ripple interval (period 74 d in FIG. 5) (i.e. the time interval between two successive occurrences of minimum voltage value 74 during the ripple interval) is within a range of pre-determined values (step 90 ). According to a preferred embodiment, the routine determines an average period of the voltage during the ripple interval over a pre-determined number of starts of the engine with reference to a new, fully charged battery (e.g. about 11.1 V plus or minus 20 percent, i.e. about 8.9 V to 13.3 V). Without intending to be limited to any particular theory, it is believed that an increase in the period of the voltage during the ripple interval may indicate there is relatively little life remaining in the battery (i.e. it takes a longer duration for the starter to crank the engine). If the monitored period of the voltage of the battery during the ripple interval is outside the range of pre-determined values, then a count is recorded representative of a weak crank of the engine (step 96 ). If the sum of the counts is not outside a range of pre-determined values (e.g. 9 counts in the last 12 attempts to start the vehicle) (step 98 ), then routine 80 continues to obtain inputs (step 82 ). If the sum of the counts is outside the range of pre-determined values (step 98 ), then an output signal is provided representative of a warning that the battery may not deliver a sufficient amount of power for a sufficient amount of time.
Referring further to FIG. 6, the battery monitoring system makes a determination whether the monitored cranking time required to start the engine (period 74 d in FIG. 5) is within a range of pre-determined values (step 92 ). According to a preferred embodiment, the routine determines an average cranking time required to start the engine over a pre-determined number of starts of the engine with reference to a new, fully charged battery (e.g. less than about 1.2 seconds plus 20 percent, i.e. about 0 to 1.4 seconds). If the monitored cranking time required to start the engine is outside the range of pre-determined values, then a count is recorded representative of a weak crank of the engine (step 96 ). If the sum of the counts is not outside a range of pre-determined values (e.g. 9 counts in the last 12 attempts to start the vehicle) (step 98 ), then routine 80 continues to obtain inputs (step 82 ). If the sum of the counts is outside the range of pre-determined values (step 98 ), then an output signal is provided representative of a warning that the battery may not deliver a sufficient amount of power for a sufficient amount of time.
Referring further to FIG. 6, the battery monitoring system makes a determination whether the monitored rate of change of the voltage of the battery during the ripple interval (period 74 d in FIG. 5) is within a range of pre-determined values (step 94 ). According to a preferred embodiment, the routine determines an average rate of change of the voltage of the battery during the ripple interval over a pre-determined number of starts of the engine with reference to a new, fully charged battery (e.g. a rate greater than about 0). If the rate of change of the voltage of the battery during the ripple interval is outside a range of pre-determined values, then a count is recorded representative of a weak crank of the engine (step 96 ). If the sum of the counts is not outside a range of pre-determined values (e.g. 9 counts in the last 12 attempts to start the vehicle) (step 98 ), then routine 80 continues to obtain inputs (step 82 ). If the sum of the counts is outside the range of pre-determined values (step 98 ), then an output signal is provided representative of a warning that the may not deliver a sufficient amount of power for a sufficient amount of time.
According to a particularly preferred embodiment, routine 80 is run after routine 50 makes a determination that there is relatively little life remaining in the battery (e.g. 10 percent life remaining, about 330 days of life remaining, more than 1000 life cycling counts used by the battery, etc.). The pre-determined values of routine 80 may be adjusted according to the amount of life remaining in the battery as determined by routine 50 according to an alternative embodiment.
The input signals (or combination of input signals) may be representative of conditions or states of the battery system such as voltage of the battery, current drawn by loads connected to the battery, resistance of the battery, temperature of the battery, time, etc. according to any preferred or alternative embodiments. The input signals may also relate to a characteristic of the battery (such as model number, purchase date, installation date, size, capacity, cold cranking capability rating, reserve capacity rating, etc.) according to any preferred or alternative embodiment. The range of the pre-determined values that are compared to the input signals by the battery management system may be preprogrammed or determined during operation, use, testing, etc. of the vehicle according to any preferred or alternative embodiments. The range of the pre-determined values may be adjusted or calibrated over time according to any preferred or alternative embodiments. The “other devices” for providing inputs to the battery management system may comprise an input device such as a keyboard, display (e.g. touch screen), etc. according to alternative embodiments. The other devices may include a “remote connection” to the battery management system such as a wireless device (e.g. HomeLink (™) wireless control system, key fob, cellular or digital device, etc.) communicated by a variety of methods and protocols (e.g. infrared, radio frequency, Bluetooth, Wide Application Protocol, etc.) according to alternative embodiments. The “other devices” may comprise a magnetically coupled communication port such as a Manual Swipe Magnetic Card Low-Co Reader/Writer model no. RS-232 commercially available from Uniform Industrial Corp., Fremont, Calif., USA according to a particularly preferred embodiment.
The battery management system may comprise a computing device, microprocessor, controller or programmable logic controller (PLC) for implementing a control program, and which provides output signals based on input signals provided by a sensor or that are otherwise acquired. Any suitable computing device of any type may be included in the battery management system according to alternative embodiments. For example, computing devices of a type that may comprise a microprocessor, microcomputer or programmable digital processor, with associated software, operating systems and/or any other associated programs to implement the control program may be employed. The controller and its associated control program may be implemented in hardware, software or a combination thereof, or in a central program implemented in any of a variety of forms according to alternative embodiments. A single control system may regulate the controller for the battery management system and the controller for the vehicle according to an alternative embodiment.
It is important to note that the use of the term battery “management” or “battery management system” is not intended as a term of limitation insofar as any function relating to the battery, including monitoring, charging, discharging, recharging, conditioning, connecting, disconnecting, reconnecting, etc., is intended to be within the scope of the term.
