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This application claims benefit of 60/309,226 filed Jul. 31, 2001.
BACKGROUND OF THE INVENTION
The present invention relates generally to the field of protecting people from the negative effects of ultra-violate rays, and specifically to methods and apparatus for applying sunscreen lotion to the body of a user.
The cosmetic and health-related dangers of being exposed to the ultra-violet (“UV”) rays found in sunlight have become a major concern of people worldwide. Among the negative effects resulting from UV ray exposure are skin cancer and increased “wrinkling” of the skin. Despite these dangerous and unwanted consequences, people continue to frequent beaches, pools, and resorts where they tend to spend substantial portions of their days exposed to the direct sunlight. One very common way in which people protect themselves from the harmful effects of the sun is to apply sunscreen lotion to their skin. Sunscreen contains compositions that shield the wearer's skin from the UV rays contained in sunlight. Thus, applying sunscreen to the skin allows the user to spend his or her day in the direct sunlight while minimizing the risk of the negative effects associated with such exposure.
The amount of UV ray protection that a sunscreen lotion provides to a user depends on a number of variables, such as frequency of application, the amount of sunscreen lotion applied per application, and the particular sun protection factor (“SPF”) of the sunscreen lotion being used. Sunscreen lotions come in various grades having SPF ratings, the most common of which vary from 2 to 45. The higher the SPF factor of a sunscreen lotion, the more protection that sunscreen lotion will provide to the user. For example, a sunscreen lotion having an SPF rating of 2 provides very little protection from UV rays as compared to a sunscreen lotion having an SPF rating of 45. However, because sunscreen lotion also prevents tanning of the skin, all users do not wish to maximize UV ray protection by choosing a sunscreen lotion with the highest possible SPF rating. Thus, what is considered a desirable grade of sunscreen lotion to be applied to the skin varies from person to person.
Currently, when a person is at a beach, pool, or other outside area and they desire to utilize the protective effects of sunscreen lotion, they apply the sunscreen lotion to their skin by squeezing the lotion from the bottle into their hands. Once in their hands, the sunscreen lotion is applied to the remaining areas of their skin by manually rubbing it on the skin. This manual application has a number of drawbacks, the most significant which is the inability of the user to reach all areas of their skin. Even with the help of a second person, uneven distribution of the sunscreen lotion can occur, resulting in an uneven tan or unwanted exposure of certain areas of the skin to UV rays. Thus, improved methods and apparatus for applying sunscreen lotion to the skin are needed.
While a number of apparatus do exist that are capable of automatically applying sunscreen lotion to the skin of a user, these apparatus have a number of deficiencies and are not suited for convenient outdoor use. Examples of such apparatus are disclosed in U.S. Pat. No. 6,302,122, Parker et al.; U.S. Pat. No. 5,664,593, McClain; and U.S. Pat. No. 5,460,192, McClain. Typically, these existing apparatus are used to apply sun-tanning compositions to the body of a user and are located indoors within tanning spas. User access to these apparatus is regulated by an operator or other person working at the spa. Because these apparatus are located indoors, the circuitry and other susceptible components of these machines are not adequately protected from outdoor elements. Nor are these apparatus designed to provide the necessary privacy to a user in an outdoor public setting. As such, these apparatus can not be positioned outdoors at such places as on a beach or near a pool, the exact places where people most often experience the immediate need to apply sunscreen lotion. In addition to not being physically adapted for outdoor use, existing apparatus can not be placed on beaches and achieve economic success because access to existing apparatus can not be restricted without hiring extra personnel to monitor and operate the machines and collect revenue. Thus, a need still exists for an economically efficient machine that can effectively apply sunscreen lotion to a user in an outdoor setting.
SUMMARY OF THE INVENTION
These objects and others are met the present invention which in one aspect is a vending machine for dispensing sunscreen lotion comprising: means to accept payment from a user, means to store sunscreen lotion, and means to spray sunscreen lotion coupled to the means to store sunscreen lotion, the means to spray adapted to spray the user with the stored sunscreen after acceptance of payment. Preferably, the user obtains access to the machine through a door having a locking controller. In order to ensure that each user provides payment for the application of the sunscreen lotion, the locking means is electrically coupled to the means to accept payment. As such, the door unlocks only upon the means to receive payment receiving a payment from a user. In one embodiment, the locking means is coupled to a one-way lock that permits exit from inside the machine at all times. Using a one-way lock allows the user to freely exit the machine at any time and ensures that the door locks thereafter. Also preferably, the means to accept payment and the means to spray sunscreen lotion are coupled so that the means to spray sunscreen lotion can be activated only once for each payment received by the means to receive payment.
The machine can comprise user detection means adapted to detect location of the user within the machine. In this embodiment, the user detection means can be coupled to the means to spray sunscreen lotion. The user detection means can then be adapted so that upon detecting the user in a predetermined location in the machine, the means to spray sunscreen lotion are automatically activated. In this way, the sunscreen lotion can be applied to the user after payment has been made. Alternatively, the machine can comprise an activation means, wherein the activation means is coupled to the means to spray sunscreen lotion. Upon the activation means receiving an input from the user, the means to spray sunscreen lotion will be activated, applying sunscreen lotion to the user.
It is preferable that the means to store sunscreen lotion be adapted to store a plurality of grades of sunscreen lotion. In this embodiment, the machine will further comprise means for the user to select which grade of sunscreen lotion will be sprayed by the means to spray sunscreen lotion. Moreover, it is further preferable for the grades of sunscreen lotion to vary as to sun protection factor (SPF).
In yet another embodiment, the machine comprises means to store a disinfectant. In this embodiment, the means to spray sunscreen lotion is coupled with the means to store disinfectant which enables the means to spray sunscreen lotion to also be capable of spraying the disinfectant. Preferably, the disinfectant will be sprayed to clean and sanitize the interior of the machine after the user has been sprayed with sunscreen lotion and has exited the machine. Whether the user has exited the machine or not can be determined by the user detection means discussed above.
It is also preferable for the machine to be adapted for outside use. In such an embodiment, the machine can comprise a drain that is fluidly connected to a reservoir. The drain and fluidly connected reservoir will drain any extra fluids that may remain in the machine after use. This allows the machine to be positioned anywhere, such as on the beach or near a pool. Additionally, the drain helps keep extra liquid from building up and forming slippery surfaces within the machine. In regards to preventing slipping, the machine can comprise a no-slip floor.
In order to further enable outside use, the machine can further comprise a water supply line that is fluidly connected to the means to spray sunscreen lotion on one end and a water supply on the other.
In the preferred embodiment, the machine will comprise both an application booth and a preparation booth. In this embodiment the means to spray sunscreen lotion will be located within the application booth which is adapted to fit the entire body of the user. The preparation booth will act as a staging area for the user in preparing for the application of the sunscreen lotion. As such, it will preferably have opaque walls and a means to hang a bathing suit.
In another aspect, the invention is a method of dispensing sunscreen lotion comprising: providing a machine which is adapted to receive and accept payment and store and spray sunscreen lotion; and spraying a user with the sunscreen lotion for a predetermined amount of time or volume of lotion upon a user providing payment to the machine.
In this aspect, it is preferable that the method further comprise the step of unlocking the machine so as to allow the user access to the machine after payment is received by the machine. Additionally, the step of spraying disinfectant in the machine after the user is sprayed with the sunscreen lotion can be performed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of the present invention, a sunscreen application vending machine.
FIG. 2 is a top view of the sunscreen application vending machine of FIG. 1 .
FIG. 3 is a front view of a user control panel that can be sued to control some of the functions of the sunscreen application vending machine of FIG. 1 .
FIG. 4 is a schematic of the control system and equipment of the sunscreen application vending machine of FIG. 1 .
FIG. 5 is a side view of an embodiment of sprayer assembly used in the sunscreen application vending machine of FIG. 1 .
FIG. 6 is side view of a hut shell that can be sued to encompass the sunscreen application vending machine of FIG. 1 for aesthetic purposes.
DETAILED DESCRIPTION
Referring to FIG. 1 , one embodiment of a sunscreen application vending machine 10 according to the present invention is illustrated. Sunscreen vending machine 10 comprises preparation booth 20 , application booth 30 , and equipment housing 40 . Sunscreen vending machine 10 further comprises payment receiver 60 . In order to better illustrate the interior elements of the invention, sunscreen vending machine 10 is illustrated without a roof over preparation booth 20 , application booth 30 , and equipment housing 40 . However, in order for sunscreen vending machine 10 to be positioned outdoors, it is preferred that a roof be placed over preparation booth 20 , application booth 30 , and equipment housing 40 . The roof can be weather-tight so that water can not enter any of the interior areas of the machine 10 . If desired, the entire machine 10 can be enclosed by a hut 90 ( FIG. 6 ) or other aesthetically desirable enclosure.
Payment receiver 60 is mounted to front wall 21 of preparation booth 20 . Payment receiver 60 comprises receiving slot 61 for receiving any type of conventional payment method, including coins, bills, credit cards, debit cards, or the like. Payment receiver 60 comprises a properly programmed processor 62 (FIG. 4 ). Processor 62 is properly configured and connected to other internal elements and circuitry of payment receiver 60 so as to be capable of determining the amount of money inputted by a user into receiving slot 61 or reading the amount of credit/debit on an inserted card. In the case of debit cards, processor 62 will deduct the required payment amount from the account and record the new balance on the magnetic strip. In the case of credit cards, payment receiver 60 ensures the required payment by connecting to the corresponding account through a communications line, such as a phone line or cable, and adding the required payment to the credit line of the card (as is done with conventional credit card machines). Once payment receiver 60 receives the required payment from a user, processor 62 sends the proper output signals to a variety of electrically connected devices. Any payment receiving system can be used, for example, those disclosed in U.S. Pat. No. 6,367,658, Kenney et al., and U.S. Pat. No. 6,367,696, Inamitsu et al.
Front wall 21 of preparation room comprises doorway 22 . Doorway 22 provides users with access to the interior of sunscreen vending machine 10 . Door 23 is mounted to doorway 22 by hinges 24 . Door 23 comprises door knob 25 for opening and closing door 23 . Door knob 23 is a “one-way locking door knob.” When door 23 is closed, a user can not simply turn door knob 25 from the outside to gain entrance to the interior of sunscreen vending machine 10 . However, door knob 23 does not lock from the interior and so if a user is within sunscreen vending machine 10 , he or she can exit the machine by simply turning door knob 25 despite it being locked from the outside. Moreover, turning door knob 25 from the inside does not changed the locked status of the door knob from the exterior. Such door knobs and locking apparatus are very well known. Door 23 further comprises locking controller 26 ( FIG. 4 ) within door 23 and coupled to door knob 25 . Locking controller 26 controls when a user can gain access to the interior of sunscreen vending machine 10 by unlocking door knob 25 from the exterior upon receiving a proper signal from payment processor 62 (FIG. 4 ).
The walls of preparation booth 20 are preferably constructed of an opaque material. This provides a user with the privacy necessary if the user decides to remove his or her bathing suit before entering application booth 30 for the application of sunscreen lotion. Preparation booth 20 will further comprise hook 27 mounted to the one of the walls from which the user can hang his or her bathing suit. While a single book 27 is illustrated in FIG. 1 , a multitude of apparatus can be used, including a clip, knob, peg, rack, or other suitable extrusion. Additionally, preparation booth 20 can further comprise a mirror, a bench, and disposable eye and head wear for the user.
Referring to FIGS. 1 and 2 , as illustrated, application booth 30 is a hexagonally shaped chamber. However, application booth 30 can be any shape, but it is preferred that its dimensions be designed so that a user can fit entirely therein and stand upright. For example, suitable length, width, and height dimensions could approximately be 90 inches, 48 inches, and 96 inches respectively.
Application booth 30 is adjacent to preparation booth 20 with a second doorway (not illustrated) leading from the interior of the preparation booth 20 to the interior of application booth 30 . Second doorway 31 has a second door (not illustrated) extending the full length of second doorway 31 . When the second door is closed, application booth 30 is an essentially closed chamber. The second door and doorway may or may not contain a door knob and coupled locking controller as described above.
Application booth 30 further comprises spray assemblies 31 mounted to the walls of application booth 30 . Spray assemblies 31 are fluidly connected to the sunscreen lotion storage containers 41 ( FIG. 4 ) that are located in equipment housing 40 . Spray assemblies 31 spray atomized sunscreen lotion in an air current into application booth 30 . Spray assemblies 31 are positioned around application chamber 30 so as to evenly coat the entire skin of a user who is standing in the center of the booth 30 .
Application booth 30 also comprises sensors 32 located around the application booth 30 . Sensors 32 can detect the presence and location of a user inside of application booth 30 . Sensors 32 can be any type of conventional sensor that can detect objects and transmit appropriate signals to communicate with other devices, such as photo-optic, ultrasonic, and infrared sensors. As will be discussed in detail below, sensors 32 are electrically coupled to and can control the activation and deactivation of sprayer assemblies 31 .
Additionally, application chamber comprises drain 33 and no-slip floor 34 . Drain 33 is located in the approximate center of application chamber 30 . Drain 33 is fluidly connected to a reservoir 37 (FIG. 4 ). As fluids, such as the sunscreen lotion or disinfectant, enter the application booth 30 , excess fluid will build up. This excess fluid is removed from the booth 30 by drain 33 . Because the excess fluid may contain chemicals that are not environmentally safe to be dumped, the drain can be fluidly connected to a reservoir 37 ( FIG. 4 ) from which the fluids can be removed and/or treated. Flow of the excess fluid into drain 33 is facilitated by the pitch of the floor 34 (indicated by the striped lines). Preferably, floor 34 is constructed so as to be a no-slip floor (i.e., slip-resistant). Slip resistant floors are very well known in the art and generally consist of raised portions and channels for carrying away fluid located between the raised portions. An example of a slip-resistant floor is disclosed in U.S. Pat. No. 5,815,995, Adam.
Finally, application chamber 30 comprises user control panel 35 . User control panel 35 is mounted to the wall of application chamber 30 .
Referring to FIG. 3 , user control panel 35 contains a variety of buttons 80 - 85 . In the illustrated embodiment, a user can select which SPF grade of sunscreen lotion he or she wishes to have applied by sprayer assemblies 31 by pressing the corresponding button 81 - 85 on control panel 35 . As will be discussed in reference to FIG. 4 below, control panel 35 is coupled to sprayer assemblies 31 and the pumps that control which SPF grade will be sprayed therethrough. Additionally, control panel 35 will comprise activation button 80 in those embodiments of the sunscreen application vending machine 10 that do not have sensors 31 that will automatically start spraying sunscreen lotion upon the user being detected in a predetermined position and an SPF grade of sunscreen lotion being chosen as discussed above. Upon a user pressing activation button 80 , sprayer assemblies 31 will be activated, spraying the user with the selected SPF grade of sunscreen lotion.
Referring back to FIG. 1. , equipment housing 40 holds the necessary equipment, circuitry, and supplies needed to operate sunscreen application vending machine 10 . For example, equipment housing 40 holds the pumps, containers of sunscreen lotion with various SPF grades; disinfectant liquid, flow meters, wiring, and the like.
Referring now to FIG. 5 , an example of a suitable spraying assembly 31 is shown. While the illustration shows one embodiment of a spraying system, suitable spraying mechanisms and are very well known in the art. For examples of such sprayers, see U.S. Pat. No. 6,302,122, Parker et al.; U.S. Pat. No. 5,664,593, McClain; and U.S. Pat. No. 5,460,192, McClain. Spraying assembly 31 comprises an arm 50 having three active nozzles 51 . One spray nozzle 51 is on the central portion of arm 50 and one spray nozzle 51 is on each of the two outer portions of arm 50 . Each spray nozzle 51 , when activated sprays in a direction towards a certain location in the application booth 30 , said location being the location for positioning a user during use, also referred to as the predetermined location.
In operation, the plurality of spray nozzles 51 produce a spray optimized to provide a relatively even coating on the skin of a user, with substantially no streaking or dripping. This can be accomplished by regulating the spray patterns and spray direction geometries of the nozzles, as well as the average droplet particle size, the nozzle liquid and air feed pressures, and the viscosity of the sunscreen lotion. One specific example of a suitable nozzle and operating conditions, without limitation, is the external mix, flat spray, air atomizing 1/8J with a SUE 18B Spray set-up available from Spraying Systems Co., Wheaton Ill., operating at a liquid pressure of about 5 to about 20 psi (about 35-140 kPa), preferably about 10 psi (about 70 kPa) and air pressures in the range of about 15 to about 30 psi (about 100 to about 200 kPa).
A predetermined location within the booth is provided for a user to stand during a sunscreen lotion application operation according to the present invention. It is generally convenient for the location to be in the central portion of the application booth 40 though alternatives may be suitable for design considerations, as for example, the back, side or front of the booth relative to the arm. In one embodiment, the predetermined location is in front of the spray nozzles at a horizontal distance of between about 25 cm and 60 cm, measuring to the surface of the user's body closest to the nozzles. Greater or lesser distances can be used by adjusting the nozzle liquid and air feed pressures accordingly, as for example by increasing the feed pressures for greater distances. Greater distances, however, may lead to greater spray pattern dispersion and more combining of spray droplets, resulting in a sub-population of less desirable large droplets, which may drip or streak after deposition on the skin or result in an uneven coating.
In the illustrated embodiment, arm 50 is a manifold. The manifold 50 is a two compartment bar providing pressurized feed of sunscreen lotion through sunscreen lotion feed line 52 into one compartment, and pressurized feed of air through compressed air feed line 53 into the second compartment. In this manner, each nozzle 51 receives equivalent feeds of air and liquid which is then atomized into a spray in the nozzle 51 . Optionally, manifold 50 may be fitted with disinfectant feed line and a water feed line to spray application booth 30 in a cleaning and sanitizing step.
FIG. 4 is a schematic representation of the control system and equipment used to make sunscreen application vending machine 10 works. In order to use sunscreen application vending machine 10 , a user must approach the machine 10 and deposit the required payment in payment receiver 60 as described above. Upon detecting receipt of adequate payment into payment receiver 60 , payment receiver processor 62 sends the appropriate output signal 100 to locking controller 26 . Payment receiver processor can be any type of properly programmed CPU chip, such as those manufactured by Intel. Upon receiving output signal 100 , locking controller 26 unlocks door knob 25 so the user can access the interior of preparation room 20 . Locking controllers that are capable of locking and unlocking doors upon receiving an such inputs are well known in the art. See for example U.S. Pat. No. 6,365,986, Nonome, and U.S. Pat. No. 6,382,003, Watanuki et al.
Additionally, upon detecting receipt of adequate payment into payment receiver 60 , payment receiver processor 62 sends output signal 700 to panel processor 36 within user control panel 35 . Before receiving output signal 700 , panel processor 36 and user control panel 35 are in a deactivated state and cannot be receive input directly form a user within application booth 20 . However, once output signal 700 is received, panel processor 36 and user control panel 35 are “awakened” and can perform the function described below.
Once the user is within preparation booth 20 , door 23 closes behind the user, automatically locking from the outside. In order to ensure that door 23 closes, hinges 24 can be spring loaded. The user will then prepare for the application of the sunscreen lotion by taking off his or her bathing suit and wearing eye and head gear if desired. The user then enters application booth 30 . Upon entering application booth 30 , the user will select which SPF grade of sunscreen lotion that he or she desire to have applied to their body by pressing the corresponding button 81 - 85 on user control panel 35 . User control panel 35 comprises properly programmed control panel processor 36 which receives the inputted SPF grade selection from the user. In response to receiving this input, panel processor 36 sends signal 110 to the appropriate pump 181 - 185 . Pumps 181 - 185 are operably coupled to corresponding fluid lines 281 - 285 which in turn are fluidly connected to corresponding sunscreen lotion tanks 381 - 385 . Sunscreen lotion tanks 381 - 385 are located within equipment housing 40 and each contain a different SPF grade of sunscreen lotion. Assuming that the user presses SPF selection button 83 , which corresponds to sunscreen lotion having an SPF of 20, panel processor 36 send output signal 110 to pump 183 , activating pump 183 . Pump 83 then pumps the SPF 20 sunscreen lotion from tank 383 through fluid line 283 until the sunscreen lotion reaches flow valve 400 . At this point flow valve 400 is closed and as such, the sunscreen lotion can not flow into sunscreen feed line 52 as of yet. In order to avoid mixing of the various SPF grades, single-direction flow valves must be strategically placed on fluid lines 281 - 289 .
In addition to sending output signal 110 , panel controller also sends appropriate output signal 120 to air compressor 600 , thus activating air compressor 600 . Once activated, air compressor 600 forces air to flow through compressed air feed line 53 and into spraying assemblies 31 and out of nozzles 51 as described in relation to FIG. 5 above.
Once the user has selected the desired SPF grade of sunscreen lotion to be applied, the user positions himself in the center of application booth 30 (i.e., the predetermined location) Upon moving into the predetermined location, sensors 32 detect the user's presence therein and sensor processor 70 (which is located in the sensors 32 ) sends output signal 130 to flow valve 400 . Upon receiving output signal 130 , valve 130 is opened to allow an appropriate volume of the SPF 20 sunscreen lotion being pumped by pump 183 to flow therethrough and into sunscreen lotion feed line 52 and eventually sprayer assemblies 31 . Spray assemblies 31 then spray the sunscreen lotion mist onto the user as described above with respect to FIG. 5 . Alternatively, in an embodiment that does not use sensors 32 , panel processor 36 will send output signal 130 to flow valve 400 upon a user pressing the activate sprayer button 80 .
After a predetermined period of time (or volume flow of sunscreen lotion), panel processor 36 sends output signals to both air compressor 600 and pump 183 to terminate operation, thereby discontinuing spray of sunscreen lotion mist. At this point, user control panel 35 and panel controller 36 go into a deactivated state and cannot be activated again until payment processor sends another output signal 700 confirming payment.
Upon the user leaving application booth 30 , sensors 32 detect the absence of the user and sensor processor 70 sends output signals 800 and 900 to disinfectant pump 810 and water pump 910 respectively, activating pumps 810 and 910 . Simultaneously, a signal 130 is sent to flow valve 400 , causing flow valve 400 to once again be closed. Pump 810 is fluidly connected to disinfectant tank 820 which holds a disinfectant solution. Water pump 910 is fluidly connected to water supply tank 920 . Upon being activated, pumps 810 and 910 pump disinfectant solution and water through disinfectant feed line 830 and water feed line 930 respectively. The water and disinfectant solution are then fed into sprayer assemblies 31 . Sprayer assemblies 31 then spray the disinfectant-water solution over the interior of the application booth 30 , cleaning and sanitizing the entire booth 30 . After a predetermined period of time, sensor processor 70 sends an appropriate signal to pumps 810 and 910 to terminate operation. Optionally, water pump 910 can be allowed to operate for bit longer in order to clean the feed lines and sprayers of any chemicals.