It is important to note that the construction and arrangement of the elements of the battery monitoring system as shown in the preferred and other exemplary embodiments is illustrative only. Although only a few embodiments of the present invention have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, the battery management system may be installed directly on the battery or otherwise electrically connected to the battery according to alternative embodiments. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The input signals may be representative of the current drawn from the battery according to an alternative embodiment. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention as expressed in the appended claims.
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A battery monitoring system is disclosed. The system comprises a means for acquiring a value representative of a first period of time during which the battery will deliver a sufficient amount of power. The system also comprises a means for measuring a set of parameters comprising a voltage of the battery and a temperature of the battery during a second period of time. The system also comprises a means for predicting whether the battery will deliver the sufficient amount of power during a third period of time less than the first period of time. An output signal is provided if the means for predicting determines that the battery will deliver the sufficient amount of power during the third period of time. A system for determining whether a battery for a vehicle will deliver a sufficient amount of power for a sufficient amount of time is also disclosed.
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[0001] This application is the U.S. national phase application of PCT International Application No. PCT/EP2004/011298, filed Oct. 8, 2004, which claims priority to German Patent Application No. DE 103 58 292.4, filed Dec. 12, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The invention relates to a roller for a web-shaped medium, preferably for mechanically, thermally or thermo-mechanically treating a web-shaped medium.
[0004] The treatment can in particular be pressing, drying or smoothing the medium, or a combination of these types of processing. The medium is preferably a paper web.
[0005] 2. Description of the Related Art
[0006] Such rollers are for example used in calenders, with which paper webs are smoothed. Calenders comprise a number of rollers which are mounted, such that they can rotate and move with respect to each other, in a frame supported on a foundation. The paper web to be treated is guided through between the rollers, wherein the rollers exert pressure on the paper web. The smoothing process is understood as impressing the smooth surface of the roller, at high pressure, onto the initially rough surface of the paper web. An increased temperature of the surface of the roller is advantageous, for which reason such rollers are in many applications heated.
[0007] Inevitable imperfections from the manufacture of the rollers, for example production tolerances at various stages of production, lead to imbalances and deformations of the rollers during operation. This becomes apparent in the form of oscillations and vibrations which are capable of significantly impairing operations. Once produced, the rollers are therefore balanced, i.e. the imbalances are measured and compensated for by suitable measures. In order to take thermal deformations into account, the rollers are also balanced at an increased temperature.
[0008] Tolerances also apply to the balancing, beyond which the cost of further improvement is no longer economical. Furthermore, the deformations during actual operation are also dependent on loads which cannot be completely simulated in a balancing machine. Rollers are also operated at different speeds and temperatures. The balancing itself, however, can only be optimized for a particular operational state. Residual imbalances, which lead to oscillations and vibrations during operation, therefore remain for the operational states deviating from this.
[0009] Calender rollers are therefore configured such that they are operated at a sufficient offset from their critical resonant frequencies. In the vicinity of the critical resonant frequencies, the oscillations and vibrations of the roller are amplified by resonance which is shared by the entire system of the calender, up until oscillation states which no longer permit the calender to be operated. This can be caused by markings on the paper web generated by rotational-frequency oscillations in the linear pressure, and can continue up until components of the calender are jeopardized by fatigue.
SUMMARY OF THE INVENTION
[0010] It is an object of the invention to improve the oscillation characteristics of rollers for web-shaped media, in particular rollers for treating web-shaped media.
[0011] For machine tools, DE 100 46 868 C2 discloses filling the machine bed of a machine tool with a mixture having a pulpy consistency and consisting of a liquid and granular solids. This can effectively dampen oscillations which enter the machine bed during operation. The machine bed transfers the oscillations onto the liquid, which for its part tries to move the solid grains. Due to their mass inertia, however, the solid grains stay in place, and there is a relative movement between the liquid and the grains. Liquid friction on the grains and turbulence in the liquid itself dissipate energy, which dampens the oscillations in the machine bed and therefore the entire machine.
[0012] By analogy to this, a roller framework, for example a calender frame, which is embodied as a hollow construction, for example as a hollow welded construction, can also be fitted with a major dampening by filling the hollow spaces of the framework.
[0013] The invention, however, goes a decisive step further by filling a hollow space formed in the roller of a web-treating roller completely or partially with an energy-dissipating mixture. The web-processing roller can in particular be a calender roller. The roller can be used not only in paper machines but also for example in rotary printing machines or in processing metal or plastic films or strips.
[0014] The mixture consists of a liquid and at least one insoluble co-ingredient in the liquid, formed by solid particles, preferably a granular solid, or by another liquid. The mixture can include a number of different liquids. The mixture can also contain a number of different types of preferably granular solid, wherein the particles of the individual solids can differ in terms of size, shape and/or specific weight. In the mixture which in such cases is formed as a dispersion, the solid particles should however be uniformly and finely distributed, such that the mixture has a uniform mass distribution as viewed in the hollow space as a whole. The solid can in particular exhibit the consistency of sand. Although a dispersion is preferred, the mixture can in principle also be an emulsion consisting of at least two different liquids.
[0015] Preferred dispersions are disclosed in DE 100 46 868 C2, which is referenced in this respect.
[0016] The solid in preferred dispersions exhibits a shape, preferably with edges, which generates optimally high friction forces in the event of a relative movement of the solid in the liquid. If sand forms the solid, it is preferably crushed sand.
[0017] The mixture preferably has a pulpy consistency within the entire operating temperature range of the roller.
[0018] In preferred first embodiments, the at least one hollow space is a central hollow space, such that the rotational axis of the roller extends through the mixture. The hollow space is preferably concentric with the rotational axis. Rollers for mechanically or thermo-mechanically treating web-shaped media, as represented in particular by calender rollers, are predominantly fitted with a central hollow space. The embodiment of the hollow space can be design-related, as for example in so-called displacement rollers having a thermal treatment channel formed as an annular gap, or can be provided for the purpose of reducing operational stresses, as for example in rollers having thermal treatment channels formed as peripheral bores for conducting a heating fluid or cooling fluid. The roller shell itself can directly form a container wall for the mixture. The mixture can also be accommodated in a container provided specially for the mixture, and this container can be arranged in the interior of the roller. A number of such separate mixture containers can also be arranged in the interior of the roller, for example adjacently and spaced from each other along the rotational axis. The number of mixture containers can be rigidly or elastically supported in the interior of the roller.
[0019] In preferred second embodiments, the at least one hollow space is an annular gap which remains between the roller shell and a cylindrical body surrounded by the roller shell. The annular gap can be completely or partially filled with the mixture, wherein the roller shell forms an outer container wall for the mixture and the cylindrical body forms an inner container wall for the mixture. Furthermore, the hollow space can also be formed only within the cylindrical body. The cylindrical body can equally surround a central first hollow space, and a second hollow space can be formed in the annular gap. The two hollow spaces can each be completely or partially filled with the same mixture, or as appropriate also with different mixtures which however are each in their own right a mixture of the type described. As previously in the case of the at least one central hollow space, so also in these embodiments the roller shell or cylindrical body need not directly form a container wall for the mixture, although this is preferred.
[0020] While the at least one hollow space is preferably a hollow space which is concentric with the rotational axis of the roller, this is not however absolutely essential. Alternatively, a number of respectively non-concentric hollow spaces can also be provided, which however in their entirety should be arranged rotationally symmetrical about the rotational axis, in order not to cause imbalances for their part alone.
[0021] Filling the hollow space or number of hollow spaces has no effect on the balancing characteristics of the roller. It neither reduces the roller imbalance, nor can it for example influence a temperature-related bending of the roller which for its part again leads to an imbalance. On the contrary, filling the roller bore during an excursion of the mass of the roller would increase the centrifugal inertial forces as compared to a hollow space which is not filled. A dampening effect, such as caused by filling a roller framework which may be hollow, is also not to be expected. A little while after the roller has started up, the filling of the hollow space will rotate at the same frequency as the roller. Even in the event of a rotational-frequency central deviation—the predominant cause of roller imbalance at high speeds—there would be no relative movement between the roller and the mixture which could ultimately have a dampening effect. This has also been confirmed by practical experiments. The imbalance of a roller tube is not changed by filling the interior of the tube with the mixture, which is preferably provided as a pulpy dispersion.
[0022] The so-called smooth running of a roller filled with the mixture, as compared to a roller without any filling, as the critical resonant frequency is approached or even exceeded, is by contrast remarkable. When the roller was not filled, the speed of the balancing machine had to be curbed because it was in danger of jumping off the rolls, while after the hollow space of the roller had been filled, it was possible to pass the critical speed without any problems. The roller even ran smoothly in the so-called super-critical range.
[0023] In retrospect, theory also provides a plausible explanation for this: as long as the roller and its filling rotate with each other in the sub-critical range without moving relative to each other, additional dampening is not possible. As the resonant frequency is approached, however, there is a phase shift in real systems—which constantly exhibit an elasticity and dampening. The excursion caused by the imbalance force remains short of the imbalance force by an increasing rotational angle, until a stable phase shift of 180° is achieved above the resonant frequency. However, as soon as the imbalance force—or the centrifugal force due to the imbalance—deviates from the direction of the excursion, currents form in the filling, i.e. in the mixture, which have a dampening effect. Filling the at least one hollow space in accordance with the invention thus affords the option of manufacturing cost-effective rollers which can be operated near their resonant frequency and even in the super-critical range. Due to the invention, the rollers can be embodied with smaller diameters. Furthermore, not only can the rollers in a calender be embodied to be smaller, lighter and more cost-effective at an unchanged calender width, but the entire calender can also thus be dimensioned to be smaller.
[0024] An additional positive effect is that a roller in accordance with the invention is also capable of effectively dampening oscillations and vibrations generated by other components with which the roller cooperates in treating the web, for example one or more companion rollers, by drives, bearings, etc. or also by the web-shaped medium itself. Thus, for example, a significant improvement can also be expected with regard to the occurrence of barring, as is a fear with calenders.
[0025] Lastly, even in the range of the so-called semi-critical speed, a roller in accordance with the invention also exhibits greater smooth running than a roller which is identical in design but has no filling. Semi-critical resonances occur when there is anisotropy in the roller cross-section. Such a roller then has different rigidities in two planes perpendicular to each other. If such a roller, mounted in its two trunnions and under its own weight or an additional linear load, is rotated once about its axis, the magnitude of its sagging passes through two periods. Such a roller experiences a stimulation twice at a rotational speed corresponding to half its resonant frequency, i.e. at this speed, it is stimulated at a frequency corresponding to its resonant frequency. Given this stimulation, the dampening by the filling becomes fully effective.