All excess fluids that enter application booth 20 flow into drain 33 , through drain lines 330 , and eventually into reservoir 37 . Once inside reservoir 37 , these excess fluids can be properly disposed of or treated.
The foregoing discussion discloses and describes merely exemplary embodiments of the present invention. As will be understood by those familiar with the art, the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
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An automatic sunscreen application vending apparatus which accepts payment from a user, stores a plurality of grades of sunscreen lotion, allows the user to select a grade of suntan lotion such as by SPF factor, and sprays the user with the selected grade of stored sunscreen lotion after acceptance of payment.
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This application claims the priority under 35 U.S.C. §119 of European patent application no. 10196871.7, filed on Dec. 23, 2010, the contents of which are incorporated by reference herein.
FIELD OF THE INVENTION
This invention relates to a power management device and method, and more particularly to a device and method for managing power from a transient power source.
BACKGROUND OF THE INVENTION
It is common for electronic circuits have a continuous energy supply, such as a steady dc voltage, during operation. However, in some cases it may be necessary to use a power source that is transitory or transient in nature, such as the energy pulse generated by a piezoelectric generator. Piezoelectric generators and other forms of energy harvesting device are finding use in a wide range of applications where it is undesirable or impossible to provide a wired power supply or where replacement of batteries is impractical. Energy harvesting is also beneficial for the environment, by reducing the need for production and disposal of batteries, which include toxic components, and by making use of renewable energy sources and “waste” energy. An example of an application using a piezoelectric generator is in powering a wireless switch. The switch may emit a radio signal when actuated, for example, to turn on or off a device configured to receive the signal. The switch may be arranged such that actuation strikes a piezoelectric crystal, generating a voltage pulse. This pulse charges a capacitor, which in turn powers a radio circuit that emits the signal, avoiding the need for a battery or other stored power source.
Where power is supplied by transient energy pulse, it is known to use the energy pulse to charge a capacitor, and the energy stored on the capacitor may then be used to power an electronic circuit or system. An exemplary arrangement is shown in FIG. 1 , which shows a voltage source 100 that generates a transient signal V in , that is passed to power management circuit 110 . Power management circuit 110 supplies a current I Load to power an electronic system 120 . The power management circuit 110 is shown in more detail in FIG. 2 , and includes a capacitor C which acts as a storage element and is charged by the energy pulse received at V in . A diode 220 between the capacitor C and V in prevents a current flowing from the capacitor to V in when the voltage across C, V C , is greater than that at V in , such as immediately following the energy pulse. The voltage V C is supplied to V out , which connects to the circuit or system to be powered (I Load ).
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a power management device comprising: an input for receiving a transient energy pulse; a first storage section and a second storage section for storing energy from the input; an output; a switching section for selectively connecting the input, first storage section, second storage section and output in at least first and second configurations, wherein the first configuration the first and second storage sections are connected so as to distribute energy from the transient energy pulse between the first and second storage sections, in the second configuration the respective voltages across the first and second storage sections are combined additively to produce an output voltage at the output, whereby the output voltage after switching to the second configuration is greater that the output voltage before switching to the second configuration.
The power management device may be such that the output voltage immediately after switching to the second configuration is greater than the output voltage immediately before switching to the second configuration.
The switching section may be arranged to switch to the second configuration when the voltage across the output decays to a threshold voltage.
The switching section may be switched based on output from at least one of: a voltage comparator, or a timer circuit.
The power management device may further comprise a diode or rectifier between (i) the input and (ii) the first and second storage sections.
The switching section may switch the input, first storage section, second storage section and output via an intermediate configuration when switching from the first configuration to the second configuration, and the intermediate configuration may isolate the second storage section from the first storage section.
The switching section may be arranged to switch to a third configuration in which the first storage section is (i) disconnected from the second storage section and the output, and (ii) partially discharged, and the switching section may be arranged to switch from the first configuration to the third configuration, and then to the second configuration.
The power management device may further comprise a third storage section switchably connectable to the first storage section, wherein in the third configuration the first storage section is connected to the third storage section so as to charge the third storage section by discharge of the first storage section.
In the third configuration the first storage section and the third storage section may be connected in parallel.
The power management device may further comprise a load circuit arranged to receive energy from the output, the load circuit having a maximum input voltage, wherein the first storage section is partially discharged in the third configuration, whereby the output voltage does not exceed the maximum input voltage when the power management device is switched to the second configuration by the switching section.
The first storage section may include a first storage element switchably connected to a second storage element, and the switching section may be arranged to switch the second storage element from a state in which it is disconnected from the first storage element to a state in which it is connected to the first storage element in order to charge the second storage element before switching to the second configuration.
The power management device may further comprise a load circuit arranged to receive energy from the output, the load circuit having a minimum operating voltage, wherein the switching section switches from the first configuration when the output voltage reaches or goes below a threshold, wherein the threshold is substantially equal to the minimum operating voltage.
The power management device may be arranged such that the voltage produced at the output immediately before switching to the second configuration is non-zero.
The invention also provides a power supply comprising: the power management device, and a transient power source arranged to provide the transient energy pulse to the power management device.
The transient power source may be a piezoelectric generator.
The invention further provides a power management device comprising: first and second capacitors arranged in parallel for storing energy received from an energy pulse supplied by a transient power source, and for providing the stored energy to an output; a switching section for switching the first and second storage sections into a series arrangement for providing the stored energy to the output.
The switching section may switch the first and second capacitors to the series arrangement when it is determined that a predetermined time period has elapsed, or a voltage at the output is (i) less than a predetermined level, or (ii) less than or equal to a predetermined level.
The switching section may be arranged to switch the first and second capacitors into a third configuration after the first configuration and before second configuration, and the third configuration may be arranged to at least partially discharge the first capacitor.
In the third configuration the first capacitor may be connected in parallel with a third capacitor, so as to charge the third capacitor by the at least partial discharge of the first capacitor, and in the third configuration the second capacitor may be connected to the output so as to produce a voltage at the output.
The invention also provides a method of supplying power, the method comprising: a step of receiving at an input an energy pulse from a transient power source; storing energy from the energy pulse by first and second energy storage sections arranged in a first configuration; producing, by the first and second storage sections, an output voltage at an output; switching the first and second energy storage sections to a second configuration, such that the output voltage is greater immediately after the switching than immediately before the switching.
The method according may further comprise: after the storing and before the switching to the second configuration, switching to a third configuration in which the first energy storage section is isolated from the output and is partially discharged, and an output voltage is produced at the output by the second energy storage section.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which:
FIG. 1 shows a prior art arrangement using a power management device.
FIG. 2 is a circuit diagram of a prior art power management device.
FIG. 3 is a simplified example of input and output voltages when the prior art device of FIG. 2 is supplied with an energy pulse.
FIG. 4 is a circuit diagram illustrating an embodiment of the invention.
FIG. 5 illustrates example input and output voltages when the device of FIG. 4 is supplied with an energy pulse, and also shows the states of the switches in FIG. 4 .
FIG. 6 is a circuit diagram illustrating another embodiment of the invention.
FIG. 7 illustrates example input and output voltages when the device of FIG. 6 is supplied with an energy pulse, and also shows the states of the switches in FIG. 6 .
FIG. 8 is a flow chart showing a method of operation according to the invention and usable with the arrangement of FIG. 4 .
FIG. 9 is a flow chart showing a method of operation according to the invention and useable with the arrangement of FIG. 6 .
DETAILED DESCRIPTION OF EMBODIMENTS
The invention will now be illustrated by reference to non-limiting examples that are intended to describe rather than define the present invention.
FIG. 3 shows a simplified example of the input and output voltages V in and V out in the arrangement of FIG. 1 . An initial input energy pulse, which is triangular in this example, starts at time t 0 and peaks at time t 1 , charging the capacitor C and producing a potential at V out equal to that at V in . The energy pulse at V in then drops rapidly to 0V, but the diode 220 prevents current flowing from the capacitor C to V in . V out decays as current flows from the capacitor C to the load circuit connected at V out . The decay of V out is shown here as a linear decrease. In practice, the rate and form of the decay will depend on the nature of the circuit connected to V out . For example, if the circuit has a constant resistance, the decay would be exponential.
In most cases, the circuit or system to be powered has a minimum operating voltage, below which it cannot operate. This is shown as V min in FIG. 3 . When V out is below V min (at time t 4 in FIG. 3 ) the circuit to be powered ceases to operate.
The inventor of the present invention has realized that the energy that remains stored on the capacitor when the output voltage decays below a minimum operating voltage of a load circuit is not used, and that greater efficiency can be achieved if the output voltage is converted to a higher potential when it reaches the minimum operating voltage. This increases the duration in which V out is above the minimum operating voltage, permitting the circuit attached to V out to operate for longer, and potentially complete more complex tasks.
The present invention is directed to overcoming deficiencies in prior art power supplies for use with transient power sources, and increasing the energy utilized from the transient source.
FIG. 4 shows a power management circuit 400 according to an embodiment of the invention. The power management circuit 400 of FIG. 4 includes a first capacitor C 1 , linked to an input node V in via a diode 420 . The circuit of FIG. 4 also includes a second capacitor C 2 and first through third switches S 1 , S 2 and S 3 . The switches are arranged to selectively connect the first and second capacitors C 1 , C 2 in series and parallel arrangements. In particular, the switches are arranged so that when the first and second switches S 1 and S 2 are closed and the third switch S 3 is open, the first capacitor C 1 and the second capacitor C 2 are connected in parallel. Furthermore, when the first and second switches S 1 and S 2 are open and the third switch S 3 is closed, the first capacitor C 1 and the second capacitor C 2 are connected in series. In the present embodiment, the first switch S 1 is positioned between the positive plate of the first capacitor C 1 and the positive plate of the second capacitor C 2 , while S 2 is between the positive plate of the first capacitor C 1 and the negative plate of the second capacitor C 2 . The second switch S 2 is between the negative plate of C 2 and ground (earth).
The circuit of FIG. 4 is arranged to receive a positive voltage at V in (i.e. a positive voltage component will pass the diode 420 , but as would be apparent to the skilled person, the circuit could be arranged with opposite polarities, that is reversing the diode 420 and receiving a negative voltage at V in (i.e. such that a negative voltage component passes the diode 420 ). In this case, the positive and negative plates of the capacitors would be reversed relative to the above description. The capacitors themselves need not have an intrinsic polarity, and could be standard parallel plate capacitors, for example.
The first through third switches S 1 , S 2 and S 3 form part of a switching section that additionally includes a controller 430 for the switches. The switches S 1 , S 2 and S 3 may be embodied by switching devices such as transistors, FETs or any other components that achieve the switching function described herein. The controller 430 for the switches may include a microprocessor, voltage comparator or other component(s) suitable for controlling the switches S 1 , S 2 and S 3 as described herein. FIG. 4 illustrates the operational connection between the controller 430 and the switches S 1 , S 2 and S 3 by dashed lines leading to the switches. The controller 430 may also receive information on the voltages at V in and/or V out , and this is shown by dashed lines leading to the controller 430 . The controller 430 could, alternatively or in addition to information on V in , receive information on the voltage on the other side of the diode 420 from V in . The controller may be embodied by any suitable component or components. For example, the controller may include an application-specific integrated circuit (ASIC). In some embodiments the controller may be arranged as a bistable or tri-stable circuit, and may include a voltage comparator, operational amplifier and/or timing circuit.
The switching section is arranged so that, when an energy pulse is received via V in , the power management circuit 400 is in a first configuration, in which the first and second capacitors C 1 and C 2 are connected in parallel. In this configuration both capacitors are charged by the energy pulse. In the embodiment of FIG. 4 , this corresponds to S 1 and S 2 being closed and S 3 being open. In the arrangement of FIG. 4 C 1 and C 2 may have the same capacitance values, but this is not essential. Both capacitors C 1 and C 2 may be charged to the same voltage, but this need not be the case in all embodiments. As a result of the arrangement in FIG. 4 , the sum of the peak voltages across each of the capacitors C 1 and C 2 is greater than the peak input voltage, although in the first configuration the voltages across C 1 and C 2 are not combined additively.
The switching section is further arranged such that, after the energy pulse, the power management circuit 400 is switched to a second configuration, in which the first and second capacitors C 1 and C 2 are in series. Accordingly, the voltages across each of the capacitors C 1 and C 2 combine additively to produce an output voltage at V out that is greater than the voltage across either of C 1 or C 2 individually.
A circuit of system to be powered, herein referred to as a load circuit, is connected at note V out .
FIG. 5 shows the variation of input and output voltages with time according to an exemplary embodiment of the arrangement of FIG. 4 . FIG. 5 also shows the states of the switches S 1 , S 2 and S 3 . “Closed”, ie. conducting, is shown as a high signal and “Open”, i.e. non-conducting, is shown as a low signal.
As can be seen in FIG. 5 , the power management circuit 400 is initially in the first configuration, such that the capacitors C 1 and C 2 are in parallel (S 1 and S 2 closed, S 3 open). At time t 0 an energy pulse is received at V in , charging both of the capacitors C 1 and C 2 . The energy pulse may be from any transient power source, and may be from a piezoelectric generator, for example. The form of V in is not particularly limited, other than being transient. Transient herein is used to describe a signal that is initially zero, then non-zero for a short period, and then zero again. The period in which V in is non-zero is short relative to the period in which V in is 0V, and is also short relative to the period of operation of the load circuit after V in returns to 0V. As would be understood by the skilled person, a transient energy pulse is distinguished from a dc input voltage. The shape of V in is not particularly limited. V in is illustrated with a linear increase and decrease and a single peak, but other possibilities exist, and V in can have any shape consistent with the above description of a transient signal.
At time t 1 , the capacitors C 1 and C 2 have been charged to the voltage Vpeak and the energy pulse begins to decrease toward zero, as reflected by the input voltage V in in FIG. 5 . The charge (and energy) stored on the capacitors C 1 and C 2 decreases, schematically shown as a linear decrease (although the skilled person would appreciate that the decrease may take other forms), until the output voltage V out reaches a threshold voltage V thresh . Where the load circuit has an associated minimum operating voltage V min , V thresh is preferably equal to or slightly higher than V min .
At t 2 the output voltage V out reached V thresh , and the switching section switches the power management circuit 400 to the second configuration. In the second configuration, S 1 and S 2 are open and S 3 is closed, and the capacitors are in series. Thus, the voltages across the capacitors C 1 , C 2 are combined additively, and the output voltage increases. In the arrangement of FIG. 4 , V out is increased to 2×V thresh , the sum of V C1 and V C2 , the voltages across C 1 and C 2 , respectively.
As a result of the switching section switching the power management circuit 400 to the second configuration, V out is increased, remaining above V thresh , and also above V min . This extends the period of time in which V out is greater that V min , permitting the load circuit to operate for a longer period of time than in the arrangement of FIG. 2 . The load circuit can operate until V out crosses (becomes smaller than) V min at t 4 . On the other hand, if the power management circuit 400 remained in the first configuration and was not switched to the second configuration, the load circuit would be able to operate only until t 3 when V out would have crossed V min .
In the second configuration, V out decreases more rapidly than in the first configuration, as the combined capacitance of C 1 and C 2 is switched from C 1 +C 2 in the first configuration to (1/C 1 +1/C 2 ) −1 in the second configuration.
According to this arrangement, no power is drawn from V source after the initial charging period, as V source is transient.
In some embodiments V thresh could be set equal to or less than V min . Where the output voltage V out drops below V min , the load circuit may cease to function, but would resume or restart functioning when the power management circuit 400 switched to the second configuration, assuming V out then exceeds V min . Where it is acceptable or desirable for such resuming or restarting, V thresh may be less than V min .
The switching section may include a voltage comparator in order to determine when V out reaches V thresh and cause the power management circuit 400 to switch to the second configuration when V out is less than V thresh (or when V out is equal to V thresh ). In an alternative embodiment, the switching section may include a timer. In this case, the energy pulse would start (or reset) the timer, and the switching section would cause the power management circuit to switch to the second configuration after a time period (approximating the period of time between t 0 and t 2 ) has elapsed. V out at the end of this time period would define V thresh , and the time period may be selected such that V thresh approximates a particular voltage, such as V min . The time period may be determined by the switching section, and may be a fixed time period. The time period may be variable, being determined by the switching section based on the value of Vpeak, for example. Other factors could be used to determine the time period.
The switching section may be arranged to switch each of switches S 1 , S 2 and S 3 simultaneously. Alternatively, one or more of the switches S 1 , S 2 , S 3 can be switched separately. Where the switches are not switched simultaneously, they are preferably switched according to a predetermined sequence. In the embodiment of FIG. 4 , a preferred sequence of switching is S 1 and S 2 opening simultaneously or in sequence, followed by S 3 closing as quickly as possible thereafter, or at least a short period thereafter. This sequence ensures that S 2 and S 3 are not closed at the same time, and so prevents the positive terminal of C 1 being connected to ground, which would allow charge from C 1 to flow to ground without passing through the load circuit.
FIG. 5 shows V out decaying to 0V after t 4 at the same rate as before t 4 . However, this is not necessarily the case, and V out may remain constant, decay more slowly, or decay more rapidly. For example, the controller 430 may be arranged to disconnect (e.g. by a further switch that is not illustrated) the load circuit from V out when it is determined that V out is below V thresh at t 4 . Assuming negligible leakage, this would result in V out remaining constant at, or just below, V thresh until another energy pulse is received at V in . Where leakage is not negligible, V out would continue to decay, but more slowly than before t 4 . The switching section may be arranged to switch the power management circuit to the first configuration at or after t 4 , in readiness for a next energy pulse. In this case, V out would be reduced abruptly (e.g. halved) when switching from the second to the first configuration.
FIG. 8 illustrates a method 800 performed by an exemplary embodiment of the arrangement of FIG. 4 . The method starts at step 805 and at step 810 the power management circuit 400 is in the first configuration. The energy pulse is received at step 815 and charges capacitors C 1 and C 2 at step 820 . Energy is supplied via V out at step 825 , and C 1 and C 2 discharge accordingly. Steps 815 , 820 and 825 may be performed simultaneously. At step 830 the switching section determines whether V out ≦V thresh . Alternatively, the switching section could determine whether V out ≧V thresh . If V out is determined to be greater than V thresh , the method returns to step 825 . When V out is determined to be less than or equal to V thresh , the method continues to step 835 , where the power management circuit 400 is switched to the second configuration, in which C 1 and C 2 are connected in series and the voltages across C 1 and C 2 combine additively, resulting in an increase in V out . At step 840 the power management circuit 400 continues to supply energy via V out , and C 1 and C 2 continue to discharge. At step 845 a determination is made as to whether the operation has completed. This could be based on, for example: (i) a time elapsed since receiving the energy pulse; (ii) whether V out has decreased to or below V min , in which case the load circuit may be unable to continue to operate; or (iii) whether the load circuit has completed the functions it is required to perform and no longer needs energy. If it is determined that operation is not completed, the method returns to step 840 . If it is determined that operation is completed, the switching section returns the power management circuit 400 to the first configuration (step 850 ), in preparation for receiving a subsequent energy pulse. The method then ends at step 855 . The determination that operation has finished need not require an active decision-making element. Furthermore, the power management circuit 400 may be arranged to return to the first configuration when a next energy pulse is received, or between energy pulses. For example, the switches S 1 , S 2 and S 3 may be arranged to the default to the first configuration in the absence of a signal generated by the energy stored on C 1 and C 2 . In such cases, step 845 may be unnecessary or may be performed passively.
Generally, dc-dc converter circuits, for converting an input dc voltage to an output dc voltage, are known, but these are intended for use with a continuous source of power, and work by continually drawing power from the input dc source. Thus, such converter circuits are not suitable for use when the power source is transient, and there is no energy available between the transient powering events, which may be a long time. Furthermore, dc-dc converters typically include a large number of components, and may draw a significant amount of energy compared with the energy available from a transient source. For these reasons, conventional dc-dc converter circuits may not be suitable for use with a transient power source.
FIG. 6 shows another embodiment of the present invention. The embodiment of FIG. 6 is similar to that of FIG. 4 , with an additional capacitor, C 3 and an additional switch S 4 . The other components of FIG. 6 are as described above in relation to the corresponding components of FIG. 4 .
Capacitor C 3 and switch S 4 are arranged in series with each other, and both are in parallel with capacitor C 1 . The controller 630 of the switching section is arranged to control switch S 4 , in addition to switches S 1 , S 2 and S 3 . In the first configuration S 4 is open, and so there is no connection between C 3 and either of C 1 and C 2 . In the second configuration S 4 is closed so that C 3 is in parallel with C 1 and each of C 1 and C 3 are in series with C 2 .
The arrangement of FIG. 6 is particularly advantageous when the load circuit has a maximum operating voltage, V max , which V out must not exceed. In the power management device of FIG. 4 , when V max is less than 2×V thresh (or the sum of voltages across C 1 and C 2 ) the output voltage V out immediately after switching to the second configuration will exceed V max , possibly damaging the load circuit. The arrangement of FIG. 6 can be used to avoid V out exceeding V max .
FIG. 7 shows the variation of input and output voltages with time according to an exemplary embodiment of the invention. FIG. 5 also shows the states of the switches S 1 , S 2 , S 3 and S 4 . As in FIG. 5 , a high signal shows as “Closed”, or conducting, state, and a low signal shows an “Open” or non-conducting state.
FIG. 7 shows that initially the circuit is in the first configuration, with capacitors C 1 and C 2 in parallel (S 1 and S 2 closed, S 3 and S 4 open). At time t 0 an energy pulse is receive as V in , charging each of the first and second capacitors C 1 and C 2 . At time t 1 , the capacitors C 1 and C 2 have been charged to the peak voltage Vpeak and the energy pulse (V in ) begins to decrease to zero. In some arrangements, the capacitors will not necessarily be charged completely to Vpeak, and may be charged to a lower voltage, for example. The charge stored on the capacitors C 1 and C 2 decreases as the capacitors discharge through the load circuit via node V out . As in FIG. 5 , the discharge is illustrated as linear, but may take other forms. Due to diode 620 providing isolation between V in and V out and the charge stored on the capacitors C 1 , C 2 , V out decreases at a different rate (more slowly than) V in .