[0026] In preferred embodiments, the mixture can be charged with a pressure burden, preferably by means of a chamber which can be or is already expanded by a hydraulic fluid. The chamber is preferably arranged within the mixture, but can in principle also form an outer wall of a hollow space which in this case is as a whole variable in its volume. The walls of the chamber are flexible, as a whole or in areas. In the latter case, the chamber is formed by a bubble. The chamber can however also be formed only from rigid chamber walls, at least one of which can move with respect to at least one other container wall and so vary the enclosed volume. Such a chamber can in particular be formed in the manner of a piston-cylinder arrangement, wherein a chamber wall forming the piston is preferably linearly guided by the surrounding chamber wall. A combination of flexible and moving, rigid chamber walls is also advantageous. The chamber can in particular be formed by means of an elastic restoring means, in particular bellows, preferably metal bellows. The moving container wall cited can be fastened to a top end of the bellows or can be formed directly by the top end, while the bottom end of the bellows is connected to another container wall. The pressure force of the enclosed fluid and the elasticity force of the bellows advantageously superimpose each other positively, such that if the mixture expands in volume, the volume of the chamber is reduced and the chamber pressure and also the restoring elasticity force of the bellows are thus increased. The chamber can advantageously compensate for changes in the volume of the hollow space and/or the mixture situated in it and can thus act as an equalizing chamber. Changes in volume even occur solely due to changes in the temperature of the roller.
[0027] Instead of pressurizing it by means of one or more chambers, the mixture can in principle also be directly placed under a pressure burden by charging it with hydraulic fluid. The hydraulic fluid can be a gas or gas mixture, in particular air, or can also be an additional liquid. In an alternative, likewise preferred embodiment, the hollow space can be evacuated, i.e. the mixture contained in it can be charged with a partial vacuum.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Example embodiments of the invention are explained below by way of figures. Features disclosed by the example embodiments, each individually and in any combination of features, advantageously develop the subjects of the claims and also the embodiments described above. There is shown:
[0029] FIG. 1 a roller in a first example embodiment, comprising a roller shell filled with an oscillation-dampening mass in which an equalizing chamber is arranged;
[0030] FIG. 2 a roller in a second example embodiment, comprising a roller shell filled with the mass and a modified equalizing chamber arranged in the mass;
[0031] FIG. 3 a roller in a third example embodiment, comprising at least one dampening body arranged in the roller shell;
[0032] FIG. 4 a roller in a fourth example embodiment, comprising a double-walled roller body in which the annular gap is filled with the oscillation-dampening mass;
[0033] FIG. 5 a roller in a fifth example embodiment, comprising a roller shell and a hollow displacement body elastically supported in it;
[0034] FIG. 6 a roller in a sixth example embodiment, comprising a roller shell and a solid displacement body elastically supported in it;
[0035] FIG. 7 a roller in a seventh example embodiment, comprising a roller shell and a displacement body fixedly supported in it and filled with the mass; and
[0036] FIG. 8 a roller in an eighth example embodiment, comprising a roller shell and a displacement body fixedly supported in it and filled with the mass, wherein an annular gap remaining between the roller shell and the displacement body is also filled with the mass.
DETAILED DESCRIPTION
[0037] FIG. 1 shows a roller in a first example embodiment, comprising a circular cylindrical roller shell 1 to which a trunnion 2 is fastened via a trunnion flange at each of its two axial ends. The roller thus obtained can be mounted on its two trunnions 2 such that it can be rotated and driven about a rotational axis R. The roller can in particular be a calender roller for smoothing a paper web.
[0038] In the roller shell 1 , which is rotationally symmetrical with respect to the rotational axis R, a central hollow space 3 is formed which is likewise rotationally symmetrical with respect to the rotational axis R. On its peripheral side, the shell inner surface of the roller shell 1 forms the wall of the hollow space. The two trunnion flanges seal the hollow space 3 at the two axial front sides of the roller shell 1 .
[0039] The hollow space is filled with a mixture 4 consisting of a liquid and a multitude of solid particles. The solid particles are granular. The mixture 4 as a whole exhibits a pulpy consistency. The mixture 4 completely fills the hollow space 3 , except for a chamber 5 filled with a gas. A flexible membrane 6 forms the wall of the chamber 5 . The membrane 6 is preferably elastic. The chamber 5 is thus formed as a bubble, preferably an elastic bubble. The chamber 5 is filled with air, wherein the air pressure in the chamber 5 is greater than the pressure in the surrounding roller. The chamber 5 and thus the whole of the mixture 4 are therefore under a pressure burden. The chamber 5 acts as an equalizing chamber by equalizing changes in volume which the hollow space 3 and the mixture 4 experience relative to each other.
[0040] The roller shell 1 is shown as a simple tube. If the roller 1 , 2 is a roller for thermo-mechanically treating a web, then the roller shell 1 can be thermally treated, i.e. heated or cooled. The roller 1 , 2 can for example comprise peripheral thermal treatment channels which extend axially through the roller shell 1 and preferably port at both axial ends. As a displacement roller, it could comprise an annular gap surrounding the rotational axis R as a thermal treatment channel formed between the roller shell 1 and a displacement body arranged in it. The displacement body can directly envelop the hollow space with the mixture 4 , such as the roller shell 1 in the example shown.
[0041] FIG. 2 shows a second example embodiment of an oscillation-dampened roller 1 , 2 , which only differs from the roller 1 , 2 of the first example embodiment with respect to the equalizing chamber. The equalizing chamber 7 of the second example embodiment includes a rigid chamber wall 8 , a disc-shaped chamber wall 9 and elastic pleated bellows 10 . The pleated bellows 10 are metal spring bellows. The chamber wall 8 surrounds the chamber wall 9 and forms a linear guide along the rotational axis R for the chamber wall 9 . Furthermore, it also surrounds the pleated bellows 10 . The chamber wall 8 is cup-shaped with a preferably circular cylindrical base and a completely encircling side wall which projects from the base, parallel to the rotational axis R, and guides the chamber wall 9 . The chamber wall 8 is fastened to one of the trunnion flanges; in the example embodiment, its base is placed onto the flange. The equalizing chamber and the components 8 to 10 forming it preferably exhibit rotational symmetry about the rotational axis R. The bottom end of the pleated bellows 10 is fastened to the cup rim of the chamber wall 8 and thence protrudes into the cup formed by the chamber wall 8 . The chamber wall 9 is fastened to the top end of the bellows 10 . The chamber wall 8 and the chamber wall 9 together form a piston-cylinder arrangement. The main part of the chamber 7 is formed by the hollow space between the chamber wall 9 and the opposing base of the chamber wall 8 along the rotational axis R. Behind the chamber wall 9 , as viewed from the base of the chamber wall 8 , a secondary chamber remains between the chamber wall 8 and the pleated bellows 10 . The chamber 7 and the secondary chamber are preferably connected to each other, such that pressure equalization can occur. The chamber 7 is sealed off from the mixture 4 by fastening the pleated bellows 10 circumferentially fluid-proof to the chamber wall 8 . An expansion of the pleated bellows 10 is counteracted on the one hand by their restoring elasticity force and on the other by the associated increase in pressure in the chamber 7 , which can equalize changes in volume which the hollow space 3 and the mixture 4 can experience relative to each other.
[0042] FIG. 3 shows a roller 1 , 2 in a third example embodiment in which the roller shell 1 does not directly form the container wall of the mixture 4 , as in the first and second example embodiment, but rather a dampening body is arranged in the central hollow space 3 of the roller. The dampening body is formed by a container 11 and the mixture 4 which completely fills the container 11 . The container 11 is a circular cylindrical container in which the cylindrical shell sits solidly on the roller shell 1 and is rigidly fastened directly to the shell inner surface of the roller shell 1 , preferably in a non-positive lock. The circular cylindrical container 11 comprises walls which are thin in comparison to its diameter and length. The cross-section of the hollow space enclosed by the container 11 therefore substantially corresponds to the cross-section of the hollow space 3 of the roller. The axial length of the hollow space 3 of the roller, measured in the direction of the rotational axis R, is however significantly greater than the axial length of the hollow space of the dampening body 4 , 11 filled with the mixture 4 . Preferably, a number of the dampening bodies 4 , 11 are arranged in the hollow space 3 of the roller, spaced from each other along the rotational axis R, and supported on the roller shell 1 . By arranging the mixture 4 axially in sections, as may be realized using the dampening body 4 , 11 or number of dampening bodies 4 , 11 , the oscillation characteristics of rollers can be influenced particularly specifically, and individually for each roller. Separate dampening bodies 4 , 11 are also particularly suitable for retrofitting rollers which were not originally provided with such oscillation dampening. In one modification, the shell of the container 11 could be replaced by the roller shell 1 by only inserting the disc-shaped bases of the container 11 into the roller shell 1 , as front walls.
[0043] FIG. 4 shows a fourth example embodiment of an oscillation-dampened roller, in cross-section. The roller includes a double-walled roller body consisting of a thin outer roller shell 1 and a thin inner hollow cylindrical body 12 . The roller shell 1 and the cylindrical body 12 are fixedly connected to each other via the two trunnion flanges which correspond to the trunnion flanges 2 of the other example embodiments. The roller shell 1 and the cylindrical body 12 can also be connected to each other in other connecting points over the axial length, but this is not absolutely essential.
[0044] The annular gap is completely filled with the mixture 4 . The roller shell 1 and the cylindrical body 12 thus form, directly and in conjunction with the two trunnion flanges, the container walls of the hollow space filled with the mixture.
[0045] In a fifth example embodiment, FIG. 5 shows a displacement roller in cross-section. The roller comprises a roller shell 1 and a cylindrical body 13 formed as a displacer which is arranged within the roller shell 1 and elastically supported on and fastened to the roller shell 1 by means of elastic support bodies 14 . The roller shell 1 can be formed with peripheral thermal treatment channels, as in the first, second and third example embodiment. The hollow space formed by the annular gap between the roller shell 1 and the cylindrical body 13 is completely filled with the mixture 4 , as in the fourth example embodiment.
[0046] FIG. 6 shows a roller in a sixth example embodiment which differs from the fifth example embodiment only in that the cylindrical body 15 is not a hollow cylinder but a solid cylinder.
[0047] FIG. 7 shows a roller in a seventh example embodiment, comprising a roller shell 1 and a hollow cylindrical body 16 arranged in the roller shell 1 . The cylindrical body 16 is filled with the mixture 4 , i.e. it forms its container wall on the peripheral side. The annular gap between the roller shell 1 and the cylindrical body 16 remains free and a thermal treatment fluid can for example flow through it, as is known from displacement rollers. The cylindrical body 16 is centrically arranged in the interior of the roller and rigidly fastened to the roller shell 1 by means of rigid spacers 17 ; it is preferably shrunk in.
[0048] Lastly, FIG. 8 shows a cross-section of a roller in an eighth example embodiment which differs from the roller in the seventh example embodiment only in that both the cylindrical body 16 and the annular gap remaining between the roller shell 1 and the cylindrical body 16 are each completely filled with the mixture 4 . Instead of filling the same mixture 4 into each of the two hollow spaces, i.e. into the interior of the cylindrical body 16 and into the annular gap, the two hollow spaces can also be completely or partially filled with mixtures which differ from each other but which each correspond to the mixture 4 in terms of their type.
[0049] One or more equalizing chambers can be provided in the hollow spaces, filled with the mixture 4 , of all the example embodiments, for example at least one chamber 5 and/or at least one chamber 7 .
[0050] In the foregoing description, preferred embodiments of the invention have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principals of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth they are fairly, legally, and equitably entitled.
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A web processing roll comprising at least one cavity. The cavity of the roll is at least partially filled with a mixture of a liquid and at least one mixing partner that is insoluble in the liquid. Solid particles, preferably a granular solid, or another liquid constitute the mixing partner.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the powering of a plurality of functional circuits within a telephone or other terminal device, through a subscriber's line of a telecommunication system, such as a telephone network, and, in particular, to a system for splitting a limited amount of supply current received from the line among a plurality of functional circuits in a terminal device, such as a telephone, capable of being powered through the line.