At time t 2 , the output voltage V out reaches the threshold V thresh , and the switching section switches the power management circuit to a third configuration. In the third configuration the first capacitor C 1 is disconnected from the second capacitor C 2 , and connected in parallel to the third capacitor C 3 . Capacitor C 3 is initially discharged, according to the current example, and so in the third configuration charge is transferred from the first capacitor C 1 to the third capacitor C 3 . In the third configuration, C 2 remains connected to V out , providing power to the load circuit via V out
At time t 2 ′ the switching section switches the power management circuit to the second configuration, in which the first and third capacitors are in parallel with each other, and the second capacitor C 2 is in series with each of C 1 and C 3 . This causes the output voltage to increase to the sum of the voltages across the first and second capacitors C 1 and C 2 . If the interval between t 2 and t 2 ′ is sufficient to fully charge C 3 , the voltage across C 3 will equal the voltage across C 1 , but this is not essential. The interval between t 2 and t 2 ′ is not particularly limited, but typically would be chosen to be relatively short, being just long enough for C 1 to discharge into C 3 , such that V C1 and V C3 are generally equal.
After t 2 ′, the output voltage V out decreases. At t 4 V out reaches V min , and V out is then too low to power the load circuit. As described in relation to FIG. 5 , various possibilitier exits for V out after t 4 . For example, V out may continue decreasing, remain at or just below V thresh , or may change abruptly.
FIG. 9 illustrates a method 900 suitable for use with the embodiment of FIG. 6 . Steps 905 , 910 , 915 , 920 , 925 , 930 , 935 , 940 , 945 , 950 and 955 respectively correspond to steps 805 , 810 , 815 , 820 , 825 , 830 , 835 , 840 , 845 850 and 855 , described above in relation to FIG. 8 . FIG. 9 also includes steps 931 , 932 , 933 and 934 . In the method of FIG. 9 , after it is determined in step 930 that the output voltage is less than or equal to the threshold voltage, the method proceeds to step 931 , in which the power management device 400 is switched to the third configuration. Energy is then supplied to V out by C 2 (step 932 ) and C 2 discharges, although as noted above, the discharge of C 2 in this configuration may be negligible. In step 934 charge is transferred from C 1 to C 3 , charging C 3 with a corresponding discharge of C 1 . Steps 932 and 933 may occur simultaneously, depending on the relative timing of the switches S 1 and S 4 . At step 934 , it is determined whether the power management circuit 400 should be switched to the second configuration. This determination could be based on a predetermined time delay following the switch to the third configuration and/or could be based on the voltage across C 1 , for example. The determination could additionally or alternatively be based on V out . If it is determined that the power management circuit 400 should be switched to the second configuration, the method continues with step 935 . Otherwise, the method returns to step 932 .
According to the embodiment of FIG. 4 , when the power management circuit is switched to the second configuration, V out increases to 2×V thresh . However, as noted above, the load circuit may have a maximum voltage that should not be exceeded, V max . Moreover, it is possible that 2×V thresh is greater than V max . In such cases, the embodiment of FIG. 6 is particularly advantageous, and can be used to prevent V out exceeding V max , even if 2×V thresh is greater than V max .
In some embodiments according to the arrangement of FIG. 6 , the capacitance of the third capacitor C 3 and/or the interval t 2 -t 2 ′ can be chosen such that C 1 is discharged to a level where V C1 =V max −V thresh between t 2 and t 2 ′. In this case, assuming that the discharge of C 2 is negligible between t 2 and t 2 ′, V out will increase to V max . In some cases it will be desirable for the value of V out to increase to just below V max at time t 2 ′. More generally, the skilled person can select the capacitance of the third capacitor C 3 such that the voltage increases to a desired peak value at time t 2 ′. If the discharge of the second capacitor C 2 is not negligible between t 2 and t 2 ′, this can be taken into account based on actual or likely discharge rates through the load circuit.
According to the arrangement of FIG. 6 , no power is drawn from V source after the initial charging period, as V source is transient.
In the arrangements of FIG. 4 and FIG. 6 , the controller 430 , 630 for the
switches may be power by V out and could form part of the load circuit. In this case the load circuit would control switching of switches S 1 , S 2 , S 3 and S 4 (where present), while also performing the normal operations of the load circuit.
FIG. 5 shows switches 51 , S 2 and S 3 switching at the same time, t 2 . However, as noted above, other possibilities exist, and the switches could be arranged to switch in sequence one or two at a time. When S 1 is arranged to open at time t 2 , before S 2 and S 3 are closed at time t 2 ′ (not shown in FIG. 5 ), C 2 will discharge while the charge on C 1 remains the same (in the interval t 2 -t 2 ′). This means that between t 2 and t 2 ′ the voltage across C 2 will decrease while the voltage across C 1 remains constant. Accordingly, by varying the period between t 2 and t 2 ′, the peak voltage at t 2 ′ can be controlled.
FIG. 7 shows S 1 and S 4 switched at the same time (t 2 ), and S 2 and S 3 switched together at time t 2 ′ after t 2 . However, S 4 could be closed before S 1 is opened, for example. The order and timing of switching in FIGS. 5 and 7 is not particularly limited.
In some arrangement, S 1 may be open when the voltage pulse is received. In this case, C 1 is charged by the energy pulse, and C 2 may be charged from C 1 after the energy pulse has passed by closing S 1 . In this case, the initial arrangement is different from the first configuration and the power management circuit 400 ; 600 is switched to the first configuration after the energy pulse has passed.
The third capacitor C 3 and fourth switch S 4 in FIG. 6 form an additional stage relative to the arrangement of FIG. 4 . Further stages could be added. For example, a fourth capacitor and fifth switch could be added in series with each other and in parallel with C 1 and C 3 .
As would be appreciated by the skilled person, certain simplifying assumptions have been made in the foregoing description, in the interests of providing a clear description the present invention. For example, in reality V source is a real voltage or current source and may not behave as an idealized source, e.g. it may be finite impedance and/or limited energy. As previously noted, form of V in is not particularly limited, other than being transient. Transient herein is used to describe a signal that is initially zero, then non-zero for a short period, and then zero again. The period in which V in is non-zero is short relative to the period in which V in is 0V, and is also short relative to the period of operation of the load circuit after V in returns to 0V. As would be understood by the skilled person, a transient energy pulse is distinguished from a dc input voltage. The shape of V in is not particularly limited. V in is illustrated with a linear increase and decrease and a single peak, but other possibilities exist, and V in can have any shape consistent with the above description of a transient signal.
For simplicity, capacitors are shown having linear charging and discharging rates. However, the rate of charging and/or discharging may be non-linear.
Herein, each of capacitors C 1 and C 2 is charged to the same peak voltage. However, this is not necessarily the case and may depend on the specific circuit arrangement. Similarly, description of the voltage increasing to 2×V thresh depends on the circuit arrangement, and other possibilities exist.
In practice the load circuit will not be an ideal current source, but a real impedance or circuit load.
The above embodiments include a diode 420 , 620 . However, any rectifying element could be used. In particular, if a full bridge rectifier is used, useful energy may still be obtained even if V in becomes negative. In some embodiments, a rectification element may be unnecessary. For example, if the connection to the source if the energy pulse may be broken (e.g. by a switch) soon after Vpeak is reached.
Switches S 1 , S 2 , S 3 and S 4 may be embodied by any suitable switching element, as would be clear to the skilled person. Transistors may be used, for example. The capacitance values of the capacitors C 1 , C 2 and C 3 could be appropriately selected by the skilled person, taking into account the voltage source and/or the load circuit, and are not particularly limited. The drawings use the circuit diagram symbol for fixed, non-polarized capacitors, but any suitable energy storage element could be used.
Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments.
The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
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A power management device comprises: an input for receiving a transient energy pulse; a first storage section and a second storage section for storing energy from the input; an output; a switching section for selectively connecting the input, first storage section, second storage section and output in at least first and second configurations, wherein in the first configuration the first and second storage sections are connected so as to distribute energy from the transient energy pulse between the first and second storage sections, in the second configuration the respective voltages across the first and second storage sections are combined additively to produce an output voltage at the output, whereby the output voltage after switching to the second configuration is greater than the output voltage before switching to the second configuration.
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[0001] This Application claims the benefit of U.S. Application Ser. No. 60/547,442 of RICHARD COPPOLA filed Feb. 26, 2004 for TELESCOPING UNDERWATER GUIDE, the contents of which are herein incorporated by reference.
[0002] This application is a continuation-in-part of U.S. application Ser. No. 11/050,976 of RICHARD COPPOLA filed Feb. 4, 2005 for TELESCOPING UNDERWATER GUIDE, the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to an independently segmental, multi-segmental, and sectional telescoping device for guiding elongated rigid and flexible objects such as directional, variable angle drill, bore and such machine and other stems, rods, piping, tubing, hoses, cables, lines and other similar elongated structures through atmospheric, vacuum, partial vacuum, semi-submerged, and completely submerged underwater environments operating through the atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials and without environmental impact.
[0005] More specifically, it relates to a means for guiding directional, variable angle drill, bore, and such machine, equipment and rigid and flexible material stems, rods, piping, tubing, hoses, cables, lines and other similar structures underwater through varying water column depths at variable longitudinal lengths and angles by creating an infinitely adjustable independently segmented and telescoping, dynamic and lockable telescoping guide segments thereby infinitely adjusting in static, dynamic and hybrid functions to the distance between fixed, variable elevation, floating, or submerged work surfaces, and surface machinery, equipment and materials and the waterway bottom and other materials. Its installation and operational length and operational angle is infinitely adjustable. Its optionally incorporated integrated floatation and buoyancy in water is infinitely adjustable per segment or over its entire length. Its structural width is adjustable per segment or over its entire length thereby permitting the handling and installation of various dimension drill, bore, machine, stems, rods, piping, tubing, hoses, cables, lines and other similar structures in semi-submerged and submerged underwater applications into and through waterway bottom and other materials without environmental impact.
[0006] 2. Description of Related Art
[0007] Variable angle bore, drill stems and other type pipe, rod and elongated objects are limited and prevented from penetration and installation through the atmosphere, vacuum, fluid, and water columns into and through waterway and other bottom materials due to absence of a segmented and telescoping underwater guide providing infinitely adjustable dynamic and static longitudinal adjustment functions and operation while providing variable structural width and lateral support for bore, drills, stems rods, piping, tubing, hoses, cables, lines and other elongated objects and similar structures in semi-submerged and submerged underwater applications and absence of adjustability to accommodate varying water column depths between the water surface and waterway bottom and other material elevation(s), as well as other clear dimensional applications and absence of the ability to sectionally and telescopically adjust the guide length statically, dynamically and in hybrid mode in single, and multi-sectional length, sectional width, and its angle to the waterway bed and other material elevations and absence of a system and method of handling and installing various dimension drill, bore, machine, stems, rods, piping, tubing, hoses, cables, lines and other similar structures in semi-submerged and submerged underwater applications while eliminating environmental impact. For these reasons, there is a need in the art for a new system to permit penetrations through varying water column depths, into and through waterway bed and other materials at various angles in atmospheric, submerged, semi-submerged and other applications which overcomes the above disadvantages and limitations described.
SUMMARY OF THE INVENTION
[0008] According to an aspect of the present invention, there is a method for drilling in an environment having a fluid and a bed. The method comprises positioning a platform such that the fluid is between the platform and the bed; assembling a guide, the assembled guide being straight; placing the guide such that the guide is supported by the platform, and a major length of the guide and a normal to the bed defines an angle, the angle being greater than 0; and sending a variable angle drill inside the guide, from the platform into the bed.
[0009] According to another aspect of the present invention, there is a method for drilling in an environment having a fluid and a bed. The method comprises positioning a support such that the fluid is between the support and the bed; assembling a guide, the assembled guide being straight; placing the guide such that the guide is supported by the support, and a major length of the guide and a normal to the bed defines an angle; changing the angle; and sending a variable angle drill inside the guide, from the support into the bed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a general illustration matrix of the rigid segment, and telescoping underwater guide segment assembly.
[0011] FIG. 2 is a general illustration matrix of different length rigid guide segment.
[0012] FIG. 3 is a detailed plan view (lower left) and elevation view (upper view) of the optionally used binding block.
[0013] FIG. 4 is a general illustration matrix of the telescoping guide segments.
[0014] FIG. 5 is a general illustration matrix of the telescoping guide segments.
[0015] FIG. 6 is a general illustration matrix of the telescoping guide segments.
[0016] FIG. 7 is a general illustration matrix of the telescoping guide segments.
[0017] FIG. 8 is a profile view of a variant work surface.
[0018] FIG. 9 is a profile view of a variant work surface.
[0019] FIG. 10 is a profile view of a variant work surface.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0020] In the absence of prior art and in order to eliminate prior restrictions and limitations, the exemplary embodiment has been devised for guiding, orienting, directing and installing elongated structures such as directional and variable angle machine, bore, drill, equipment, materials, stems, rods, piping, tubing, hoses, cables, lines and other elongated structures being not submerged, semi-submerged and/or fully submerged underwater and through varying air and water column distances in atmospheric, vacuum, partial vacuum, lakes, streams, rivers, coastal waters, oceans and through waterway bottom and other materials. The exemplary embodiment has been devised as a means for inserting, guiding and installing directional, variable angle drill, bore, and such machine, equipment and material stems, rods, piping, tubing, hoses, cables, lines and other elongated structures at variable angles by creating a segmented, incremental, infinitely adjustable and telescoping, lockable, static, and telescoping guide being infinitely adjustable in static, dynamic and hybrid states in length, dimension, and angle between stationary, fixed, moving, variable elevation, floating work surfaces, machinery, equipment, materials to and through waterway and marine bottom and other materials. Its longitudinal length and operational angle is infinitely adjustable. Its optionally attached integrated floatation and buoyancy vessels are either segmentally fixed or infinitely adjustable per segment and over the guide assembly's entire length. Its structural width is adjustable per segment or over its entire length thereby permitting the handling and installation of various dimension drill, bore, machine, stems, rods, piping, tubing, hoses, cables, lines and other similar elongated structures being not submerged, semi-submerged and/or fully submerged underwater and through varying air and water column distances in atmospheric, vacuum, partial vacuum, lakes, streams, rivers, coastal waters, oceans and through waterway bottom and other materials without environmental impact.
[0021] FIG. 1 is a general illustration matrix of the rigid segment, and telescoping underwater guide segment assembly. One or more segments may be used as shown. FIG. 1 includes three profile views of two rigid guide segments coupled together in three different configurations thereby providing structural and lateral support for the elongated objects placed within the guide to be installed, and if desired, the inner-friction/spacer sleeve ( 5 ). The illustration to the left shows one rigid guide segment ( 1 ) and one telescoping guide segment ( 1 , 2 ) comprised of one rigid guide segment and a telescoping element ( 2 ) slidable with infinite adjustment, incremented, or selected locking points. Also shown is an angled, flare, or cone end ( 4 ) optionally installed at the end of the telescoping segment.
[0022] The illustration at center shows two rigid guide segments ( 1 ) oriented as coupled with an optionally installed angled, flare, or cone end ( 4 ) secured directly to the end of the rigid segment. The illustration to the right shows two rigid guide segments ( 1 ) oriented as coupled without the telescoping guide segment or angled, flare, or cone end installed.
[0023] Referring to FIG. 1 , there is a general illustration matrix of the rigid segment, and telescoping underwater guide segment assembly. One or more segments may be used as shown. FIG. 1 includes three profile views of two rigid guide segments coupled together in three different configurations thereby providing structural and lateral support for the elongated objects placed within the guide to be installed, and if desired, the inner-friction/spacer sleeve ( 5 ). The illustration to the left shows one rigid guide segment ( 1 ) and one telescoping guide segment ( 1 , 2 ) comprised of one rigid guide segment and a telescoping element ( 2 ) slidable with infinite adjustment, incremented, or selected locking points. Also shown is an angled, flare, or cone end ( 4 ) optionally installed at the end of the telescoping segment. The illustration at center shows two rigid guide segments ( 1 ) oriented as coupled with an optionally installed angled, flare, or cone end ( 4 ) secured directly to the end of the rigid segment. The illustration to the right shows two rigid guide segments ( 1 ) oriented as coupled without the telescoping guide segment or angled, flare, or cone end installed.
[0024] FIG. 2 is a general illustration matrix of different length rigid guide segment, ( 1 ) end flanges ( 6 ) and an optionally installed base plate ( 9 ) with mounting brackets ( 10 ) for securing hardware and machinery to the base plate. Connecting hardware ( 11 ) comprised of bolting, pinning, banding, clipping and such methods for securing and coupling guide segments is shown. The lower section is a profile view of a rigid guide segment showing the binding block ( 7 ) which is secured to the rigid guide segment for the locking of the telescoping element in a fixed position or adjusted to permit dynamic extension and retraction of the telescoping segment and the underwater guide assembly.
[0025] Referring to FIG. 2 , there is a general illustration matrix of different length rigid guide segment, ( 1 ) end flanges ( 6 ) and an optionally installed base plate ( 9 ) with mounting brackets ( 10 ) for securing hardware and machinery to the base plate. Connecting hardware ( 11 ) comprised of bolting, pinning, banding, clipping and such methods for securing and coupling guide segments is shown. The lower section is a profile view of a rigid guide segment showing the binding block ( 7 ) which is secured to the rigid guide segment for the locking of the telescoping element in a fixed position or adjusted to permit dynamic extension and retraction of the telescoping segment and the underwater guide assembly.
[0026] FIG. 3 is a detailed plan view (lower left) and elevation view (upper view) of the optionally used binding block ( 7 ) components comprising of the threaded block body ( 7 ), and binding hardware consisting of set screws thereby locking or dynamically controlling the telescoping guide segment ( 2 ).
[0027] FIG. 4 is a general illustration matrix of the telescoping guide segments. The illustration at left is a telescoping segment without flanges ( 3 ) installed for coupling an angled, flare, or cone end ( 4 ) which may optionally be used as an intermediate telescoping segment within the underwater guide assemble shown in FIG. 9 The illustration at center left is a telescoping section with a flange installed for mounting an angled, flare, or cone end ( 4 ) as oriented for connection as shown. The illustration at center right is a telescoping segment ( 2 ) with the angled, flare, cone end ( 4 ) installed. The illustration at right is a telescoping segment ( 2 ) with the angled, flare, cone end ( 4 ) installed with an optionally installed inner-friction/spacer sleeve ( 5 ).
[0028] Referring to FIG. 4 , the illustration at left is a telescoping section without flanges ( 3 ) installed for coupling an angled, flare, or cone end ( 4 ) which may optionally be used as an intermediate telescoping segment within the underwater guide assemble shown in FIG. 9 The illustration at center left is a telescoping section with a flange installed for mounting an angled, flare, or cone end ( 4 ) as oriented for connection as shown. The illustration at center right is a telescoping segment ( 2 ) with the angled, flare, cone end ( 4 ) installed. The illustration at right is a telescoping segment ( 2 ) with the angled, flare, cone end ( 4 ) installed.
[0029] FIG. 5 is a general illustration matrix of the telescoping guide segments. The top illustration is a profile view of the optionally installed external floatation vessel ( 12 ) composed of rigid, solid, semisolid, hollow, static, flexible, or inflatable vessel materials for in-water floating assembly of the underwater guide assembly. The external floatation vessel is secured to the underwater guide segments by rigid connecting hardware, straps, clips, braces, ties, and such securing devices. Inflation, deflation, and over pressure relief valves for deployment, recovery, pneumatic control, and positioning of independent and multiple guide segments are optionally attached to the external floatation vessel. The top center illustration is a profile view of a rigid guide segment. ( 1 ) The bottom center illustration is a profile view of a rigid guide segment ( 1 ) with an external floatation vessel ( 12 ) attached. The bottom illustration is a profile view of a variant of a rigid guide segment whereby the rigid guide segment or segments are of open configuration where elongated objects inserted into the guide assembly are predominantly exposed and visible being secured to the rigid guide segment or segments by guide bolts, pins, clamps, straps and such anchoring devices.
[0030] Referring to FIG. 5 , the top illustration is a profile view of the optionally installed external floatation vessel ( 12 ) composed of rigid, solid, semisolid, hollow, static, flexible, or inflatable vessel materials for in-water floating assembly of the underwater guide assembly. The external floatation vessel is secured to the underwater guide segments by rigid connecting hardware, straps, clips, braces, ties, and such securing devices. Inflation, deflation, and over pressure relief valves for deployment, recovery, pneumatic control, and positioning of independent and multiple guide segments are optionally attached to the external floatation vessel. The top center illustration is a profile view of a rigid guide segment. ( 1 ) The bottom center illustration is a profile view of a rigid guide segment ( 1 ) with an external floatation vessel ( 12 ) attached. The bottom illustration is a profile view of a variant of a rigid guide segment whereby the rigid guide segment or segments are of open configuration where elongated objects inserted into the guide assembly are predominantly exposed and visible being secured to the rigid guide segment or segments by guide bolts, pins, clamps, straps and such anchoring devices.
[0031] FIG. 6 is a general illustration matrix of the telescoping guide segments. The top left illustration is a plan view of a removable end flange plate ( 13 ) for a variant type of rigid guide segment whereby solid or slotted support rails ( 17 ), hollow support rails ( 18 ), and other rigid structural supports are connected to the end flange plates forming a rigid guide assembly. The top right illustration is a plan view of a removable end flange plate ( 14 ) for a variant type of an adjustable width rigid guide segment where adjustment in size is made by securing the support rails to alternate mounting holes or other slot positions and whereby solid or slotted support rails ( 17 ), hollow support rails ( 18 ), and other rigid structural supports are connected to the end flange plates forming a rigid guide assembly. The bottom left illustration is an end view of a variant open guide segment with a fixed, removable, or adjustable optionally installed end plate ( 15 ) for joining a plurality of segments together, and securing hardware ( 16 ) comprised of connecting containment hardware comprised of either straight, curved, or formed plates, bars, bolts, pins, straps, and such rigid and flexible materials used in conjunction with an open type variant of the rigid guide segment or segments. The bottom right illustration is an end view of a variant open guide segment ( 15 ) with the connecting containment hardware ( 16 ) secured.