2. Discussion of the Related Art
In certain telecommunication networks and typically in wired telephone systems, a plurality of functional circuits, e.g. the speech circuitry, the dialling circuit, etc. of a telephone, must be capable of functioning with electrical power made available through the subscriber line by a dedicated battery installed in a remote switching station. Commonly, within an apparatus connectable through a user's line to a central system, there is a circuit dedicated to oversee the derivation from the line of a DC current necessary for powering the various functional circuits at respective stabilized supply voltages.
In a prior U.S. patent application Ser. No. 07/991,564, filed on Dec. 16, 1992, by the present applicant, an improved stabilized voltage power supply circuit for functional circuits of a subscriber's apparatus is disclosed. The circuit derives a current from the line and is capable of ensuring a reduced voltage "droop", i.e. a low voltage drop along the path between the physical connection point of the apparatus to the line and the point where a certain current is absorbed at a stabilized voltage by a certain functional circuit of the subscriber's apparatus. The bifilar subscriber's line normally constitutes also a signal path in these telecommunication systems. An important aspect of the practice of powering several user's circuits through a bifilar line, which has a nonnegiigeable influence on the global power consumption of the system, is represented by the manner in which a given amount of current that may be derived from the subscriber's line (normally a major portion of it) is eventually split among a plurality of functional circuits to be powered in the apparatus. The splitting must necessarily take place in respect of a certain predefined order of priority or rank of the various circuits. A typical example of this recurrent situation is represented by the subscriber's side speech circuits, where a dedicated circuit present in the telephone derives a current from the telephone line and distributes it, partially for powering itself, partially for powering logic control circuits, partially for powering an eventual microprocessor, partially for powering a circuit overseeing the so-called amplified-listening mode (if present in the telephone) and so forth among a plurality of functional circuits. Each of these functional circuits may have a maximum design current absorption and, in such an operating range, it may have a variable instantaneous current absorption depending on the actual working conditions. Depending on the functional characteristics and conditions of the various circuits and the interactions among the circuits, a certain rank of priority is assigned to each circuit and is used to determine the possibility of that circuit receiving power via the circuit overseeing the splitting of the available DC current derived from the line.
Commonly, in normal systems, the subdivision of the available supply current is performed taking into account the rank of priority of the various functional circuits, in the sense that current is supplied first to the circuit ranking higher in priority and so forth to all the other circuits in a decreasing order of priority as far as there is an adequate availability of supply current. For each user's circuit a maximum current absorption is set at the design stage and according to the known technique each of them will absorb in practice such a maximum current whenever they are activated. In other words, the available line current, that is the current which is derived by a certain subscriber I L , is split so as to supply current to the functional circuit of highest rank for a maximum current absorption of that particular circuit. The remaining current is made available to a second functional circuit of a lower rank for its maximum design current absorption value and the remaining current may then be made available to a third functional circuit of lower rank and so forth. This common system of splitting the available supply current among a plurality of functional circuits of different rank, may be expressed by the relationship:
I.sub.L =I1max+I2max+I3max+. . .
where I L is the total current which is derived from the line.
This way of managing the splitting of the supply current is not always efficient. For example, if the current which is actually absorbed by a certain functional circuit of the apparatus connected to the line has a relatively low stand-by value (DC) and relatively large absorption peaks (AC), a remarkable waste of current may occur.
OBJECTIVE AND SUMMARY OF THE INVENTION
A main objective of the present invention is to provide an improved method for splitting a supply current derived from a subscriber's line among a plurality of functional circuits of a local installation or equipment corrected to the line and a current splitting circuit, which implements such a novel method.
Basically, the system of the invention employs a dedicated circuit functionally connected across the supply nodes of the functional circuit of highest rank and optionally (and more preferably) also across the supply nodes of the other functional circuits of decreasing rank. Such a dedicated circuit monitors the current which is effectively absorbed at any instant by the respective functional circuit and diverts any current that at the moment is in excess of the effective absorption of such a functional circuit to a functional circuit or to the functional circuits of lower rank, without sinking the excess current toward a virtual ground node of the functional circuit, as is customarily done in the systems of the prior art.
For example, the circuit of the invention may sense an eventual rise of the regulated supply voltage of such a first functional circuit of highest rank as a consequence of a drop of the current that is being actually absorbed by the functional circuit itself, and generates a control signal. Such a control signal is utilized as a "feedback" signal for modifying the dynamic behavior of a differential current-dividing stage of the supply circuit of the instant invention. According to a first embodiment of the invention, said control signal may be used for generating an offset between the control nodes of said differential stage in order to proportionally decrease the current delivered to said first functional circuit and increase the current which is delivered to a second (or to other) functional circuit and vice versa.
Such an offset type current-splitting circuit permits in practice to switch even the whole supply current from a first to a second (in rank) functional circuit (or to all the circuits that come after the first functional circuit of highest rank). In fact, by making said differential, current-dividing stage with a pair of bipolar junction transistors (BJT), an offset voltage of just about 100 mV is sufficient to determine a ratio of about 90:1 between the currents delivered through the two transistors of the differential pair to two distinct functional circuits.
Naturally, according to the system of the invention, all the current that a functional circuit of highest rank may absorb will be derived from the line (if available) as needed, and this amount obviously will reduce the residual amount of supply current which may be delivered to functional circuits of lower rank. The system of the instant invention prevents the waste of current that was determined in known systems, which delivers to any functional circuit its maximum design current, by sinking any current that may be temporarily in excess of the actual absorption of the powered functional circuit through a voltage stabilizing shunt networks.