[0032] Referring to FIG. 6 , the top left illustration is a plan view of a removable end flange plate ( 13 ) for a variant type of rigid guide segment whereby solid or slotted support rails ( 17 ), hollow support rails ( 18 ), and other rigid structural supports are connected to the end flange plates forming a rigid guide assembly. The top right illustration is a plan view of a removable end flange plate ( 14 ) for a variant type of an adjustable width rigid guide segment where adjustment in size is made by securing the support rails to alternate mounting holes or other slot positions and whereby solid or slotted support rails ( 17 ), hollow support rails ( 18 ), and other rigid structural supports are connected to the end flange plates forming a rigid guide assembly. The bottom left illustration is an end view of a variant open guide segment with a fixed, removable, or adjustable optionally installed end plate ( 15 ) for joining a plurality of segments together, and securing hardware ( 16 ) comprised of connecting containment hardware comprised of either straight, curved, or formed plates, bars, bolts, pins, straps, and such rigid and flexible materials used in conjunction with an open type variant of the rigid guide segment or segments. The bottom right illustration is an end view of a variant open guide segment ( 15 ) with the connecting containment hardware ( 16 ) secured.
[0033] FIG. 7 is a general illustration matrix of the telescoping guide segments. The top and center illustrations are profile and end views of variant type rigid guide segments whereby a plurality of solid, slotted, or hollow support rails ( 17 ) and ( 18 ), and other rigid structural supports are connected to end flange plates ( 13 ) and ( 14 ) forming a rigid guide assembly. The bottom illustration is a profile and end view of an assembled variant guide segment with a plurality of removable support rails ( 17 ) and ( 18 ) and end flange plates ( 13 ) and ( 14 ) with an optionally installed inner-friction/spacer sleeve ( 5 ). The guide segments and variants thereof functions with or without the inner-friction/spacer sleeve ( 5 ).
[0034] Referring to FIG. 7 , the top and center illustrations are profile and end views of variant type rigid guide segments whereby a plurality of solid, slotted, or hollow support rails ( 17 ) and ( 18 ), and other rigid structural supports are connected to end flange plates ( 13 ) and ( 14 ) forming a rigid guide assembly. The bottom illustration is a profile and end view of an assembled variant guide segment with a plurality of removable support rails ( 17 ) and ( 18 ) and end flange plates ( 13 ) and ( 14 ) with an optionally installed inner-friction/spacer sleeve ( 5 ). The guide segments and variants thereof functions with or without the inner-friction/spacer sleeve ( 5 ) with an optionally installed inner-friction/spacer sleeve ( 5 ).
[0035] FIG. 8 is a profile view of one variant work surface being a marine barge ( 20 ) as shown and a matrix of underwater guide assembly options. The illustration at the left shows the guide secured to the work surface or machinery. The guide configuration is comprised of three short length rigid guide segments, ( 1 ) one longer length rigid guide segment, ( 1 ) and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration. The illustration at left center shows the guide configuration comprised of three short length rigid guide segments, two longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) and an angled, flare, cone end ( 4 ) attached to the end of the lower rigid guide segment ( 1 ) ( 15 ) ( 19 ) in a fixed length guide configuration resting on the bottom ( 21 ) of the body of water. The illustration at right center shows the guide configuration comprised of three short length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) and two longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration. The illustration at the right shows the guide configuration comprised of one longer length rigid guide segment, ( 1 ) ( 15 ) ( 19 ) resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration.
[0036] Referring to FIG. 8 , the guide configuration is comprised of three short length rigid guide segments, ( 1 ) one longer length rigid guide segment, ( 1 ) and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration. The illustration at left center shows the guide configuration comprised of three short length rigid guide segments, two longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) and an angled, flare, cone end ( 4 ) attached to the end of the lower rigid guide segment ( 1 ) ( 15 ) ( 19 ) in a fixed length guide configuration resting on the bottom ( 21 ) of the body of water. The illustration at right center shows the guide configuration comprised of three short length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) and two longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration. The illustration at the right shows the guide configuration comprised of one longer length rigid guide segment, ( 1 ) ( 15 ) ( 19 ) resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration.
[0037] In the configuration of FIG. 8 , the guide is positioned at a 55 degree angle, with respect to the surface of the bed. In other words, the guide and a normal to bed define an angle of 35 degrees. The guide in FIG. 8 has a length of 34′ and, because of the angle, a 16′ lateral reach.
[0038] Winch 25 acts to change the angle position of the guide.
[0039] FIG. 9 is a profile view of one variant work surface being a marine barge ( 20 ) as shown and a matrix of underwater guide assembly options. The illustration at the left shows the guide secured to the work surface or machinery. The guide configuration is comprised of five short length rigid guide segments, ( 1 ) one longer length rigid guide segment, ( 1 ) one flangeless telescoping section ( 3 ) for optional intermediate or end extension of rigid guide segments, and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration. The illustration at right shows a variant of the guide configuration comprised of two open frame half section longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) whereby the rigid guide segment or segments and optionally attached angled, flare, cone end ( 4 ) are of open configuration where elongated objects inserted into the guide assembly are predominantly exposed and visible, resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration.
[0040] Referring to FIG. 9 , the guide configuration is comprised of five short length rigid guide segments, ( 1 ) one longer length rigid guide segment, ( 1 ) one flangeless telescoping section ( 3 ) for optional intermediate or end extension of rigid guide segments, and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration. The illustration at right shows a variant of the guide configuration comprised of two open frame half section longer length rigid guide segments, ( 1 ) ( 15 ) ( 19 ) whereby the rigid guide segment or segments and optionally attached angled, flare, cone end ( 4 ) are of open configuration where elongated objects inserted into the guide assembly are predominantly exposed and visible, resting on the bottom ( 21 ) of the body of water in a fixed length guide configuration.
[0041] In the configuration of FIG. 9 , the guide is positioned at a 35 degree angle, with respect to the surface of the bed. In other words, the guide and a normal to bed define an angle of 55 degrees. The guide in FIG. 9 has a length of 44′ and, because of the angle, a 40′ lateral reach.
[0042] FIG. 10 is a profile view of one variant work surface being a marine barge ( 20 ) as shown and a matrix of underwater guide assembly options. The illustration shows the guide secured to the work surface or machinery. The guide configuration is comprised of three short length rigid guide segments, ( 1 ) four longer length rigid guide segments, and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration.
[0043] Referring to FIG. 10 , the guide configuration is comprised of three short length rigid guide segments, ( 1 ) four longer length rigid guide segments, and one telescoping guide segment ( 1 ) and ( 2 ) with an angled, flare, cone end ( 4 ) resting on the bottom ( 21 ) of the body of water in a telescoping guide configuration.
[0044] In the configuration of FIG. 10 , the guide is positioned at a 20 degree angle, with respect to the surface of the bed. In other words, the guide and a normal to bed define an angle of 70 degrees. The guide in FIG. 10 has a length of 72′ and, because of the angle, a 60′ lateral reach.
[0045] The above-described embodiments provide for an underwater guiding apparatus comprising independent rigid segments and independent telescoping segments assembly of one or more sectional segments wherein one or more tubing, open frame segments are static and one or more segments are movable being of different dimension than the static segments with a means for coupling the segments wherein the means permits the segmental extension and retraction of the telescoping segment assembly and a means for varying the length of the underwater guiding apparatus by adding and removing rigid or telescoping segments thereby extending and retracting the assembly with a combination of rigid segments and telescoping segments for guiding, containment, direction, penetration, placement, and installation, of elongated structures such as directional, variable angle machine, bore, drill, equipment, materials and such elongated structures such as stems, rods, piping, tubing, hoses, cables, lines and other similar structures through the atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials and without environmental impact, and other applications with the following distinct features and advantages.
[0046] 1. It provides for guiding, direction, penetration, placement, and installation, of elongated structures such as directional, variable angle machine, bore, drill, equipment, material and such elongated structures such as stems, rods, piping, tubing, hoses, cables, lines and other similar structures through the atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials and without environmental impact at variable segmented and assembly lengths and angles by creating an infinitely adjustable angle, length, diameter, dimension, width, dynamic and statically controlling segmental and telescoping guide segments thereby adjusting its length and angle from end to end.
[0047] 2. It is infinitely adjustable in length. It can be adjusted to any length within its operational limits for use in atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials.
[0048] 3. It is infinitely adjustable in orientation and angle of installation. It can be adjusted to any angle within its operational limits for use in atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials.
[0049] 4. It can be incrementally sized in segmented or overall diameter, dimension, and width to accommodate a variety of elongated structures and guide components for various directional, variable angle machine, bore, drill, stems, rods, piping, tubing, hoses, cables, lines equipment, materials and other such elongated structures.
[0050] 5. It permits variable configuration of primary and supportive guide components such as tubes, brackets, rails, beams, frames, clamps, through hole plates, trusses, and standoffs.
[0051] 6. It permits variable configuration of the guide support rails and longitudinal support members such as number, shape, and configuration of rails along with a variety of rail materials such as solid, angular, box, and tubular materials which can be drilled, slotted, and machined to accommodate various features, options, equipment, capabilities and attachment points.
[0052] 7. It permits independent and combined sectional and telescoping guide configuration using solid wall tubing, drilled or slotted tubing, rings, beams, support rails, trusses, frames and angular or box materials.
[0053] 8. It permits variable configuration of the telescoping segments such as locking, sectional, and telescoping extension and retraction mechanisms such as dynamic friction and static lock down screws, pressure screws, travel limitation screws, springs, bolts, pins, bolts, and control linkage.
[0054] 9. It permits variable mounting and attachment of individual and multi-segment end segments such as angled, flare, bell, and cone ends by bolting, sliding, clamping, clipping, machine fitting or being fixed as well as variable configurations in angle, length, diameter, curved, solid wall, slotted, banded, caged, rigid or flexible.
[0055] 10. Once installed, it can function statically thereby fixing its overall length.
[0056] 11. Once installed, it can function dynamically thereby self adjusting its length for varying distances in atmosphere, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and dynamic changes in end to end clear dimension due to movement including but not limited to such movements from wind, wave action, tides, changes in work surface elevation, external mechanical, natural forces and other factors.
[0057] 12. Once installed, it can function both statically and dynamically thereby partially and segmentally fixing its overall length while partially and segmentally adjusting its length for varying water column depths and changes in end to end clear dimension due to movement including but not limited to such movements from wind, wave action, tides, changes in work surface elevation, external mechanical, natural forces and other factors.
[0058] 13. It is self deploying. Attaching support equipment and machinery to base plate(s) secured anywhere along its length such as equipment to assist in handling, setup, deployment, adding and removing segments, extension, retraction, recovery, breakdown, and storage of the guide components as well as support equipment and machinery for handling, manipulation and recovery of elongated structures.
[0059] 14. Each guide segment is rigid thereby providing lateral support for elongated structures while reducing overall deflection using single or multiple guide segments.
[0060] 15. It can be manufactured from a variety of materials such as aluminum, steel, alloys, composites, and plastics.
[0061] 16. It can be universally mounted to a variety of fixed, land based, suspended, marine, aerospace, and movable construction, mechanical, and scientific type equipment.
[0062] 17. It is dynamic and can be used from fixed or movable locations of varying water column depths and changes in end to end clear dimension due to movement including but not limited to such movements from wind, wave action, tides, changes in work surface elevation, external mechanical, natural forces and other factors.
[0063] 18. It is fully adjustable and expandable in length, diameter, width, dimension, and operational capabilities by adding and removing guide segments and components to increase its scope and range of operation.
[0064] 19. It is simple. It has no mechanical moving parts.
[0065] 20. It is portable. Each rigid guide segment can be sized in as desired in length, width, and dimension and can be completely or partially dismantled, and easily transported in a small vehicle, and operates with no moving parts.
[0066] 21. It is light weight. Each of its accordingly sized segments, components can be lifted and transported by hand, and operates with no moving parts.
[0067] 22. The exemplary embodiment provides a professional and aesthetic appearance with functional performance. The optionally drilled and slotted support rails and beams reduce overall deflection, reduce weight and provide numerous connection points along their full length. The optional external box support rails provide lateral support for the inner guide components while providing internal integrated floatation control for individual and multiple guide segments.
[0068] 23. Guide components can be easily assembled, used, and dissembled in-water close to the water surface using the externally or integrated floatation vessels providing floatation control for individual and multiple guide segments.
[0069] 24. The segment end components such as angled, bell, flair, cone assists in self alignment, docking and recovery of installed elongated structures and associated installation machinery and equipment.
[0070] 25. The optionally installed floatation vessels permits infinite operational floatation and buoyancy adjustment and control for individual and multiple guide segments.
[0071] 26. The guide segments and assembly provides a means for guiding, handling, direction, penetration, placement, and installation, of elongated structures through the atmosphere, vacuum, partial vacuum, fluid, fluid and water columns in man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans and into and through such waterway and other bottom materials without environmental impact.
[0072] 27. The above advantages and uses may be employed in any area of application limited only by the imagination of the user. For example, in underwater applications, the method of the exemplary embodiment may be employed in the following environments and applications.
[0073] 1. Underwater, Above Water, Fluids.
[0074] 2. Semi-submerged.
[0075] 3. Aerospace.
[0076] 4. Containment Vessels, Tanks, and Containers.
[0077] 5. Disposal Facilities
[0078] 6. Installation of power and other cables and lines.
[0079] 7. Installation of fiber optic and other type communications cables.
[0080] 8. Installation of utility and other lines and conduits.
[0081] 9. Installation of pipelines.
[0082] 10. Installation of navigation lighting and related systems.
[0083] 11. Installation of anchoring cables and similar structures.
[0084] 12. Bottom and sub-bottom material sampling.
[0085] 13. Probing, Remote testing.
[0086] 14. Installation of sub-bottom sensors.
[0087] 15. Installation of sub-bottom instrumentation.
[0088] In summary, The exemplary embodiment is an underwater guiding apparatus comprising independent rigid segments and independent telescoping segments assembly of one or more sectional segments wherein one or more tubing, open frame segments are static and one or more segments are movable being of different dimension than the static segments with a means for coupling the segments wherein the means permits the segmental extension and retraction of the telescoping segment assembly and a means for varying the length of the underwater guiding apparatus by adding and removing rigid or telescoping segments thereby extending and retracting the assembly with a combination of rigid segments and telescoping segments.
[0089] The underwater guiding apparatus comprises a means for locking the telescoping assembly in fixed length configurations and further comprises a means for adjusting the angle of the guiding apparatus.
[0090] The underwater guiding apparatus comprises a segment for anchoring and securing the underwater guiding apparatus to a fixed or variable elevation work surface, mechanical equipment and machinery. The underwater guiding apparatus comprises rigid fixed length segments and telescoping segment or segments in an assembly wherein the telescoping segment assembly comprises an outer segment, an inner extension segment, and an angular, flare, cone end, wherein the inner extension segment is slidably engaged with the outer segment to permit extension and retraction of the inner extension segment, the end being secured to one end of the inner extension segment.
[0091] The underwater guiding apparatus wherein the telescoping segment assembly further comprises one or more binding blocks with set screws and pins for locking the inner extension segment in a fixed position. The underwater guiding apparatus wherein one or more telescoping segment assemblies comprises an inner extension segment of differing dimension being positioned between the rigid outer receiver segments to permit both segmental extension and extension and retraction of the telescoping segment assembly.
[0092] The underwater guiding apparatus wherein the angled, flare, cone end is secured to the end of a rigid segment or end of an inner telescoping segment of the telescoping assembly being temporarily secured by connecting hardware or permanently secured by welding the end section to the inner telescoping segment assembly.
[0093] The underwater guiding apparatus wherein one or more of the segments of the telescoping segments are comprised of a plurality of bars, connecting hardware, or guides in a cylindrical or angular pattern and a friction sleeve positioned within and secured by the bars connecting hardware, or guides.
[0094] The underwater guiding apparatus bars are constructed containing airtight cavities thereby enabling the pipe to function as a floatation vessel. The underwater guiding apparatus wherein one or more of the components of the telescoping assembly further comprise integrated or attached flotation vessels.
[0095] The underwater guiding apparatus is constructed containing a completely or partially enclosed containment cavity or channel and a single or plurality of lateral containment tubes, channels, pins, and connecting hardware thereby providing the elongated objects such as directional, variable angle drill, bore and such machine and other stems, rods, piping, tubing, hoses, cables, lines and other similar elongated rigid and flexible structures with lateral support.
[0096] The underwater guiding apparatus wherein one or more of the components of the fixed length segments and telescoping segments further comprise integrated or attached flotation vessels.
[0097] The underwater guiding apparatus enables a method of guiding underwater submerged elongated structures through varying water column depths comprising the steps of: selecting a single or plurality of rigid fixed length segments and installing the assembly at a desired work angle and if desired, connecting one or a plurality of telescopic segments to the fixed length segment or segments and positioning the underwater guiding apparatus in the area and location where the elongated structures are to be guided and orienting the assembly to the desired angle and extension length.
[0098] The method for guiding underwater submerged elongated structures wherein the elongated rigid and flexible structures are one or more of stems, rods, piping, tubing, hoses, cables, and lines. The method for guiding underwater submerged elongated structures wherein the guiding is performed for the placement and installation of both rigid and flexible elongated structures. The method for guiding underwater submerged elongated structures further comprises the step of securing the assembly to a fixed or variable elevation work surface, machinery and equipment.
[0099] In other words, there is a system for positioning elongated structures such as piping, hoses, cables, wires, tubing, and such elongated structures on or below the bottom of the water columns, bodies of water such as lakes, streams, rivers, coastal waters, oceans, and fluids comprising; an underwater guiding apparatus; the underwater guiding apparatus comprising an assembly of a single and/or plurality of elongated fixed, telescopic, or combination of fixed and telescopic segments with no moving parts; each of the segments to contain, enclose, and guide the piping, hoses, cables, wires, tubing, and such elongated structures within each single or plurality of the segments; at least one of the segments individually or connected to at least one other adjacent segment by static, telescoping, or combination of static and telescoping coupling means; each the coupling means configured to permit static, and/or telescopic extension, or retraction of the adjacent segments; one or a plurality of the segments configured to be independent and/or permit the addition of one or more segments in static, telescoping, or combination of segmented fixed and telescoping relationship; at least one of the segments configured for removal from the plurality of remaining segments;
[0100] The underwater guiding apparatus further comprises means for securing and/or locking the assembly of a single or plurality of segments in a fixed, telescopic, and/or combination of fixed and telescopic segments; a work surface positioned on, above, or adjacent to a body of water and/or atmosphere; the underwater guiding apparatus secured to the work surface proximate a first end of the underwater apparatus; the underwater guiding apparatus longitudinally and angularly adjustable relative to the work surface; and at least a portion of the underwater guiding apparatus located below the surface of the water or fluid proximate a second end, in a position to guide the drills, stems, rods, piping, tubing, hoses, cables, lines equipment, materials and other such elongated structures through the guiding apparatus onto and/or under the bottom of the body of water and/or other surface atmospheric surface materials.
[0101] The guiding apparatus further comprises a means for securing or locking the fixed length segments and telescoping segments and assembly in a fixed length configuration.
[0102] The guiding apparatus further comprises a means for adjusting the angle of the fixed length segments, telescoping segments and assembly.
[0103] The guiding apparatus further comprises a segment for securing or anchoring the guiding apparatus to a fixed, movable, or variable elevation work surface.
[0104] According to an alternate embodiment, a guiding apparatus comprises: a segmented and optionally telescoping assembly; not limited to two segments for guiding elongated structures through the apparatus wherein the segmented assembly comprises a single or plurality of rigid independent segments optionally incorporating a telescoping segment within the assembly which comprises a rigid guide segment, telescoping extension segment, and an angled, flare, cone end, wherein the telescoping segment is slidably engaged with receiver segment to permit extension and retraction of the telescoping segment and guide assembly.
[0105] The alternate guiding apparatus further comprises an optionally installed base plate or plurality of base plates attached to rigid or telescoping segments for securing hardware and machinery.
[0106] The alternate guiding apparatus further comprises a rigid segment to the telescoping assembly for attaching the guiding apparatus to a fixed, movable, or variable elevation work surface, machinery or equipment.
[0107] In the alternate guiding apparatus, the sectional assembly further comprises an independent rigid segment coupled to additional rigid segments or to the telescoping segment of the sectional or telescoping assembly.
[0108] In the alternate guiding apparatus, the telescoping segment and assembly further comprises one or more binding blocks with securing hardware for locking the telescoping segment and assembly in a fixed position.
[0109] In the alternate guiding apparatus, the telescoping assembly further comprises one or more additional telescoping segments of differing dimension than the rigid guide segment positioned between the rigid guide segment the angled, flare, cone end to permit increased extension length.
[0110] In the alternate guiding apparatus, the angled, flare, cone end is secured to the fixed guide segment, telescoping segment, and assembly by being bolted, clipped, pinned or welded on to the end of a fixed guide segment or telescoping segment.
[0111] The alternate guiding apparatus further comprises a means for adjusting the angle of the fixed length or telescoping assembly. The means for adjusting the angle of may be by hand, floatation vessels, or by attached equipment or machinery.
[0112] In the alternate guiding apparatus, one or more of the segments of the rigid and telescoping assembly are comprised of a single or plurality of solid, enclosed, openly constrained, and/or hollow lateral supports in a substantially cylindrical and/or angular pattern and an optional inner-friction or spacer sleeve contained and positioned within the guide segments.
[0113] In the alternate guiding apparatus, the securing hardware are constructed containing cavities thereby enabling the guide segment lateral supports to function as a floatation vessel for the guide segments.
[0114] In the alternate guiding apparatus, one or more of the components of the guide segments and telescoping assembly further comprise externally attached or integrated flotation vessels with no moving parts.
[0115] There is an exemplary process and method for guiding elongated structures such as drills, stems, rods, piping, hoses, cables, wires, tubing, and such elongated structures through water columns, man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans, and the atmosphere with no moving parts comprising the steps of: providing a guiding apparatus; the guiding apparatus an assembly of a plurality of elongated segments; each of the segments to contain, enclose, and guide the stems, piping, hoses, cables, wires, tubing, and such elongated structures within the segments without moving parts; at least one of the segments individually or connected to at least one other adjacent segment by static, telescoping, or combination of static and telescoping coupling means without moving parts; each the coupling means configured to permit fixed, telescopic, and/or combination of fixed and telescopic extension and/or retraction of the adjacent segments; at least one or more of the segments configured to permit addition of one or more segments in fixed, telescopic, or a combination of fixed and telescopic relationship with no moving parts; at least one of the segments configured for removal from the remaining segments; the guiding apparatus further comprising means for securing and/or locking the assembly of one or more segments in a fixed, telescopic, or combination fixed and telescopic relationship; securing one or more segments to a fixed, movable, or variable elevation work surface, so that the assembly of a plurality of segments is longitudinally and angularly adjustable; orienting the assembly of a plurality of segments to a desired angle, overall length, or an extension and retraction range; positioning at least part of the guiding apparatus through water columns, man made containment vessels, artificial and natural bodies of water such as lakes, streams, rivers, coastal waters, oceans, and the atmosphere; and positioning and moving the elongated structures such as piping, hoses, cables, wires, tubing, and such elongated structures through a segment or plurality of segments into position on or below the bottom of the water columns, bodies of water such as lakes, streams, rivers, coastal waters, oceans, and fluids.
[0116] In the exemplary method, the elongated structure is one of stems, rods, piping, tubing, hoses, cables, and lines without moving parts.
[0117] In the exemplary method, the guiding is performed for the placement and installation of the elongated structures without moving parts.
[0118] The method for guiding elongated structures further comprises the step of securing a guide segment to a fixed, movable, or variable elevation work surface, machinery or equipment without moving parts.
[0119] Thus, an underwater guiding device includes one or combination of a plurality of rigid guide segments, and/or telescoping guide segments where one or plurality of segments are of fixed length and one or plurality of segments are telescoping permitting use of either a single segment, a plurality of rigid guide segments for incremental extension of the assembly, and a combination of rigid guide segments and a telescoping guide segment or segments for sectional, infinitely adjusted, and dynamic extension and retraction of the guide assembly. The assembly can be secured to a stationary or moving work surface with static or dynamic control of individual segments, multiple guide segments, and assembly. The guide can be adjusted to any length and for any angle of operation. The guide is a method for guiding underwater submerged elongated structures through the water column into and through marine and other bottom surface, and subsurface materials.
[0120] Benefits, other advantages, and solutions to problems have been described above with regard to specific examples. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not critical, required, or essential feature or element of any of the claims.
[0121] Additional advantages and modifications 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 illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or the scope of Applicants' general inventive concept. The invention is defined in the following claims. In general, the words “first,” “second,” etc., employed in the claims do not necessarily denote an order.
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Disclosed are systems and methods for drilling in an environment having a fluid and a bed. The method includes positioning a platform such that the fluid is between the platform and the bed; and assembling a guide, the assembled guide being straight. The method subsequently acts to place the guide such that the guide is supported by the platform, and a major length of the guide and a normal to the bed defines an angle, the angle being substantially greater than 0. Thus, the positioned guide allows for sending a variable angle drill inside the guide, from the platform into the bed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an X-ray examination apparatus which includes: an X-ray image means for providing an X-ray image composed of pixels, each having a grey value, and a brightness control system which is coupled to the X-ray image means in order to provide the X-ray image means with a brightness control signal of the X-ray image. The present invention also relates to a method for deriving a brightness control value from information contained in an X-ray image.
2. Description of Related Art
Such an apparatus and method are known from EP-A-0 629 105. This document discloses in particular an X-ray examination apparatus having an X-ray image means including an X-ray source, an X-ray image intensifier, a lens structure and a visible image processing device. An auxiliary light detection system of the apparatus forms a brightness control system and provides a brightness control signal which is fed back to the X-ray image means for X-ray image brightness control. In particular brightness and contrast of the X-ray image are being controlled by allowing only certain parts of the visible image to contribute to the brightness control. These parts are called measuring fields, which measuring fields are either selected manually, which is troublesome, or automatically. The prior art application discloses processor controlled automatic selection based on the brightness or grey values of parts in the visible image. The automatic selection raises additional problems in a situation wherein the image shows virtually unabsorbed, so called direct radiation and the object to be examined contains tissues having a low X-ray absorbing, for example lungs, such as in thorax (spine/lungs) images. Discrimination in such an image between parts of the body that may and parts that may not contribute to the brightness control in the X-ray examination apparatus is problematic, also because the position of the lungs in the image may vary.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide an apparatus and method providing an improved X-ray image quality and being capable of offering a physician additional possibilities for notably visual X-ray analyses of certain changes that appear in less absorbing body parts, such as in particular the lungs, without being bothered by negative influences of possible direct radiation in the image or other objects more absorbing than the lungs.
To this end, the apparatus according to the present invention is characterized in that the brightness control system comprises an image analyzing means for deriving the brightness control signal CS from a maximum over the number of times f(gr) that a grey value gr occurs in the image.
It has been found that the brightness control signal thus derived provides an advantageous, adequate indicator for discriminating between relevant sorts of information contained in the X-ray image when the aim is to derive brightness control information therefrom. Using either directly or indirectly the maximum of the number of times that a grey value occurs in the relevant visible image, the weak X-ray absorbing objects in the image can be given an optimum brightness despite their varying position in the image; this improves the image quality and makes these weak X-ray absorbing objects better discernable for medical examination purposes.
Moreover, said indicator indicates the transitional brightness area between the weak absorbing tissue of, for example, the lungs and said direct radiation. It is a further advantage of the apparatus according to the present invention that it is no longer necessary to manually specify a region of interest in the image since, given a tissue to be imaged, the apparatus provides optimized, automated brightness control information. Advantageously, the optimized brightness control signal can still be fine tuned in dependence on further particulars of the image or technical components or elements in the apparatus.
Accordingly, the method having easy and fast software implementation is characterized in that information wherefrom a brightness control value is derived includes data about a maximum in the frequency f(gr) of grey values gr occurring in the image.
One embodiment of the apparatus according to the invention, wherein the image analyzing means incorporate time averaging means for deriving the brightness control signal from a maximum over the time-averaged number of times that a grey value gr occurs in the X-ray image, provides the advantage that, despite a weak signal to noise ratio as well as jitter conditions in the available image signal, a stable brightness control signal can still be output.
With or without time averaging, in a further embodiment of the apparatus according to the invention the image analyzing means incorporate running averaging means for deriving the brightness control signal from a maximum over the running averaged number of times f(gr) that n possibly, but not necessarily, consecutive, either in time or in grey value, grey values gr occur in the image. This implementation also provides increased stability, because the noise is averaged by applying the running average operation across n generally digital grey values, wherein n is generally lower than about 15; in a practical, sufficiently reliable software implementation n equals 5.
In still a further embodiment of the apparatus according to the invention the image analyzing means comprises threshold means for deriving the brightness control signal from a percentage p of the maximum in the number of times a grey value occurs in the image. Advantageously the threshold means are arranged to allow the percentage p to be adjustable, preferably programmably adjustable, the percentage p being between 30% and 98%, preferably between 60% and 95%, and more preferably about 90% lower than said maximum number of times a grey value occurs in the image; the latter percentage has proven to be optimally suited for effective visualization of certain lung tissues.
The present invention mainly provides flexibility by being capable of empirically determining p and/or n in dependence on inter alia image parameters, such as image amplifier format or type, maximum number of available grey values, amount of or estimation of direct radiation present in the image, X-ray intensity (X-ray tube current), film type, X-ray frequency spectrum (X-ray tube high voltage) and/or object parameters such as expected absorption coefficients of imaged objects such as, for example lungs, brain etcetera. Preferably, well known Fuzzy Logic is used in order to provide a software implemented image brightness control based on Fuzzy Logic rules.
BRIEF DESCRIPTION OF THE DRAWING
The apparatus and method according to the invention will now be elucidated further, together with their additional advantages, while making reference to the appended drawing wherein similar components are denoted by the same reference numerals. In the drawing:
FIG. 1 shows schematically an embodiment of the apparatus according to the invention,
FIG. 2 shows an exemplary histogram of an image containing lung tissue, where direct radiation is present in the image and an optimum brightness control signal is determined by means of the apparatus of FIG. 1,
FIG. 3 shows another histogram with virtually no direct radiation, and
FIG. 4 shows still another histogram without direct radiation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows schematically an X-ray apparatus 1 , including an X-ray source 2 having a brightness control input 3 for influencing the intensity of X-rays emanating from the source 2 . The X-rays irradiate an object O and form an X-ray image thereof on an image convertor/intensifier 4 of the apparatus 1 . The apparatus 1 also includes a lens structure 5 interposed between the image intensifier 4 and a video means 6 , for example provided, with a video camera or video recording means (not shown). The means denoted by the reference numerals 2 - 6 thus form X-ray image means for providing the X-ray image of the object to be examined, which may be a human being or generally a part thereof. The video means 6 outputs an image signal (IS), e.g. an electronic video signal which represents the image information in the X-ray image. The image signal is applied to a monitor 20 so as to display the image information. The image signal IS is also applied to a buffer unit 21 . The image signal is stored in the buffer unit 21 while awaiting the printing of the image information on a hard-copy or the further processing of the image signal.
The optical image present in the lens structure 5 is used to derive therefrom using a brightness control system 7 , a brightness control signal CS on control output 8 which in its turn is coupled to the control input 3 . Proper adjustment of the brightness of the acquired image is vital to a physician so as to allow high quality visual inspection of the part to be examined with the aid of the video means 6 . A brightness control system may be embodied as described in EP-A-0 629 105 which is considered to be incorporated herein by way of reference. The brightness control system 7 schematically shown in FIG. 1 includes a CCD detector 9 which has a detector output 10 for providing spatial information about the visual image and a photosensor 11 which is coupled to a beam splitter 12 . The photosensor 11 applies a sensitivity control signal SCS, having a sufficient dynamic range of brightness, to a sensitivity control circuit 13 which in its turn is connected to the CCD detector 9 . Finally, a spatial information signal SIS, having the required dynamic range of brightness, is fed from the detector 9 to an image analyzing means 14 in order to allow digital manipulation of pixels of the visual image. The image analyzing means 14 outputs, in a way yet to be described, a mean value spatial information signal MSIS to a multiplier 15 for multiplication by the sensitivity control signal SCS, which multiplication yields the desired brightness control signal CS on the control output 8 .
The extraction of the spatial information signal MSIS in the image processing unit 14 while using the brightness of relevant parts, such as lungs, contained in the visible image will now be described in detail. Convenient starting points from a point of view of clarity of description are histograms, such as the graphs exemplified in FIGS. 2-4, wherein the number of times f(gr) a grey value gr occurs in every pixel of a visual image, i.e. the grey value frequency f(gr), is graphically shown in dependence on possible pixel grey values gr. Possible grey values extend from 0 (full black) to gr max (full white). Such a histogram can be prepared by means of a method and device as described for instance in EP-A-0 748 148, which is considered to be included herein by way of reference. The image analyzing means 7 includes an arithmetic unit 22 which computes the histogram from the spatial information signal SIS. Information contained in the histogram is useful for automatically determining the optimum brightness control signal (CS) value. The information in the histograms which is important because it contains the pixels in the X-ray image representing low absorption tissue, such as lung tissue, is included in the first/left lobe in FIG. 2 . The second/right lobe represents lighter (brighter) pixels. The second lobe is identified as direct or virtually unabsorbed X-ray radiation.
The graphs exemplified in the FIGS. 3 and 4 show no second lobes. A brightness control value can be derived from the graphs of the histograms of FIGS. 2-4 by image analyzing means 14 which is included in the apparatus 1 in order to derive the optimum brightness control signal CS from a maximum f Max in the number of times a grey value occurs in the image. Usually the X-ray image analyzing means 14 comprises possibly software implemented threshold means 16 for deriving the brightness control signal CS from a percentage p of the maximum in the number of times a grey value occurs in the visible image. Suppose, for example, that the maximum frequency occurring in the histogram of FIG. 3 is f Max ; if p=80% a breakpoint PB then lies at 0.2 times f Max . PB thus indicates the ‘position’ of the lungs in the histogram, that is to say PB can be taken as a measure for controlling the brightness of the X-ray image by means of the control signal CS; as a result the lungs will generally be very well discernable therein.
A second embodiment will be explained while referring again to FIG. 2 . Now the frequency threshold value in the threshold means 16 is based on a percentage p which equals, for example 90%. If the X-ray analyzing means incorporate running averaging means 17 , the brightness control signal CS may be derived from the maximum of the running averaged numbers of times that n, for example, consecutive grey values occur in the X-ray image. In that case the running average maximum f H is at least composed of f Max and of frequency values around f Max . So in the specific example where n=5 and the threshold value lies 90% below the highest average grey value frequency f H , namely at f 0.1H , the running averaged or convoluted frequency graph f c shown in dotted form in FIG. 2 determines the breakpoint PB where the line f 0.1H crosses the graph f c . FIG. 4 schematically shows the case where PB is determined for p=95% and n=1, similar to the embodiment of FIG. 2 . Again the result PB can be taken as a measure for controlling the brightness of the X-ray image by means of the control signal CS for optimized discernability, in particular for low-absorption tissues.
There are, however, situations where the breakpoint PB as such and as defined above does not indicate the ‘position’ of the lungs in the histograms accurately enough to base the brightness control thereon. Such situations arise when there is less or no direct radiation present in the histogram and hence the hatched area in FIG. 2 is small, as is shown in the FIGS. 3 and 4. It has been found that relating the above mentioned measure for controlling the brightness of the X-ray image to an additional parameter DIFF according to the formula:
DIFF= 1 −PB/gr max
yields a more stable algorithm for accurate control of the brightness in cases not involving too much direct radiation in the X-ray image. In those cases the hatched area is small.
In cases with more direct radiation, such as shown in the histogram of FIG. 2, the hatched surface area alone can be taken as a measure for the amount of direct radiation; this measure can be used to correct PB for providing an accurate brightness control in those cases too.
In practice an additional correction can be achieved by correcting PB for the image format used by the image intensifier 4 .
Generally speaking the X-ray analyzing means incorporate time averaging means 18 for deriving a stable and low-jitter brightness control signal from the maximum over the time averaged number of times a grey value gr occurs in the image. Thus, in practice the control signal SIS is time averaged before being applied to the threshold means 16 .
It has been found in practice that many variations can be introduced such that the above n and p can be fine tuned and adjusted to the specific needs of a physician who wishes to visually analyze parts or details in weakly absorbing, mostly human objects. Empirical determination in dependence on inter alia image parameters, such as image amplifier format or type, maximum number gr max of available grey values gr, amount of or estimation (hatched area in FIG. 2) of direct radiation present in the histogram of the image, X-ray intensity (X-ray tube current), X-ray film type, X-ray frequency spectrum (X-ray tube high voltage) and/or object parameters, such as expected absorption coefficients of objects for example lungs, brain etc. is possible.
The method has proven to be a powerful tool for discriminating relevant information from less relevant information in an histogram of an image containing in particular, but not exclusively, weakly absorbing tissues or body parts.
Preferably, the apparatus 1 comprises Fuzzy Logic means 19 for performing accurate control of the brightness of the image according to Fuzzy Logic rules in dependence on the above-mentioned image and object parameters. The Fuzzy Logic means 19 is coupled to the arithmetic unit 22 . The arithmetic unit applies the histogram to the Fuzzy Logic means 19 . The Fuzzy Logic means outputs settings of the running averaging means 17 and the threshold means. In particular, the Fuzzy Logic means 19 applies suitable values of the parameters n and p to the running averaging means 17 and to the threshold means 16 , respectively. The Fuzzy Logic means 19 notably is also coupled to the threshold means 16 and to the running averaging means 17 . In particular the amount of direct radiation represented by the hatched area (see FIG. 2) can be used to decide in a Fuzzy Logic way whether or to what extent PB or DIFF are used as parameters for accurate brightness control for weakly absorbing tissues, such as the lungs. The variety of different functions elucidated above will be implemented in either hardware or software in a (micro)processor or suitably programmed computer. A variety of alternative embodiments and implementations are now within reach of a person skilled in the relevant art.
All references cited herein are incorporated herein by reference in their entirety and for all purposes to the same extent as if each individual publication or patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety for all purposes.
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An X-ray examination apparatus is provided including: an X-ray image means for providing an X-ray image composed of pixels each having a grey value, and a brightness control system which is coupled to the X-ray image means in order to apply a brightness control signal of the image to the X-ray image means. The brightness control system comprises an X-ray image analyzing means for deriving the brightness control signal from a maximum in the number of times that a grey value occurs in the X-ray image. The apparatus provides optimized brightness in the visual image such that a physician is capable of properly examining changes in weakly absorbing tissues or body parts, such as lungs or the like, thus enabling optimized visual analysis.
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CONTINUITY DATA
This application is a continuation application of U.S. patent application Ser. No. 14/595,644 filed Jan. 13, 2015, now allowed, which is a continuation of U.S. patent application Ser. No. 14/478,615 filed Sep. 5, 2014, now U.S. Pat. No. 9,015,766, which is a continuation of U.S. patent application Ser. No. 14/282,280 filed May 20, 2014, now U.S. Pat. No. 8,955,018, which is a continuation application of U.S. patent application Ser. No. 14/090,385 filed Nov. 26, 2013, now U.S. Pat. No. 8,776,131, which is a continuation application of U.S. patent application Ser. No. 13/940,992 filed Jul. 12, 2013, now U.S. Pat. No. 8,782,708, which is a continuation of U.S. patent application Ser. No. 13/837,094 filed Mar. 15, 2013, now abandoned, which is a continuation of U.S. patent application Ser. No. 13/614,306 filed Sep. 13, 2012, now U.S. Pat. No. 8,443,391, which is a continuation of U.S. patent application Ser. No. 13/099,856 filed May 3, 2011, now U.S. Pat. No. 8,347,335, which is a continuation of U.S. patent application Ser. No. 12/776,063 filed May 7, 2010, now U.S. Pat. No. 7,962,939, which is a continuation of U.S. patent application Ser. No. 12/222,588 filed Aug. 12, 2008, now U.S. Pat. No. 7,761,895, which is a continuation of U.S. patent application Ser. No. 11/075,928, now U.S. Pat. No. 7,426,742, which is a continuation of U.S. patent application Ser. No. 09/828,865 filed Apr. 10, 2001, now U.S. Pat. No. 7,424,729, which claims priority to U.S. Provisional Application No. 60/197,677 filed Apr. 17, 2000, all of which are incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The invention is directed toward the field of digital television signal meta data generation, and more particularly to the non-uniform issuance of certain tables included within such meta data.
BACKGROUND OF THE INVENTION
It is known for a digital television (DTV) signal to include meta data representing information about the contents of the events, e.g., programs, movies, sports games, etc. contained in the DTV signal. For a terrestrially broadcast DTV signal, the Advanced Television Standards Committee (ATSC) has promulgated the A/65 Standard that defines such meta data. The A/65 standard refers to such meta data as program and system information protocol (PSIP) data.
The PSIP type of meta data is issued periodically. Data of greater importance in the meta data hierarchy is inserted into the DTV signal more frequently than data of lower importance.
In general, in this art it is desired to maximize the amount of available bandwidth that can be allocated to the transmission of the DTV program content. Unfortunately, meta data consumes bandwidth that otherwise could be used to transmit the corresponding DTV program content. But such meta data is a prerequisite to an A/65 compliant DTV signal, hence it cannot be eliminated to recover bandwidth.
It is a problem to reconcile the contradictory design criteria of maximizing bandwidth allocated to DTV program content and providing sufficient meta data to ensure compliance with the A/65 standard.
SUMMARY OF THE INVENTION
The invention is, in part, a solution to the problem of how to insert the least amount possible of meta data into the DTV signal and yet still achieve an A/65 compliant DTV signal. In other words, the invention is, in part, a recognition that it is desirable to insert meta data into the DTV signal as infrequently as possible.
The invention is, also in part, a recognition that: the A/65 standard establishes fixed frequencies of table output for some of the program and system information protocol (PSIP) data tables, e.g., such as the Master Guide Table (MGT), the Virtual Channel Table (VCT) and the System Time Table (STT), but not for some others; and such unfixed output intervals afford opportunities to lessen meta data output thereby reducing bandwidth consumption in the form of PSIP meta data without sacrificing compliance with the A/65 standard.
The invention provides, in part, a method to determine issuance intervals for like types of tables, respectively, in a digital television packet stream having a plurality of different types of tables that do not have issuance intervals set by a governing standard. Such a method comprises: setting issuance intervals for like ones of the non-governed tables, respectively, to be non-uniform. Such non-uniform issuance intervals can be determined as a function of at least one of an amount of time in the future to which the table corresponds and a degree of probable interest to a viewer. Further, such non-uniform issuance intervals can be weighted so that an issuance interval for a table corresponding to a time nearer the present is smaller than an issuance interval corresponding to a time further in the future.
Examples of meta data PSIP tables that can benefit from the method according to the invention include extended text tables (ETTs) and event information tables (EITs).
Each issuance interval between any two instances of an i th table can be determined according to the following equation:
interval( i th table)=root_time+(increment_time)* i
where interval(i th table) is the interval between any two instances of the i th table, root_time is a predetermined interval for the table corresponding most closely in time to the present, increment_time is a non-zero scalar and i is a non-zero integer.
The invention, also in part, provides a program and system information protocol (PSIP) generator to generate tables for a digital television system packet stream, the generator comprising: an interface to receive at least one issuance parameter for like tables that do not all have an issue interval assigned by a governing standard; and a non-uniform interval calculation unit to determine non-uniform issuance intervals for unassigned-interval-ones of said like tables based upon said at least one issuance parameter. Such a PSIP generator embodies the method according to the invention, e.g., as described herein.
The invention, also in part, provides a processor-readable article of manufacture having embodied thereon software comprising a plurality of code segments to cause a processor to perform the method according to the invention.
According to an aspect of the invention, there is provided an apparatus for generating at least one table in a broadcast environment, the apparatus comprising: a generator to generate an event information table (EIT) and an extended text table (ETT), the ETT having program guide information for an n-hour span and having a transmission interval, the ETT having a transmission interval and having program description information according to the EIT, wherein the transmission interval of the EIT is shorter than the transmission interval of the ETT.
According to an aspect of the invention, there is provided a method for generating at least one table in a broadcast environment, the method comprising: generating an event information table (EIT) and an extended text table (ETT), the ETT having program guide information for an n-hour span and having a transmission interval, the ETT having a transmission interval and having program description information according to the EIT, wherein the transmission interval of the EIT is shorter than the transmission interval of the ETT.
According to an aspect of the invention, there is provided a data structure for generating at least one table in a broadcast environment, the structure comprising: an event information table (EIT) having program guide information for an n-hour span and having a transmission interval; and an extended text table (ETT) having a transmission interval and having program description information according to the EIT, wherein the transmission interval of the EIT is shorter than the transmission interval of the ETT.
Advantages of the present invention will become more 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 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 from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus do not limit the present invention.
FIG. 1 is a block diagram of a PSIP generator according to the invention in the context of typical inputs to it and outputs from it.