Of course, the effectiveness of the circuit of the invention in producing a valuable energy saving will manifest itself and become remarkable as more frequent will be the occasions in which the highest rank functional circuit, and also the other circuits of decreasing rank, will be subject to temporary conditions of relatively low current absorption.
BRIEF DESCRIPTION OF THE DRAWINGS
The different aspects which characterize the invention and the relative advantages will become more evident through the following description of several embodiments and by referring to the drawings, wherein:
FIG. 1 is a basic diagram of a circuit for supplying and dividing a given limited amount of supply current among a plurality of functional circuits, which is provided with an offset-type control circuit according to the present invention;
FIG. 2 is a view of the offset-type control circuit portion of the circuit of FIG. 1;
FIG. 3 shows a circuit for dividing a supply current among four functional circuits, according to a first embodiment of the invention;
FIG. 4 shows an alternative embodiment of the invention for splitting a supply current among four functional circuits;
FIG. 5 shows another alternative embodiment of the invention.
DETAILED DESCRIPTION
With reference to FIG. 1, a supply circuit of a user's equipment connected to a bifilar line, (e.g. a subscriber's telephone line) comprises an input circuit, which may be substantially similar to the circuit described in said prior U.S. patent application, Ser. No. 07/991,564. Basically, such an input circuit comprises two resistors: R1 and R2, an operational amplifier G1 that drives two output stages: a first one composed of the current generator I1 and the MOS transistor M1 and the other of the current generator I2 and the MOS transistor M2. The description of an input circuit of this type, contained in said above-identified prior patent application Ser. No. 07/991,564, is herein incorporated by express reference. The bifilar line is symbolically represented in all the figures by the wire V L and by the ground node shown. In practice, in a telephone both the (virtual) ground node as well as the node V L may be functionally connected to the pair of real wires of the subscriber's telephone line through other circuits which may also be external to the integrated circuit containing the power supply circuit. These intervening circuits are not shown in the figures to avoid overburdening the drawings, in consideration of the fact that the eventual presence of these intervening circuits is substantially irrelevant as far as the function of the circuit of the instant invention, is concerned.
The supply current I L , which may be drawn from the line for powering the various functional circuits of the user's apparatus, is delivered through the resistance R2 of the input circuit.
Commonly, in the circuits of the prior art, and similarly also in the circuit, improved under different aspects, disclosed in the above-identified prior patent application, across each functional circuit, i.e. connected in parallel to the functional circuit to the respective supply nodes thereof, there is a shunt regulator SR, capable of maintaining constant the voltage across said supply nodes within a certain range of current absorption. These shunt regulators are intrinsically dissipative circuits, being based upon the principle that each functional circuit provided with its shunt regulator will absorb a predetermined maximum design current from the line.
By contrast, the circuit of the present invention is characterized by the fact that at least the functional circuit of highest rank is provided with a circuit capable of detecting the current that is really drawn by the functional circuit and to generate a first signal Vco, which controls an offset current generator Ico for a differential pair of current delivering transistors P2 and P3, used for splitting a supply current drawn from the line between said first functional circuit and an eventual second functional circuit or several other functional circuits of lower rank, as will be described in more detail hereinbelow.
The role of the two output stages of the input circuit is as follows. When the output stage 02 is active, i.e. when the line voltage V L is lower than the sum of the nominal regulated supply voltage of the first functional circuit to be powered (e.g. Vdd), of the Vcesat of transistor P1, and the voltage drop VR2 across the resistance R2 (i.e. V L <Vdd+Vcesat+VR2), then transistor P1 conducts and all the current I L drawn from the line flows to ground. In this manner, the whole right-hand portion of the circuit of FIG. 1, i.e. all the functional circuits, remains powered exclusively by the electrical charge which is stored in the respective storage capacitors. On the other hand, when the output 01 is active, i.e. when the line voltage V L is greater than the sum of the regulated supply voltage (e.g. Vdd) of the first functional circuit, the Vcesat of the respective current delivering transistor P2, and the voltage drop VR2 across resistor R2 (i.e. V L >Vdd+Vcesat+VR2), transistor P1 switches off thus allowing the line current I L to be distributed among to the various functional circuits.
For simplifying the illustration, the different functional circuits are schematically indicated in all the figures by as many storage capacitors of electrical charge: A, B, C, D, . . . , in a decreasing order of rank. In parallel with the functional circuits of relatively lower rank (B, C, . . . ) may be present a shunt regulator SR of any known type, as commonly used in the systems of the prior art, capable of keeping constant the voltage across its nodes, i.e. the regulated supply voltage of the respective functional circuit, e.g. (Vdd, Vcc, . . . ), according to the design value, by means of a relative reference voltage (Vrif B , Vrif C , . . . ) functionally applied to an input of the shunt regulator SR.
At least across the functional circuit A of highest rank in terms of priority of supply (FIGS. 1, 2, 3 and 5) or also across the other functional circuits of lower rank, with the exclusion of the lowest rank circuit (FIG. 4), in place of a shunt regulator SR, a voltage monitoring network composed substantially of a voltage divider Ra-Rb, is functionally connected across the supply nodes of the respective functional circuit.
The voltage Vp, present on the intermediate node of the voltage divider Ra-Rb, is a signal representative of the voltage which is present on the supply node of the functional circuit and this signal is fed to an input of a circuit block G. Block G also has a second input to which a reference voltage (e.g. Vrif A ) may be applied.