FIG. 2 is an image of a dialog window within a screen of a graphical user interface (GUI) generated by the PSIP data generator according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a block diagram of a program and system information protocol (PSIP) data generator according to the invention in the context of system 100 that can produce an Advanced Television Standards Committee (ATSC), standard A/65, compliant digital television (DTV) signal. The system 100 of FIG. 1 includes: a PSIP generator 102 according to the invention; sources of data upon which the PSIP generator operates, such as a source 108 of listing service data, a source 110 of traffic system data and a source 112 of other data; a multiplexer 114 to incorporate the PSIP data from the PSIP generator 102 into an A/65-compliant DTV signal; and a source 116 of audio data, video data, etc.
In FIG. 1 , the PSIP generator 102 includes an interface unit 104 and a non-uniform interval calculation unit 106 .
The PSIP generator 102 according to the invention can be implemented by adapting a well known PSIP generator according to the discussion herein. An example of a known PSIP generator is the PSIP BUILDER PRO brand of PSIP generator manufactured and sold by TRIVENI DIGITAL INC. The PSIP BUILDER PRO itself is based upon a programmed PC having a Pentium type of processor using the MICROSOFT WINDOWS NT4.0 operating system. The software can be written in the Java language. The other blocks of FIG. 1 correspond to known technology.
In FIG. 1 , the invention has been depicted in the context of a digital television broadcast such as a terrestrial broadcast, and more particularly one that is compliant with the Advanced Television Standards Committee (ATSC), where each event is a program, and the schedule data is PSIP data. However, the invention is readily applicable to any television format, e.g., analog terrestrial, analog cable, digital cable, satellite, etc., for which an electronic schedule is maintained and corresponding data is sent to a receiver for the purpose of presenting an electronic program guide (EPG) to a viewer.
The units 104 and 106 within the PSIP generator 102 do not necessarily correspond to discrete hardware units. Rather, the units 102 and 104 can represent functional units corresponding to program segments of the software that can embody the invention.
The interface unit 104 can generate a graphical user interface (GUI) that operates to receive at least one issuance parameter for like PSIP tables (e.g., ETTs or EITs) that do not all have an issue interval assigned by the A/65 standard. Such an interface will be described in more detail below with regard to FIG. 2 . The non-uniform interval calculation unit 106 is operable to determine non-uniform issuance intervals for ones of the like PSIP tables that do not have an assigned interval, based upon the issuance parameter(s) received via the interface unit 104 .
FIG. 2 is an example image of a dialog window 200 (a GUI) that can be generated by the interface unit 104 according to the invention. In FIG. 2 , the dialog window 200 can include: a Cycle Time Settings tab 202 ; a Miscellaneous Settings tab 204 ; a FTP Periodic Update Controls tab 206 ; an “Apply Settings” button 226 ; a “Defaults” button 228 ; a “Refresh” button 230 ; and a “Close” button 232 . The position of the cursor can be indicated via the reverse highlighting 234 . The Cycle Time Settings tab 202 can include a “Cycle Times (in seconds) for EITs:” region 208 , a “Cycle Times (in seconds) for PSIP Tables:” region 210 , a “Cycle Times (in seconds) for PSI Tables:” region 212 and a “Cycle Times (in seconds) for ETTs:” region 214 .
It is well known that EITs carry program schedule information including program title information and program start information. Each EIT covers a three-hour time span. ETTs carry text messages associated with the EITs, e.g., program description information for an EIT.
In FIG. 2 , the “Cycle Times (in seconds) for EITs:” region 208 of the dialog window 200 can include: a box 216 in which a user can enter a fixed interval for the EIT 0 table; a box 218 in which a user can enter an increment for the EIT k table; and a box 220 in which a user can enter a maximum number of EIT tables that are to be sent. Usually, the number entered in box 220 will be far smaller than the maximum number of EIT tables permitted by the A/65 standard.
Also, in FIG. 2 , the “Cycle Times (in seconds) for ETTs:” region 214 can include: a box 222 in which a user can enter a fixed interval for the ETT 0 table; and a box 224 in which a user can enter an increment for the ETT k table.
The non-uniform interval calculation unit 106 can receive the values in the boxes 216 , 218 , 220 , 222 and 224 from the regions 208 and 214 , respectively, and use them to determine the non-uniform issuance intervals of, e.g., the EIT and ETT tables. Further discussion of the operation of the unit 106 is couched in a particular non-limiting example, for simplicity.
The A/65 standard recommends a time interval for outputting the zeroith Event Information Table (EIT), i.e., EIT 0 , but provides no guidelines regarding EIT 1 through EIT 128 . For the Rating Region Table (RRT), the A/65 standard recommends a value only for the output frequency of RRT 1 . And no recommendation is made regarding the output frequencies of any of the Extended Text Tables (ETTs).
Under the A/65 standard, it is left to the discretion of the operator of a PSIP data generation system to select the frequency of table output for the unmentioned tables. The operator could specify an entry for each group of tables, but that would be burdensome because it would require a total of over 500 entries. A simple solution to the problem of unspecified output frequencies would be to set each type of table to the same output frequency, but that creates a problem in that the guidelines for bandwidth specified by the A/65 standard would be exceeded.
A further consideration to solve the problem, namely of how to insert the least amount possible of meta data into the DTV signal and yet still achieve an A/65 compliant DTV signal, is: How closely in time to the present moment does each table relate? That is, table types such as the EIT describe event information up to two weeks into the future. A user of an electronic program guide that receives such table types will typically want to view event information concerning only the next 24-48 hours. Users typically do not look farther into the future than this because (at least in part) the event schedule information two weeks into the future is much more likely to change than is event schedule information concerning the next 24-48 hours, i.e., the farther into the future, the less reliable the event information becomes.
Care must be exercised so as not to set the intervals to be too infrequent. This is because the DTV receiver can become stalled waiting for a table to arrive. If the DTV receiver is stalled for 0.5 seconds, a user might not notice or object if she did. But such a delay of, e.g., 4-5 seconds probably would be noticed by, and probably would annoy, the user. This reinforces the need to set short intervals for near term events because users are likely to want to display EPG information about them.
Again, the invention, in part, provides an interface unit 104 that defines parameters that the non-uniform interval calculation unit 106 then can use to generate the time intervals between tables of the same type. Typically (but not necessarily) the function performed by the unit 106 will be linear, e.g., with a defined start interval (the root_time) and an increment interval (increment_time). For example, if the user desires EIT 0 to be output every half second (root_time) with each succeeding EIT i to be output 0.25 seconds less frequently than the preceding EIT, namely EIT i-1 , the user would enter 0.5 seconds as the root_time in box 216 and 0.25 seconds as the increment_time in box 218 . The function for each table EIT-i interval would then be:
Time between any two instances of table i = root_time + ( increment_time * i ) = 0.5 sec + ( 0.25 sec * i )
For example, EIT 12 can be output every 0.5 sec+(0.25 sec*12)=3.5 seconds, which is less frequent than EIT 0 . Obviously, other examples are possible, e.g., the increment_time for each of different groups of like tables can be set.
A similar calculation for ETTs can be performed by the unit 106 .
The invention has at least the following advantages: 1) it provides an easy way of entering the interval times for the tables: 2) it defines the interval times for like tables that are not all fixed to a constant interval; and 3) it provides an interval function that increases the interval for tables that represent information further out in time.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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An apparatus, method and data structure for generating at least one table in a broadcast environment, are provided. The apparatus includes a generator to generate an event information table (EIT) and an extended text table (ETT). The ETT has program guide information for an n-hour span and has a transmission interval. The ETT has a transmission interval and program description information according to the EIT. The transmission interval of the EIT is shorter than the transmission interval of the ETT.
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This is a division of our copending application Ser. No. 453,911, filed Mar. 22, 1974.
DESCRIPTION OF THE INVENTION
The invention relates to and has among its objects the provision of novel plastic compositions capable of photodegradation. Further objects of the invention will be evident from the following description wherein parts and percentages are by weight unless otherwise specified.
Plastics have become an important part of the American way of life. Innumerable articles of manufacture are made of plastics. One of the main uses thereof is in the manufacture of containers for liquids and solids of all kinds, particularly foods. Another important use is the manufacture of plastic sheet materials such as films and foils. For example, plastic films are used in agriculture for covering the soil between plants, thereby to prevent the growth of weeds.
One problem with plastics is that they are not easily decomposed. Thus, for example, plastic food containers thrown by the roadside do not decompose but remain until collected, thereby polluting the environment. Similarly, plastic films used as soil coverings must be removed from the fields prior to initiating a new crop.
The invention described herein concerns a means for obviating the above problems in that it provides polyolefin plastics which are capable of photodegradation. Containers fabricated from the plastics of the invention when exposed to sunlight will gradually decompose and eventually crumble away. Thus, such containers when thrown along the roadside will eventually become part of the soil. Films prepared from the plastics of the invention when used for agricultural purposes will gradually become friable by the action of sunlight so that they can be readily plowed into the soil.
The benefits of the invention are realized by incorporating into a polyolefin any of the compounds described below.
Group I
N-halo imides of the structure ##EQU1## wherein: X is chlorine, bromine, or iodine
R is a divalent hydrocarbon radical containing 1 to 12 carbon atoms.
Illustrative examples of compounds included in Group I are:
N-chloro-succinimide
N-bromo-succinimide
N-iodo-succinimide
N-chloro-phthalimide
N-bromo-phthalimide
N-iodo-phthalimide
The N-chloro, N-bromo-, or N-iodo derivatives of the imides of malonic, glutaric, adipic, pimelic, suberic, azelaic, or sebacic acids.
Group II
N-Halo amides of the structure ##EQU2## wherein: X is chlorine, bromine, or iodine
Y is hydrogen, chlorine, bromine, or iodine R' is a monovalent hydrocarbon radical containing 1 to 18 carbon atoms.
Illustrative examples of compounds included in Group II are:
N-chloro-acetamide
N-bromo-acetamide
N-iodo-acetamide
N,n-dichloro acetamide
N,n-dibromo-acetamide
N,n-diiodo-acetamide
N-chloro-benzamide
N-bromo-benzamide
N-iodo-benzamide
N,n-dichloro-benzamide
N,n-dibromo-benzamide
N,n-diiodo-benzamide
The N-chloro-, N-bromo-, N-iodo-, N,N-dichloro-, N,N-dibromo-, and N,N-diiodo- derivatives of the amides of propionic, butyric, valeric, caproic, capric, caprylic, lauric, stearic, toluic, or cyclohexane carboxylic acids.
Group III
N-Halo lactams of the structure ##EQU3## wherein: X is chlorine, bromine, or iodine
R" is a divalent aliphatic hydrocarbon radical containing 1 to 12 carbon atoms.
Illustrative examples of compounds included in Group III are:
N-chloro-caprolactam
N-bromo-caprolactam
N-iodo-caprolactam
N-chloro-, N-bromo-, or N-iodo-butyrolactam
N-chloro-, N-bromo-, or N-iodo-valerolactam.
Group IV
N-Halo hydantoins of the structure ##EQU4## wherein: One of the Z's is chlorine, bromine, or iodine, and the other Z is hydrogen, chlorine, bromine, or iodine.
R'" is hydrogen or a lower (C 1 -C 4 ) alkyl radical.
Illustrative examples of compounds included in Group IV are:
1-chloro-hydantoin
1-bromo-hydantoin
1-iodo-hydantoin
3-chloro-hydantoin
3-bromo-hydantoin
3-iodo-hydantoin
1,3-dichloro-hydantoin
1,3-dibromo-hydantoin
1,3-diiodo-hydantoin
3-chloro-5-methylhydantoin
3-bromo-5-methylhydantoin
3-iodo-5-methylhydantoin
1,3-dichloro-5-methylhydantoin
1,3-dibromo-5-methylhydantoin
1,3-diiodo-5-methylhydantoin
1-chloro-5,5-dimethylhydantoin
1-bromo-5,5-dimethylhydantoin
1-iodo-5,5-dimethylhydantoin
3-chloro-5,5-dimethylhydantoin
3-bromo-5,5-dimethylhydantoin
3-iodo-5,5-dimethylhydantoin
1,3-dichloro-5,5-dimethylhydantoin
1,3-dibromo-5,5-dimethylhydantoin
1,3-diiodo-5,5-dimethylhydantoin
Group V
N-Halo urethanes of the structure ##EQU5## wherein: X is chlorine, bromine, or iodine
Y is hydrogen, chlorine, bromine, or iodine
Alk is a monovalent aliphatic hydrocarbon radical containing 1 to 18 carbon atoms.
Illustrative examples of compounds included in Group V are:
N-chloro-urethane
N-bromo-urethane
N-iodo-urethane
N,N-dichloro-urethane
N,n-dibromo-urethane
N,n-diiodo-urethane
The isopropyl, butyl, hexyl, decyl, dodecyl, and octadecyl esters of N-chloro-, N-bromo-, N-iodo-, N,N-dichloro-, N,N-dibromo-, and N,N-diiodo-carbamic acid.
Group VI
N-Halo sulphonamides of the structure ##EQU6## wherein: X is chlorine, bromine, or iodine
Y is hydrogen, chlorine, bromine, or iodine
R"" is hydrogen, lower (C 1 -C 4 ) alkyl, chlorine, bromine, or iodine.
Illustrative examples of compounds included in Group VI are the N-chloro-, N-bromo-, N-iodo-, N,N-dichloro-, N,N-dibromo-, and N,N-diiodo- derivatives of benzenesulphonamide, toluenesulphonamide, and isopropylbenzenesulphonamide.
Group VII
N-Halo isocyanuric acids of the structure ##EQU7## wherein: X is chlorine, bromine, or iodine.
Illustrative examples of compounds included in Group VII are trichloro-, tribromo-, and triiodo-isocyanuric acid.
Polyolefins containing any of the above compounds (or additives as they are often referred to herein) decompose readily when exposed to sunlight. The decomposition, however, is not instantaneous but is gradual, and the rate thereof depends on such factors as the type of polyolefin, the amount of the compound added, and the activity of the latter. The reaction which takes place can be described as a photo-depolymerization in which the polymeric chains are reduced to lower molecular weight under the influence of sunlight.
The amount of additive to be incorporated with the polyolefin depends on the activity of the additive, and upon the desired rate of photo-decomposition. In general, one may use about 0.1 to 10% of the additive, based upon the weight of polyolefin. For most purposes about 1 to 2% of the additive is sufficient to obtain a reasonable and useful rate of photo-degradation.
The polyolefin to which the invention is applied includes, for example, high and low density polyethylene, polypropylene, polybutylene, polystyrene, mixtures of polyethylene and polypropylene, vinyl acetate/ethylene copolymers, and the like. The incorporation of the additive with the polyolefin may be carried out in any of the ways known in the art of compounding plastics. For example, intimate mixing of the polyolefin and additive may be effected by melting and mixing the polyolefin with the additive by any suitable means such as a mixer of the Banbury or Werner type or in a screw extruder. The compositions of polyolefin and additive can be formed into any desired articles such as films, tubular sheets, foils, bags, bottles, or other containers by application of well-known molding and fabricating techniques.
It is within the compass of the invention to use known photo-sensitizing compounds such as dibenzoyl peroxide, azo-bis-isobutyronitrile, and the like in conjunction with the additives of the invention. In some instances such photo-sensitizers increase the activity of the additives of the invention. Thus, polyolefins containing an additive in accordance with the invention and a photo-sensitizer will exhibit an enhanced rate of photodegradation.
EXAMPLES
The invention is further demonstrated by the following illustrative examples.
Example 1 - Photodegradable Polystyrene Films
A. Commercial polystyrene powder was first purified as follows: The powder (90 g.) was placed in a 2-liter Erlenmeyer flask together with 510 ml. of chloroform and the mixture was shaken until dissolved. The solution was poured slowly with vigorous stirring into a 1-gallon Waring Blender containing 2 liters of methanol. The finely precipitated powder was filtered, washed with methanol, air-dried, and finally dried in a vacuum oven at 52° C. and 30 p.s.i. This procedure was repeated for a total of three times and a polystyrene containing no styrene odor was obtained.
B. Incorporation of additive: A wide-mouth jar was charged with 3 g. of the purified polystyrene powder, 0.03 g. of additive, and 17 ml. of chloroform, then shaken on a wrist-action shaker until solution was obtained. The solution was allowed to stand for a few minutes to remove entrapped air bubbles. Afterward, the solution was spread on a 4 × 8 inch glass plate with a film-casting knife with a setting of 0.038 in. The plate was suspended above chloroform in a covered tray to retard evaporation of the solvent. After the plate had dried overnight, it was placed in a tray containing distilled water, which floated the film away from the glass. This film of polystyrene plus the incorporated additive was about 0.004-0.005 inch thick. A piece, 3/4 × 13/8 inch was cut from the film and its infrared spectrum was taken.
C. Test procedure: The said piece of film was then irradiated for 66 hours by maintaining it on a revolving table 9 in. in diameter with the film sample 6 in. from a 275-watt RS sunlamp. After irradiation, an infrared spectrum of the sample was again determined. The extent of photo-oxidation was taken as a measure of the photodegradability of the irradiated material. Photooxidation was determined by measuring the increase in the carbonyl absorption band of the irradiated sample over that of an irradiated sample containing no additive.
D. Specific additives used: The sequence described above in parts A, B, and C was performed with the following additives, each in the amount of 1%, based on the weight of polystyrene: ##EQU8## The results obtained are tabulated below:
Table 1__________________________________________________________________________Polystyrene and 1% Additive Increase in carbonyl, AdditiveRun Additive absorbance effectiveness units ratio*__________________________________________________________________________A N-bromosuccinimide 1.065 6.1B N-chlorsuccinimide 0.563 3.1C N-bromocaprolactam 0.724 4.1D 1,3-dibromo-5,5-dimethylhydantoin 1.453 8.3E 3-bromo-5,5-dimethylhydantoin 1.189 6.8F N-bromoacetamide 0.506 2.9G N,N-dichlorourethane 0.325 1.9H N,N-dichlorobenzenesulphonamide 0.383 2.2I Trichloroisocyanuric acid 0.413 2.4ControlNone used 0.176 1.0__________________________________________________________________________ *Additive effectiveness ratio is equal to the increase in carbonyl for a particular additive divided by the increase in carbonyl obtained without additive (control). Thus, for example, polystyrene containing N-bromosuccinimide is oxidized photochemically 1.065/.176 or 6.1 times more than polystyrene without an additive.
Example 2 - Photodegradable Polyethylene Films
To 0.6 gram of powdered polyethylene resin was added a solution of 0.006 gram of N-bromosuccinimide in 0.6 ml. of acetone. The mixture was stirred to evenly distribute the additive solution over the particles of polyethylene. The mixture was spread as a thin layer on a Mylar sheet supported by a ferrotype chrome plate. After allowing the acetone to evaporate, the said layer was covered with another Mylar sheet and chrome plate. This assembly was heated for 30 seconds at 350° F. and then pressed at 370 psi. for 30 seconds. The assembly was then transferred to an unheated press and pressed at 4,000 psi. while cooling. A film of polyethylene and 1% added N-bromosuccinimide having a thickness of 0.003 to 0.004 inch was thus obtained.
A similar procedure was employed for the preparation of polyethylene films containing other additives. The temperature of the heated press was varied from 350°-412° F., depending on the melting point of the additive. In general, the temperature of the press was about 10° F. above the melting point of the additive.
Samples of the polyethylene-additive film and control polyethylene film without any additive were tested for photo-degradability as described in Example 1, except that the time of irradiation was 100 hours.
The results obtained are summarized below.
Table 2__________________________________________________________________________Polyethylene + Additive Increase in carbonyl, AdditiveRun Additive absorbance effectiveness units ratio__________________________________________________________________________1 N-bromosuccinimide (1%) 0.299 1.22 1,3-dibromo-5,5-dimethylhydantoin (1%) 0.332 1.43 benzoyl peroxide* (1%) 0.138 0.64 1,3-dibromo-5,5-dimethylhydantoin(1%) and benzoyl peroxide (1%) 0.415 1.7ControlNone used 0.241 1.0__________________________________________________________________________ *Not illustrative of the invention; included for the purpose of comparison.
Exaple 3 - Photodegradable Polypropylene Films
Polypropylene films containing additives were prepared by the same procedure described in Example 2. Photodegradability of the resulting film was determined as described in Example 1, but using an irradiation time of 66 hours.
The results are tabulated below.
Table 3__________________________________________________________________________Polypropylene + Additives Increase in carbonyl, AdditiveRun Additive absorbance effectiveness units ratio__________________________________________________________________________1 N-bromosuccinimide (1%) 0.912 2.02 N-iodosuccinimide (1%) 0.547 1.33 N-bromoacetamide (1%) 0.629 1.44 N,N-dichlorourethane (1%) 0.705 1.55 3-bromo-5,5-dimethylhydantoin (1%) 0.587 1.36 benzoyl peroxide* (1%) 0.786 1.77 N-bromosuccinimide (1%) andbenzoyl peroxide (1%) 2.571 5.6ControlNone used 0.462 1.0__________________________________________________________________________ *Not illustrative of the invention; included for purposes of comparison.
Example 4
To 0.6 gram of powdered polypropylene was added a solution of 0.006 gram of trichloroisocyanuric acid in 0.6 ml. of acetone. The mixture was stirred to evenly distribute the additive solution over the particles of polypropylene. The mixture was spread as a thin layer on a Teflon sheet supported by a ferrotype chrome plate. After allowing the acetone to evaporate, the said layer was covered with another Teflon sheet and chrome plate. This assembly was heated for 30 seconds at 480° F. and then pressed at 65 psi for 30 seconds. The assembly was then transferred to an unheated press and pressed at 4,000 psi while cooling. A film of polypropylene and 1% added trichloroisocyanuric acid having a thickness of about 0.004 inch was thus obtained.
Samples of this film and a control polypropylene film without any additive were tested for photodegradability as described in Example 1.
The results are given below.
______________________________________ Increase in carbonyl, AdditiveAdditive absorbance effectiveness units ratio______________________________________Trichloroisocyanuricacid (1%) 1.032 4.9None (control) 0.212 1______________________________________
Example 5
A film was prepared from purified polystyrene plus 1% N-bromophthalimide as described in Example 1. The film and a control film without the additive were tested as described in Example 1. It was found that the film containing the additive was photodegraded 3.1 times more than the control film.
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Polyolefins capable of photodegradation are prepared by incorporating in the polyolefin an additive which contains chlorine, bromine, or iodine directly linked to the nitrogen atom of an amide or imide group.
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BACKGROUND OF THE INVENTION
The invention relates to an arrangement for the electrothermal treatment of the human or animal body, in particular for the electrocoagulation or electrotomy.
The use of high-frequency alternating currents in the frequency range of 300 kHz to 2 MHZ for tissue coagulation and tissue separation has long been known in the field of surgery, resulting in the treated tissue being coagulated or vaporized, which is referred to as electrocoagulation or electrotomy. A distinction must be made here between the monopolar and the bipolar HF thermotherapy.
For the monopolar thermotherapy, an electrode—also referred to as the neutral electrode—is configured as a large-surface patient lead and is installed near the place of incision on the patient. The shape of the actual working electrode—referred to as the active electrode—is adapted to the respective application. Thus, large-surface sphere, disk or needle electrodes are used for the tissue coagulation, whereas thin lancet or loop-type electrodes are used for tissue separation.
In the bipolar HF thermotherapy, on the other hand, both electrodes are arranged in close proximity to the place of incision, so that the effect of the alternating current is limited to the area immediately surrounding the place of incision, thereby resulting in a high degree of safety for the patient and the user since accidents caused by capacitive leakage currents or burning at the neutral electrode can no longer occur. Another advantage of the bipolar HF thermotherapy consists in the considerably lower load resistance of the tissue between the two electrodes, which permits a reduction in the necessary generator output while maintaining the thermal effect.
Based on the position of the electrodes, the HF thermotherapy can furthermore be divided into the surface coagulation on the one hand and the depth coagulation on the other hand.
The bipolar technique uses two parallel-arranged tactile electrodes for the surface coagulation, which are placed onto the tissue surface. As a result of this, the tissue underneath is heated, owing to the flow of current, and is thus coagulated.
The use of needle, lancet, or loop-type electrodes for the monopolar electrotomy is known in the field of depth coagulation. Electric arcs must be generated for this on the active electrode in order to vaporize the tissue, positioned in front of the active electrode, thereby realizing a tissue cut. This is relatively simple with the monopolar technique because only a specific field strength is required to trigger a spark discharge at the active electrode. The bipolar technique makes higher demands on the design of the electrode configuration since the physical processes in this case cannot be controlled as easily. That is why only a few bipolar electrode arrangements for the depth coagulation are known, e.g. the bipolar needle electrode, which is suitable, among other things, for the myoma therapy. This known bipolar electrode arrangement consists of two parallel-arranged needle electrodes that are stuck into the tissue, by means of which the tissue between the electrodes is heated as a result of the current flow and is thus coagulated.
However, the known bipolar electrode arrangements for the depth coagulation have the disadvantage that placement of the electrodes through two puncture sites is relatively involved. Furthermore, the predetermination of the field distribution by the user is relatively imprecise because the position of the two electrodes relative to each other generally cannot be specified exactly.
The DE 43 22 955 A1 furthermore discloses the use of laser radiation for the coagulation of body tissue, which laser radiation can be transmitted into the therapy region via a cylindrical optical waveguide, wherein the known optical waveguide additionally permits the transmission of ultrasound energy, so that the two therapy methods of ultrasound tissue separation and the laser coagulation can be combined.
A waveguide is also disclosed in the DE 44 32 666 A1, which makes it possible to transmit high-frequency energy in addition to ultrasound waves and laser radiation, so that the initially mentioned methods of high frequency surgery can be used at the same time as the laser surgery and the ultrasound surgery. For this, the known waveguide has a cylindrical design and additionally comprises two layers of an electrically conductive material for the high-frequency transmission, which layers are also cylindrical and are electrically insulated against each other. Thus, the known waveguide permits the transmission of high-frequency energy from a high-frequency generator, arranged extracorporeal, into the therapy region, but it does not permit the release of the high-frequency energy to the body tissue.
SUMMARY OF THE INVENTION
It is thus the object of the invention to create an arrangement for the electrothermal treatment of the human or animal body, which permits an interstitial tissue coagulation by means of a bipolar electrode arrangement and which avoids the aforementioned disadvantages of the known types of arrangements.
The invention includes the technical teaching that a bipolar electrode arrangement is used for the thermotherapy, the two electrodes of which are arranged one after another on an elongated catheter to make it possible to insert the two electrodes jointly into the body through a single puncture site, wherein the two electrodes are connected to the catheter or form a component of the catheter.
Herewith and in the following, the term catheter is understood to have a general meaning. It is not limited to the preferably used hollow-cylindrical arrangements, described in detail in the following, but can also be realized with large arrangements of nearly optional cross sections. Critical to the function according to the invention is only that the two electrodes are inserted jointly into the patient's body, through one puncture site.
The catheter according to the invention for the first time allows placing the electrodes into deep tissue layers and obtaining a partial tissue coagulation there.
The electrodes in the arrangement according to the invention are connected to a current source that supplies the electrical energy necessary for heating up the tissue. The term current source here is not limited to narrowly defined sources having a constant current, but includes also the preferably used alternating current generators, especially high-frequency generators.
One advantageous variant of the invention provides that the axial distance between the two electrodes can be adjusted, so that the field distribution can be varied. If the insulator length in axial direction between the two electrodes is shorter, for example, than twice the electrode diameter, spherical coagulation necroses can be obtained advantageously, whereas the shape of the coagulation necroses for longer insulator lengths is more oval.
The preferred embodiment of this variant therefore provides that the proximal electrode has a hollow design, at least at its distal end, such that it can accommodate the distal electrode on its inside. The external cross section of the distal electrode is smaller than the internal cross section of the proximal electrode to allow an axial displacement of the distal electrode inside the proximal electrode. It is important in this case for the two electrodes to be electrically insulated against each other in a suitable manner, since the two electrodes can overlap in axial direction. An electrical insulation is provided for this on the inside of the proximal electrode or on the outside of the distal electrode. For example, this insulation can consist of a dielectric coating or an insulating material sleeve, preferably composed of PTFE or polyimide—as in the initially listed reference DE 44 32 666 A1—wherein the cross section for the insulating-material sleeve is preferably adapted to the cross section of the distal or proximal electrode, such that the insulating-material sleeve can be press-fitted to the proximal or distal electrode and is thus fixed on the electrode. Thus, the two electrodes are coaxially arranged and can be displaced against each other in axial direction, so that the field distribution can be changed, wherein a section of the distal electrode in longitudinal direction is held inside the proximal electrode.
In this variant of the invention, as for the other variants of the invention, the two electrodes have a cylindrical cross section, wherein the internal diameter of the proximal electrode for this variant must be larger than the external diameter of the distal electrode, so that the distal electrode can be displaced in axial direction. However, the invention is not limited to cylindrical electrode designs, but can be realized with other electrode cross sections as well. Concerning the function of this variant of the invention, it is only critical that the internal cross section of the proximal electrode is adapted to the external cross section of the proximal electrode in such a way that the distal electrode can be displaced in axial direction inside the proximal electrode in order to change the axial distance between the two electrodes.
In another variant of the invention, the adjustment of the axial distance between the two electrodes is made possible with an elongated carrier element of electrically insulating material, which is arranged such that it can be displaced inside the proximal electrode and contains the distal electrode on the side in its distal region. The proximal electrode is therefore designed to be hollow, at least at its distal end, to be able to hold the carrier element. The internal cross section of the proximal electrode in this case is adapted to the external cross section of the carrier element, such that the carrier element can be displaced in axial direction in order to be able to adjust the axial distance between the distal end of the proximal electrode and the distal electrode, arranged on the carrier element. In this variant of the invention, the distal electrode is attached to the side of the electrically insulating carrier element and can consist, for example, of a ring-shaped, metallic coating or a metallic sleeve, which is pushed axially onto the carrier element during the assembly and is press-fitted to this carrier element.
In accordance with another variant of the invention, the spacing between the two electrodes is specified, to achieve a simple design for the catheter and to ensure a predetermined field distribution. For this, the catheter also has an elongated carrier element of electrically insulating material, with the electrodes fixedly attached to the side in axial direction and at a distance to each other. On the one hand, the carrier element here is used for a mechanical fastening of the electrodes, in order to achieve a predetermined field distribution as a result of the constant distance between the electrodes. On the other hand, the carrier element must insulate the two electrodes electrically against each other and is therefore composed of an electrically insulating material. In the preferred embodiment of this variant, the carrier element has a cylindrical cross section, wherein the two electrodes have a hollow-cylindrical design and are arranged so as to be circumferential with respect to the longitudinal axis of the carrier element. In this case, the electrodes can be deposited, for example, on the carrier element surface as a metallic coating, or they can respectively form a metallic sleeve that is fitted onto the carrier element and is press fitted to it.
In another embodiment of this variant, the electrodes are not fixed axially as a result of being arranged on a carrier element, but through respectively one connecting element between the electrodes, which connects the fronts of the electrodes. In addition to the axial fixation of the electrodes, the connecting element must also insulate the two electrodes against each other and thus consists of an electrically insulating material. The electrodes and the connecting pieces in this case are preferably cylindrical and have the same cross section, so that the outside contour of the catheter is continuous, without projecting edges, at the transitions between the electrodes and the connecting elements. This is very important for the insertion of the catheter into the body of the patient, to avoid unnecessary injuries.
A modified variant of the invention provides for more than two electrodes, which are arranged at a distance to each other in axial direction of the catheter. As described in the above, the electrodes can be attached to the side of an elongated carrier element or, as previously explained, can respectively be separated from each other with the aid of a connecting element of electrically insulating material.
The preferred embodiment of this variant provides that the individual electrode pairs, arranged such that they are distributed axially along the longitudinal axis of the catheter, can be actuated separately and have separate feed lines for this, which are preferably extended out of the body through a hollow conduit inside the catheter and can be connected to an adequate control device that permits an individual adjustment of, for example, current, voltage and/or frequency. As a result of the superimposition of the fields generated by the individual electrode pairs, it is possible in this way to specify the field distribution freely within far-ranging limits, e.g. to destroy as little healthy tissue as possible during an electrocoagulation. In one advantageous modification of this variant, the extracorporeal control device has several storage elements, in which the electrical parameters such a current, voltage and frequency for various field distributions are stored, so that the user must only select the desired field distribution, whereupon the control device then reads out the electrical parameters necessary for reaching this field distribution from the respective storage element and respectively actuates the individual electrode pairs.
Other advantageous modifications of the invention are shown in further detail in the following with the aid of the figures and together with the description of the preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates preferred embodiment of the invention, depicting an arrangement for electrothermal treatment with a catheter for inserting the electrodes into the body and a manipulator for guiding the catheter;
FIGS. 2 a and 2 b illustrate the catheter for the arrangement in FIG. 1, with a core electrode inserted and pulled out;
FIGS. 3 a and 3 b illustrate various catheters with fixed electrodes for obtaining a specified field distribution;
FIG. 4 illustrates a catheter with five electrodes, making it possible to have special field distribution forms;
FIG. 5 illustrates a flexible catheter for use in the minimally invasive surgery;
FIGS. 6 a , 6 b , and 6 c illustrate various catheters making it possible to feed rinsing liquid; and
FIG. 7 illustrates another catheter with adjustable electrode spacing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As a preferred embodiment of the invention, FIG. 1 shows an arrangement 1 for the electrothermal treatment of the human and animal body, consisting essentially of a catheter 2 with a core electrode 3 and a covering electrode 4 , as well as a manipulator or handle 5 for guiding the catheter 2 , wherein the catheter 2 is shown in further detail in the FIGS. 2 a and 2 b.
The catheter 2 permits an adjustment of the axial distance between the two electrodes 3 , 4 , so that the field distribution in the therapy region can be specified. For this, the catheter 2 has the cylinder-shaped, stainless steel core electrode 3 with a diameter of 800 μm. Except for its distal end, the surface area of said electrode is covered with a 50 μm thick coating of polyimide 6 as electrical insulation. This coated core electrode 3 is positioned such that it can be displaced coaxially in the hollow cylindrical covering electrode 4 , also made of stainless steel, and has an internal diameter of 900 μm. The external diameter of the covering electrode 4 is 1500 μm for a length of 10 cm. It thus a large length-to-diameter ratio, about 67.
With the aid of a displacement mechanism, integrated into the manipulator 5 , the internal core electrode 3 can be pulled back before the catheter 2 punctures the tissue, so that the core electrode 3 and the covering electrode 4 together form a symmetrically ground puncturing spike, as shown in FIG. 2 a.
After inserting the catheter 2 into the tissue, the core electrode 3 can be extended in axial direction and thus forms a dipole configuration with the insulating polyimide layer 6 and the covering electrode 4 , as shown in FIG. 2 b . The axial displacement of the core electrode 3 furthermore allows an adjustment of the axial distance between the two electrodes 3 , 4 and thus a concerted influencing of the field distribution in the therapy region. The displacement mechanism for the core electrode 3 is operated via a push-button rocker 7 , which is integrated into the manipulator 5 that is shaped like a pistol grip for ergonomic reasons. The manipulator 5 furthermore contains a switch 8 for connecting the electrode arrangement to an HF generator, which is connected to the manipulator 5 via an electrical feed line 9 . The manipulator 5 also contains a release mechanism 10 , with which the core electrode 3 can be released and subsequently pulled axially from the covering electrode 4 . Following the release of a locking mechanism 11 , the covering electrode 4 can also be pulled out axially. By separating the electrodes 3 , 4 from the manipulator 5 , it is easily possible to sterilize and subsequently reuse the electrodes 3 , 4 .
The catheter 2 , comprising the core electrode and the covering electrode 3 , 4 , is connected to the manipulator 5 via a rotatable bearing 12 for holding and, owing to its angled form, permits an operation that is adapted to the field of vision of the physician, e.g. as is necessary for the turbinal coagulation.
The illustrated arrangement 1 furthermore allows introducing a rinsing liquid into the tissue in the therapy region, in order to improve the electrical coupling. In this way, it is possible to balance the loss of liquid that occurs during coagulation, which otherwise leads to a change in the electrical impedance of the tissue in the therapy region and worsens the electrical coupling. The manipulator 5 therefore determines the tissue impedance from the applied voltage and the current via the electrodes 3 , 4 and releases a corresponding amount of rinsing liquid to the tissue in order to keep the tissue impedance constant. The rinsing liquid is supplied by a separate rinsing pump via a hose 13 to the manipulator 5 and is pumped through the hollow covering electrode 4 into the therapy region. There, the rinsing liquid exits through a gap between core electrode 3 and covering electrode 4 into the tissue.
The FIGS. 3 a and 3 b respectively show a catheter 14 or 15 , having a proximal electrode 17 or 19 and a distal electrode 16 or 18 , wherein the spacing between the two electrodes 16 , 17 or 18 , 19 is constant in order to reach a specified field distribution and to permit a simple design for the catheter 14 , 15 . The two electrodes 16 , 17 or 18 , 19 in this case have a cylindrical design and are mechanically connected on their fronts with the aid of an also cylindrical connecting element 20 or 21 of electrically insulating material, wherein the connecting element 20 or 21 , as well as the proximal electrode 17 or 19 is provided with an axially extending hollow conduit to hold the electrode feed line. The external cross sections of the two electrodes 16 , 17 and the cross section of the connecting element 20 are identical in catheter 14 , shown in FIG. 3 a , so that the outside contour of the catheter 14 is smooth even at the transition points between the electrodes 16 , 17 and the connecting element 20 , thereby making it easier to insert the catheter 14 into the body of the patient. In contrast, the proximal electrode 19 for the catheter 15 , shown in FIG. 3 b , has a larger cross section than the distal electrode 18 and the connecting element 21 , wherein the proximal electrode 19 is conically tapered to match the cross section of the connecting element 21 at the transition point to the connecting element 21 .
The FIG. 4 also shows a catheter 22 that essentially distinguishes itself from the above-described catheters in that it has a larger number of electrodes 23 . 1 to 23 . 5 , which are arranged along the longitudinal axis of the catheter 22 and are essentially composed of ring-shaped, metallic coatings, deposited on the surface area of a cylinder-shaped carrier element 24 of electrically insulating material. The electrodes 23 . 1 to 23 . 5 are respectively contacted separately via feed lines, which are placed in an axially extending hollow conduit of the carrier element. For one thing, the larger number of electrodes 23 . 1 to 23 . 5 makes it possible to reduce the partial current density at the electrodes 23 . 1 to 23 . 5 , thereby preventing the temperature from increasing too much. For another thing, it is possible to generate a field distribution that differs from the one for only two electrodes by superimposing the individual fields. In addition, it is possible to purposely influence the field distribution by switching individual electron pairs on or off.
In another embodiment of the invention, FIG. 5 illustrates a catheter 25 , which is flexible and thus insertable insertion even into body cavities with bent inlet conduits, which is particularly important for the minimally invasive medicine (MIM). The catheter 25 essentially consists of a cylindrical core electrode 26 of spring steel wire, which is surrounded by covering electrode 27 in the shape of a hollow cylinder and formed from a flexible metal braid. The surface area of the core electrode 26 is provided with an electrically insulating coating 28 , except for its distal end, which coating is designed to insulate the two electrodes 26 , 27 against each other.
The FIGS. 6 a , 6 b and 6 c show additional advantageous embodiments of catheters 29 , 30 , 31 with respectively one hollow-cylindrical, proximal covered electrode 32 , 33 , 34 and one cylinder-shaped, distal core electrode 36 , 37 , 38 . With the illustrated catheters 29 , 30 , 31 it is advantageously possible to deliver rinsing liquid to the tissue, in order to balance the loss of liquid in the tissue during the coagulation and a therewith connected worsening of the electrical coupling. The rinsing liquid in this case is delivered through an axially extending hollow conduit in the proximal covered electrode 32 , 33 , 34 and delivery is ensured by a rinsing liquid pump, arranged extracorporeal. However, the release of the rinsing liquid in the therapy region occurs in different ways for the illustrated catheters 29 , 30 , 31 . The catheter 29 , shown in FIG. 6 a , is therefore provided with several distally arranged openings 35 in the surface area of the covering electrode 32 , through which the rinsing liquid can exit from the hollow conduit into the tissue. In contrast, with the catheter 30 , shown in FIG. 6 b , the rinsing liquid exits through a gap between covering electrode 33 and core electrode 36 into the tissue. The catheter 31 , shown in FIG. 6 c , on the other hand has a continuous hollow conduit in axial direction, which also extends through the core electrode 37 and ends at the distal front of core electrode 37 , so that the rinsing liquid is discharged into the tissue at the distal front of distal electrode 37 .
A physiological salt solution is preferably used as rinsing liquid, which ensures a good electrical coupling with the tissue and reduces the danger of tissue carbonization by limiting the temperature to <100° C. In this case, the two electrodes 32 , 38 or 36 , 33 or 34 , 37 are also insulated against each other through a coating 39 , 40 , 41 of electrically insulating material that is deposited on the core electrode 36 , 37 , 38 .
Instead of the feed line for the rinsing liquid, the hollow conduit for the catheter 31 , shown in FIG. 6 c , can also hold an optical waveguide for a modified optical biopsy, which permits a precise positioning of the catheter 31 in the therapy region through a measuring of the backscatter signal or the tissue fluorescence during X-rays. In addition, a laser transmission through an integrated optical waveguide also offers the option of measuring the blood flow through Doppler measurement, depending on the wavelength used. Furthermore, the laser radiation transmitted via such an optical waveguide into the therapy region can then be used for the thermo-optical tissue coagulation. Finally, the hollow conduit also permits the positioning of a temperature sensor for the coagulation control.
FIG. 7 finally shows another catheter 42 , which permits the adjustment of the electrode spacing so that it is possible to influence the field distribution in the therapy region. For this, the illustrated catheter 42 has a cylindrical carrier element 43 of electrically insulating material, comprising at its distal end a distal electrode 44 that is deposited on the side as a ring-shaped metallic coating.
This carrier element 43 is guided by a proximal electrode 45 with a hollow-cylinder design, wherein the external diameter of the carrier element 43 is smaller than the internal diameter of the proximal electrode 45 , so that the carrier element 43 with the distal electrode 44 can be displaced in axial direction to adjust the electrode spacing. At its distal end, the carrier element 43 is ground such that it forms a puncturing spike for inserting the catheter 42 into the body of the patient.
The design of the invention is not limited to the aforementioned, preferred embodiments. Rather, a number of variants are conceivable, which make use of the depicted solution, even if the embodiments are totally different.
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An arrangement ( 1 ) for electrothermally treating the human body or an animal body, in particular for tissue coagulation or electrotomy, includes two electrodes ( 3, 4 ) for insertion into the body to be treated. The two electrodes ( 3, 4 ) are electrically insulated from each other and are disposed at a distance from each other to produce an electric or electromagnetic field heating the body tissue in the treatment area, and each electrode is connected by a feed line with a power source arranged outside the body. An elongate catheter ( 2 ) is provided for joint insertion of the two electrodes ( 3, 4 ) into the body, which are staggered in relation to each other in the axial direction of the catheter ( 2 ) and connected to the catheter ( 2 ) or a component thereof.
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BACKGROUND OF THE INVENTION
[0001] This is a continuation-in-part of application Ser. No. 09/457,454 which is a continuation of Ser. No. 09/222,049. application Ser. No. 09/457,454 is pending.
FIELD OF THE INVENTION
[0002] This invention relates to devices used to clip or cut hair, fur and the like of humans and animals. The new device provides for a disposable cutting head including blades to simplify in an economical manner the maintenance of a relatively sharp cutting instrument.
2. Description of Related Art
[0003] There are currently in use a variety of devices for clipping, cutting and shearing hair and fur. These include devices commonly known as hair clippers or just clippers which in most instances modernly are powered by electric motors. Clippers as originally conceived and developed include cutting blades which are intended to be removed from the head of a clipper and sharpened to maintain the clipper device cutting performance. Such blades may be attached to the clipper head by screws and the like or may have clips, clamps or other retention means for attachment to the clipper.
[0004] More modernly clippers have incorporated heads which are designed to include replaceable blades which blades are not intended to be continually sharpened, but rather to be removed and disposed. U.S. Pat. No. 2,722,742, issued Nov. 8, 1955 is an example of such a device. Also, clipper head assemblies which are disposable have been designed for use with clippers. An example of a plastic disposable head assembly for clippers is disclosed in U.S. Pat. No. 4,563,814, issued Jan. 14, 1986.
[0005] The present invention provides an improved structure for a clipper head assembly with disposable blades. The entire assembly is such that the head assembly with blades is of the disposable type, but uses metal blades. If desired, the blades alone may be disposed and the head assembly reused; however, the structure is not intended for long wear and use. The head and blades are constructed such that the common problems encountered with existing removable/disposable heads and blades as for example heat retention in the blades and head and the catching and pulling of hair are minimized.