Block G may represent any circuit capable of generating on an output node a signal proportional to the difference between the voltage Vp and the reference voltage (e.g. Vrif A ). Of course many known circuits will provide such a function and may be used for the block G. For example, the circuit of a difference amplifier using an operational amplifier, according to a well known network, is perfectly suitable as block G. In this case, a voltage Vco given by the following equation: Vc=(Vp-Vrif.sub.()) ×G, where G is thee voltage gain of the circuit, will be generated on the output node of the block G. Of course, as an alternative, a differential amplifier such as an operational amplifier capable of generating through the output node a current signal proportional to the difference between the voltage Vp and the reference voltage Vrif A fed to the inputs of the differential amplifier, may also be used.
According to a first embodiment of the invention, shown in FIG. 1, control signal Vco generated by the block G is fed to a control terminal of offset current generator Ico, to force this generator to deliver a current which is a function of the control signal Vco. Such an offset current, by circulating through the resistance R3 and R4 generates an offset voltage between the control nodes of a differential pair of transistors (P2 and P3 in FIG. 1). The bias conditions of this differential pair of transistors is established by connecting the intermediate node of connection between the two offsetting resistances R3 and R4 to the output node 01 of the input stage, thus forcing a biasing current Ib through the base of transistors P2 and P3.
The effect of such an offset voltage is that of modifying the drive conditions of the differential pair of transistors, P2 and P3. The pair of transistors splits a supply current derivable from the supply node E (FIG. 1) between functional circuits A and B. The conductivity of one transistor of the pair as compared with the conductivity of the other transistor increases or decreases as determined by the cause that produces such an offset voltage.
In practice, if for example the highest rank functional circuit A decreases its current absorption, thus causing a rise in the voltage Vp, the circuit will tend to attain a new equilibrium by increasing the current delivered to the functional circuit of lesser rank and decreasing the current delivered to the highest rank circuit. Therefore any excess current will be usefully made available to the circuits of lesser rank instead of sinking it to ground.
As it is put in more evidence in the partial view of the circuit of FIG. 2, according to this embodiment, the regulating signal Vco modifies the conductivity state of the two current delivering transistors P2 and P3, which are functionally connected between a common current supply node E and the functional circuits A and B, respectively, by reducing or increase the conductivity of the transistor P2 and simultaneously increasing or reducing the conductivity of the transistor P3.
Of course the offset-type, current-splitting circuit of the present invention may be advantageously used in different applications, taking into account the relative margins for energy saving which exist in practice.
With reference to FIG. 3, the offset type current splitting circuit of the invention may be applied exclusively to the highest rank functional circuit A. All the current exceeding the current which is really absorbed by the first functional circuit A, may then be divided in a "fixed" (indiscriminate) mode among all the other functional circuits (B, C, D). Each of the lower rank circuits may be provided by a common shunt regulator (i.e. a dissipative voltage regulator).
Alternatively, as shown in FIG. 4, when the peculiar characteristics of the application warrant it, a non-dissipative, current delivering circuit may be provided also to others or to all the subsequent functional circuits of lesser and lesser rank (i.e. A, B, C) with the exception of the lowest rank circuit (i.e. D), which will be provided eventually with a normal dissipative shunt regulator SR. In the case of these other functional circuits, the control signal Vco generated by the respective block G, and given by: Vco=Vp-Vrif.sub.())×G may be directly used for driving a current delivering transistor which controls the current that is delivered to the respective functional circuit.
An alternative embodiment of the current splitting circuit of the present invention is depicted in FIG. 5.
According to this alternative embodiment, the role of the MOS transistor M2 and of the current generator I2, i.e. of the single output stage driver by the operational amplifier G1 of the input circuit, is substantially identical to that of the same elements of the input circuit shown FIG. 1.
According to this alternative embodiment, a second differential pair of transistors composed of the transistors N1 and N2 is introduced. The transistors N1 and N2 actually drive the transistors P2 and P3 of the first differential pair of transistors, which actually splits and delivers the supply current drawn from the line through the resistance R2, to the respective functional circuits A and B.
The operation of the circuit is as follows. By supposing that the voltage Vp, present on the intermediate node of the voltage divider Ra-Rb and given by the equation: Vp=Vdd×Ra/(Ra+Rb), rise because of a diminished current absorption of the functional circuit A of highest rank, the signal Vco, generated at the output of the block G, rises by an amount given by the equation: Vco=(Vp-Vrif) ×G. This tends to unbalance the differential pair of transistors N1 and N2 in the sense of increasing the current through the transistor N2 and thus force a higher current through the base of the transistor P3. The accompanying increase of the emitter current of the transistor P3 and decrease of the emitter current the other current delivering transistor P2 bring the supply current splitting circuit to reach a new equilibrium condition whereby all the current in excess of the current which is really absorbed by the highest rank functional circuit A is usefully transferred to the functional circuit B of lesser rank without any waste. The differential pair of transistors N1 and N2, used in this way, provide a functional equivalent of the offset current generator described above, controlling the offset between the control inputs of the differential pair of transistors P2 and P3. Each of transistors N1 and N2 may be referred to as an "offset control transistor" having an "offset control terminal".
Having thus described one particular embodiment of the invention, various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention is limited only as defined in the following claims and the equivalents thereto.
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A circuit is provided in telecommunication terminal equipment for splitting a limited supply of current received from a subscriber's line current among a plurality of functional circuits according to their priority rank. The circuit uses a differential pair of current delivering transistors and a special circuit to monitor the actual current of absorption of at least the functional circuit of highest rank to produce a control signal that is used for modifying the drive conditions of the current delivering transistors. All current exceeding the actual absorption needs of the highest rank functional circuit is distributed to the other functional circuits and the prior art practice of sinking unneeded current through a dissipative shunt voltage regulator associated with each functional circuit is avoided. This same principle may be advantageously applied also to functional circuits of progressively lesser rank of priority.
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