[0006] The support front edge of the base member of the present invention has no structure, such as comb teeth, which are under any portion of the cutting blades which comb teeth can catch and pull hair as, for example, in the U.S. Pat. No. 4,328,616, issued May 11, 1982 which has comb teeth under the cutting blade teeth such that when the two tooth elements are not in contact hair will be caught and pulled. In addition both cutting blades of the instant invention have a slightly concave shape, one relative to the other, along the entire blade longitudinal dimension to counter the tendency for blades to curl and separate which could cause the catching and pulling of hair as well as other problems. U.S. Pat. No. 4,765,060, issued Aug. 23, 1988 discloses a bend in the blade ends which may cause problems of separation as a result of a lack of a continuous concave shape along the longitudinal axis.
[0007] The cutting blades of the instant invention have indentations in the teeth to minimize heat build up and provide structural strength for the teeth. This is accomplished without the need for cut outs in the tooth edge wall which is done for example in sheep cutting clipper blades to provide flexibility. Such cut outs can cause loss of lubricants and also serve as a point that may catch and pull hair. In general, the new structure thus provides better cutting efficiency and minimum heat transfer to the subject being trimmed. The a disposable system achieves improved performance in cutting efficiency and is constructed to be used with existing comb snap on devices.
SUMMARY OF THE INVENTION
[0008] One object of the present invention is an improved cutting head structure for clippers which lowers friction and improves heat dissipation of the combination cutting head and blades to allow for a disposable clipper cutting head assembly. Another object is to reduce warpage of the head and/or blades during use in cutting to minimize hair pulling caused by hair becoming caught between the cutting blades rather than being cleanly cut. A further object is a disposable head and blade design which may be used with existing clip on combs. Another object is adaption of the cutting head for use with spring lock comb elements. A still further object is an upper cutting blade shoe structure for reduced friction wear of a clipper drive lug, which is usually plastic material, to which the upper blade shoe is engaged during clipper reciprocal drive operation. Another object is shielding of the clipper cavity which receives the cutting head to reduce the amount of hair or fur entering therein during a cutting operation. Yet another object is incorporation of protrusions in the base member to accommodate a variety of size of clipper blade socket mounting apparatus.
[0009] In accordance with the description presented herein, other objectives of this invention will become apparent when the description and drawings are reviewed.
BRIEF DESCRIPTION OF THE DRAWING
[0010] [0010]FIG. 1 illustrates a perspective view of the head assembly with blades and outline of clipper.
[0011] [0011]FIG. 2 illustrates a perspective view, exploded, of the head assembly and blades.
[0012] [0012]FIG. 3 illustrates a perspective view, exploded, of an alternate embodiment of the head assembly and blades.
[0013] [0013]FIG. 3A illustrates a perspective view of an alternate embodiment of the head assembly with a deflector plate.
[0014] [0014]FIG. 4 illustrates a bottom plan view of the upper cutting blade.
[0015] [0015]FIG. 4A illustrates a bottom plan view of an alternate embodiment of the upper cutting blade.
[0016] [0016]FIG. 5 illustrates an elevation edge view of the upper cutting blade.
[0017] [0017]FIG. 5A illustrates an elevation edge view of an alternate embodiment of the upper cutting blade.
[0018] [0018]FIG. 6 illustrates a top plan view of the upper cutting blade.
[0019] [0019]FIG. 6A illustrates a top plan view of the upper cutting blade with shoe lugs.
[0020] [0020]FIG. 7 illustrates a side elevation cross-section view of the upper cutting blade taken at line 6 - 6 .
[0021] [0021]FIG. 8 illustrates a bottom plan view of the lower cutting blade.
[0022] [0022]FIG. 9 illustrates an elevation edge view of the lower cutting blade.
[0023] [0023]FIG. 10 illustrates a top plan view of the lower cutting blade.
[0024] [0024]FIG. 11 illustrates a side elevation cross-section view of the lower cutting blade taken at line 10 - 10 .
[0025] [0025]FIG. 12 illustrates a side elevation cross-section view of the head assembly with blades.
[0026] [0026]FIG. 12A illustrates a side elevation cross section view of the head assembly with blades and a spring member with a deflector plate.
[0027] [0027]FIG. 13 illustrates a perspective view of the head assembly with blades and outline of an attached large tooth comb.
[0028] [0028]FIG. 14 illustrates a perspective view of the head assembly with blades attachable to a modified tooth comb mounting apparatus.
[0029] [0029]FIG. 15 illustrates a perspective view of the head assembly with blades attachable to an alternate tooth comb mounting apparatus.
[0030] [0030]FIG. 16 illustrates a perspective view, exploded, of an alternate embodiment of the cutting head assembly for attachment of a comb element.
[0031] [0031]FIG. 17 illustrates a side elevation cross-section view of an alternate embodiment of the head assembly with blades and spring mounting apparatus.
[0032] [0032]FIG. 18 illustrates a bottom plan view of the alternate cutting head with spring mounting apparatus.
[0033] [0033]FIG. 19 illustrates a perspective view of the tool for use with the spring mounting apparatus.
[0034] [0034]FIG. 19A illustrates a perspective view of an alternate form of the tool.
[0035] [0035]FIG. 20 illustrates a side elevation cross-section view of an alternate embodiment of the head assembly with base cutting blade.
[0036] [0036]FIG. 21 illustrates a top plan view of the base cutting blade.
[0037] [0037]FIG. 22 illustrates a top plan view of an alternate embodiment of the base cutting edge.
[0038] [0038]FIG. 23 illustrates a side elevation cross-section view of an alternate embodiment of the head assembly with base cutting blade.
[0039] [0039]FIG. 24 illustrates a perspective view of the comb element and base member with tabs and notches.
[0040] [0040]FIG. 24A illustrates a side elevation cross-section view of a comb element tooth.
[0041] [0041]FIG. 25 illustrates a perspective view of the comb element with taper feature.
[0042] [0042]FIG. 26 illustrates a side elevation cross-section partial view of the comb element taper feature.
[0043] [0043]FIG. 27 illustrates a perspective view of a comb tooth.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0044] The disposable cutting head is basically a four element clip together assembly with a base, lower and upper cutting blades, and spring. The base serves as the support for the entire assembly and incorporates the attachment elements for razz retention to a clipper. The spring holds the elements together, forces the cutting blades together and includes the runner under which the upper blade slides. Attachment of a comb element may also be included. Alternate embodiments are described which use screw retention means for the spring and which use a spring lock for retention of comb elements. A plastic comb element for use with the spring lock retention means is incorporated. A deflector plate may be added to the spring structure to inhibit hair entering the clipper cavity.
[0045] Referring to FIGS. 1 through 15, disposable cutting head ( 1 ) has base member ( 2 ) having a rear mounting portion ( 3 ) and lower blade support portion ( 4 ). The rear mounting portion ( 3 ) has an upstanding central bridge ( 5 ) with clipper ( 6 ) attachment lugs ( 7 ). The lower blade support portion ( 4 ) has posts ( 8 ) to retain lower cutting blade ( 9 ). The lower blade support portion ( 4 ) support front edge ( 37 ) does not extend such that it protrudes under the lower cutting blade ( 9 ) lower teeth ( 13 ). This alleviates the problem with existing cutting heads wherein the blade support element tends to catch and pull hair on the support base during cutting.
[0046] The lower cutting blade ( 9 ) is placed in lower blade support portion ( 4 ) with apertures ( 14 ) receiving posts ( 8 ). The posts ( 8 ) inhibit horizontal motion of the lower cutting blade ( 9 ) relative to the lower blade support portion ( 4 ) yet allow vertical motion of the lower cutting blade ( 9 ). This provides for a vertical “floating” condition to maintain contact with the upper cutting blade ( 15 ) under conditions as for example when heating causes a blade to curl or warp. The posts ( 8 ) and apertures ( 14 ) also allow ease of blade replacement if such is desired and do not flatten the concave curvature of the blade as when fixed in place by permanent attachment in other cutting heads.
[0047] Lower cutting blade ( 9 ) has a generally planar rectangular shape with a recessed portion ( 10 ) the longitudinal length of the blade. There are ribs ( 11 ) formed in the recessed portion ( 10 ) to provide structural strength and to aid in minimizing heat build up. The lower cutting blade ( 9 ) also has indentations ( 12 ) or creases formed in the lower teeth ( 13 ) to reduce the sliding friction surface to minimize heat build up, to allow coolant flow and to provide structural strength.
[0048] The lower cutting blade ( 9 ) is placed in lower blade support portion ( 4 ) with apertures ( 14 ) receiving posts ( 8 ). Upper cutting blade ( 15 ) is placed in sliding relationship on lower cutting blade ( 9 ) with lower teeth ( 13 ) parallel to upper teeth ( 16 ). In operation the upper cutting blade ( 15 ) slides longitudinally relative to the fixed lower cutting blade ( 9 ).
[0049] Upper cutting blade ( 15 ) is a generally planar rectangular shape with a recessed portion ( 17 ) formed along the longitudinal length of the blade which as illustrated in FIG. 2 may be formed in a stamping operation to be of upwardly arched geometry in the lateral dimension. There are a plurality of upper teeth ( 16 ) forming the forward portion which may have indentations ( 12 ) similar to lower teeth ( 13 ). There is a groove ( 18 ) parallel with and spaced from the front toothed edge.
[0050] The rear edge ( 19 ) of the upper cutting blade ( 15 ) contains an enlarged recess ( 20 ) adapted to receive a drive lug ( 21 ) or other drive element of a clipper ( 6 ). There are a pair of shoes ( 22 ) formed in enlarged recess ( 20 ) to reduce friction wear caused by the reciprocal operation of clipper drive lug ( 21 ) operating to move upper cutting blade ( 15 ) in a sliding reciprocating motion across lower cutting blade ( 9 ). The shoes ( 22 ) preferably have rounded edges ( 38 ) to reduce wear of the drive lug ( 21 ). However, a suitable curved shoe lug ( 40 ) as illustrated in FIG. 5A may also be used.
[0051] The spring member ( 23 ) is generally a U-shape element of spring steel or the like having opposed arms ( 24 ) shaped to fit the back edge ( 25 ) of the mounting portion ( 3 ) of base member ( 2 ). The opposed arms ( 24 ) may be retained on the base member ( 2 ) by arm apertures ( 26 ) engaging attachment posts ( 27 ). The opposing arms ( 24 ) curve upwardly from the base member ( 2 ) and project forward in an arched manner over the upper cutting blade ( 15 ) to terminate in a downwardly manner presenting a transverse, elongated runner ( 28 ) to engage the upper cutting blade ( 15 ) groove ( 18 ). The runner ( 28 ) would preferably have a plastic coating, sleeve or the like surface for ease in sliding motion with the groove ( 18 ).
[0052] The spring member ( 23 ) may also be retained on the base member ( 2 ) by a thread attachment method. An example is illustrated in FIG. 3 wherein posts ( 27 ) are replaced with apertures ( 47 ) and the arm apertures ( 26 ) are threaded apertures ( 46 ) to receive screws ( 48 ). In addition, apertures ( 45 ) are included to allow the screws to pass through the opposed arms ( 24 ) upper portion. The threading of the screws ( 48 ) into the spring member ( 23 ) provides a means to adjust the tightness by which the spring member ( 23 ) is removably attached. Thereby the tension may be loosened when cutting fine or loose hair to reduce blade wear due to friction and heat; yet the tension may be increased when thick or matted hair to be cut.
[0053] The spring member ( 23 ) may also have an extended plate element or deflector plate ( 55 ) as best illustrated in FIGS. 3A and 12A to inhibit entry of hair or fur into the clipper cavity ( 41 ) during cutting operation.
[0054] In the preferred embodiment the lower cutting blade ( 9 ) and the upper cutting blade ( 15 ) are formed with a slightly concave shape along their longitudinal dimension one to the other in a plane parallel to the rows of cutting teeth ( 13 , 16 ) as in FIG. 4 and 8 . This serves to counter the tendency of cutting blades to curl and partially separate from each other from the ends ( 29 , 30 ) inward when there is heat build up due to sliding friction during use. This warping can occur both in manufacture and during use. The upper cutting blade ( 15 ) may be further modified by forming a generally rectangular opening to serve as a heat aperture ( 70 ) to further facilitate heat dissipation.
[0055] The blades ( 9 , 15 ) may be press, cut and/or punched in manufacture. When manufactured there is a ragged edge on the side of the blade exiting the cutting tool. For the preferred embodiment the ragged mating edges are at the top edge, that is, the edge between blades. Thus the blades need only be machined smooth on the mating edges and the jagged edges remain to aid in, cutting hair, but do not touch the subjects skin to cause injury. To aid in attaching the upper cutting blade ( 15 ) to the fixturing for manufacture, fixturing holes ( 44 ) may be provided.
[0056] Referring to FIG. 13, a disposable cutting head ( 1 ) has attached a large tooth comb ( 31 ). The compact shape and the back-to-front width or lateral dimension of the assembly approximate more standard clipper heads and blades to allow attachment of standard comb attachments. Where a relatively flat comb attachment is desired, a metal or other strong structural material may be used as compared to the typical plastic comb ( 31 ). FIG. 14 illustrates an example of a thin comb element ( 32 ) with comb teeth ( 33 ) having groove notch ( 34 ) to receive the front edge ( 36 ) of the disposable cutting head ( 1 ) and spring clip ( 35 ) back edge to engage and retain the thin comb element ( 32 ). Either the plastic comb ( 31 ) or thin comb element ( 32 ) may include one or more mounting tabs ( 76 ) under which the base member ( 2 ) support front edge ( 37 ) may be placed when attaching a comb ( 31 , 32 ). Mounting notches ( 75 ) may be formed in the support front edge ( 37 ) to mate with the mounting tabs ( 76 ). The comb teeth ( 33 ) may include a tooth ridge element ( 78 ) attached to the tooth front edge ( 77 ). This reduces flatness of the comb teeth ( 33 ) at the front edge which is experienced in the manufacturing molding process. The tooth ridge element ( 77 ) aids in guiding the hair to be cut between the comb teeth ( 33 ).
[0057] The tooth comb ( 31 ), comb element ( 32 ) and comb teeth ( 33 ) may be coated with a low friction substance, as for example, that sold under the tradename TEFLON, vacuum deposited aluminum with a lacquer coating and the like coatings and sealers. The comb ( 31 ), comb element ( 32 ) and comb teeth ( 33 ) may be formed of metallic and silica additives in plastic for added strength of material as compared to plastic combs.
[0058] A variation of this spring force attachment is illustrated in FIGS. 15 through 18. In this case a back plate ( 51 ) replaces the spring clip ( 35 ) and side elements ( 65 ) are added. This provides a structure for the comb element ( 32 ) when a thin comb made of plastic or similar material is desired. A rivet indentation ( 66 ) may be provided if clearance is required when the comb element ( 32 ) is mounted. The back plate ( 51 ) has a slot ( 52 ) therein into which plate ( 53 ) protrudes by extension ( 56 ). The plate ( 53 ) has spring tabs ( 43 ) which engage springs ( 50 ) placed in spring cavities ( 49 ). The back plate ( 51 ) may be tapered in the portion ( 68 ) above the slot ( 52 ) for ease of inserting the extension ( 56 ) into the slot ( 52 ). The plate ( 53 ) is attached to the base member ( 2 ) by means of a rivet ( 61 ), screw or the like passing through aperture ( 60 ) and sliding aperture ( 62 ). Pressure on push tabs ( 42 ) compresses the spring ( 50 ) as the plate ( 53 ) is pushed against the force of the spring ( 50 ). This moves extension ( 56 ) to allow comb element ( 32 ) to be removed from or mounted on the cutting head ( 1 ). When thus mounted the groove notch ( 34 ) will engage the front edge ( 36 ) of the cutting teeth and when the plate ( 53 ) is released the extension ( 56 ) will engage the slot ( 52 ). A tool ( 63 ) with posts ( 64 ) may be provided as illustrated in FIGS. 16 and 19 to aid in pushing push tabs ( 42 ). The tool ( 63 ) with posts ( 64 ) may also have a blade or hex head for use in adjusting the tension for screws ( 48 ).
[0059] An alternate configuration of the tool ( 63 ) is illustrated in FIG. 19A wherein posts ( 64 ) are round tipped and the blade or hex head ( 67 ) is located opposite the posts ( 64 ).
[0060] The base ( 2 ) may have a more exaggerated rounding of the corners ( 54 ) to aid the user in turning the clipper while cutting in confined areas such as animal limb joints and the like.
[0061] The base member ( 2 ) may also include protrusions ( 58 ) on the inside of attachment lugs ( 7 ) and in mounting cavity ( 57 ) which protrusions ( 58 ) are compressible. When the cutting head ( 1 ) is mounted to a clipper ( 6 ) a tongue is inserted in mounting cavity ( 57 ). The clipper tongues of various clippers ( 6 ) are not always of the same dimensions. The protrusions ( 58 ) accommodate a variety of sizes of tongues to reduce vibration from what otherwise would be a loose fit. The protrusions ( 58 ) on attachment lugs ( 7 ) serve a similar purpose when the cutting head ( 1 ) is attached to the clipper ( 6 ).
[0062] The base member ( 2 ) and lower cutting blade ( 9 ) may be replaced with a one piece base cutting blade ( 80 ). In this embodiment the upstanding central bridge ( 5 ) and other elements are attached and supported by the base cutting blade ( 80 ). The spring clip ( 23 ) is attached on the base cutting blade ( 80 ) and the plate ( 53 ) with springs and other elements is replaced by a leaf spring ( 81 ) having a spring extension ( 82 ) for engaging slot ( 52 ).
[0063] While the invention has been particularly shown and described with respect to the illustrated and preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention.
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The disposable cutting head is basically a four element clip together assembly with a base, lower and upper cutting blades, and spring. The base serves as the support for the entire assembly and incorporates the attachment elements for retention to a clipper. The spring holds the elements together, forces the cutting blades together and includes the runner under which the upper blade slides. The entire assembly is such that the head assembly with blades is of the disposable type, but uses metal blades. If desired the blades alone may be disposed and the head assembly reused; however, the structure is not intended for long wear and use. The head and blades are constructed such that the common problems encountered with existing removable/disposable heads and blades as for example heat retention in the blades and head and the catching and pulling of hair are minimized. Use with clipper comb elements is also accommodated.
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FIELD OF THE INVENTION
The present invention relates to a method and apparatus for tensioning fabric and particularly, but not exclusively, to a method and apparatus for tensioning a fabric supported by a frame in a marquee.
DESCRIPTION OF RELATED ART
It is well understood in the art that the fabric of a marquee should be preferably tensioned in order to improve structural and aesthetic quality. Tensioning of roof and gable fabric has generally been achieved with straps which extend from the fabric to the ground or the base of the marquee frame structure. By manually pulling the ends of such straps adjacent the ground or frame base, the straps and associated roof/gable fabric are tensioned. However; a tensioning strap extending down the side wall of a marquee can be problematic when two marquees are to be located in close proximity to one another with a guttering extending between adjacent walls. Specifically, it has in the past been necessary to pass the tensioning straps through custom made, slits in guttering which has the consequential affect of allowing water to escape from the guttering in an undesirable fashion.
This problem has been overcome to a certain extent by the provision of a tensioning system comprising a circular disc rotatably mounted to a marquee frame adjacent the roof line. The disc is rotatably mounted off-center and in a vertical plane so that, when the disc is rotated, roof/gable fabric engaging the lowermost peripheral edge of the disc may be pressed downwards in a camming action. This system however is not entirely satisfactory since the disc can be awkward to rotate, the amount of tension applied cannot be adjusted, and the disc itself is in an inherently unstable condition when rotated to the tensioning position. As a consequence of the latter characteristic, there is an inherent tendency for the disc to undesirably move to a non-tensioning position. The provision of the disc on the side of a marquee can also be unsightly.
SUMMARY OF THE INVENTION
A first aspect of the present invention provides a fabric tensioner for use in tensioning a fabric supported by a frame of a marquee, the tensioner comprising means for mounting the tensioner to a frame of a marquee; and means for connecting said mounting means to a fabric to be tensioned, wherein said connecting means comprises a resiliently bendable elongate member being resiliently connected to said mounting means and comprises means for engaging said fabric so as to permit a transfer of force between said fabric and said mounting means.
Accordingly, the present invention provides fabric tensioning apparatus which may be attached to the frame of a marquee through use of the aforementioned mounting means. Once the tensioner has been mounted to a marquee frame, the connecting means may be resiliently bent so that the fabric engaging means may be appropriately attached to fabric to be tensioned. The resiliently bendable elongate member may be of a one-piece elastic material such as rubber. The resiliently bendable elongate member may comprise two or more rigid members hingedly connected together to allow resilient bending. Attachment of the fabric engaging means is also assisted by means of the resilient connection between the connecting means and the mounting means. Again, this resilient connection may be of a one-piece rubber construction so that the entire fabric tensioner may in practice be manufactured as a one-piece resilient component. Once the fabric engaging means has been attached to the fabric, the connecting means may be moved from its bent position so that the fabric is pushed or pulled into tension. The fabric tensioner may be configured so that, when tensioned, the fabric tends to pull the connecting means against the frame of the marquee preventing movement of the connecting means to its bent position and a subsequent relaxation of the fabric.
It is preferable for said connecting means to be resiliently connected to said mounting means by means of a pivot connection. Said connecting means may be telescopically extendible. Said fabric engaging means may also comprise a rod for locating within an aperture in said fabric. Said rod is preferably provided with means for resisting a tendency for said rod to move from said fabric aperture during use. Said resisting means may comprise a member extending laterally from said rod. It is further preferable for said laterally extending member to be a flange. It is also preferable for said resisting means to be of resilient material such as rubber or a plastics material.
It is particularly desirable for said resiliently bendable elongate member to comprise first and second members pivotally connected to one another. It is also preferable for said mounting means to be connected to said first member and for said fabric engaging means to be provided on said second member, the pivot connection between said first and second members being located between end portions of the first member. Said pivot connection between said first and second members may be located nearer to the resilient connection of said first member to said mounting means than to the end of said first member distal to said resilient connection.
Furthermore, it is preferable for said second member to comprise two members telescopically mounted to one another by means of cooperating screw threads. One of said telescopically mounted members is preferably connected to said first member and the other one of said telescopically mounted members is preferably provided with said fabric engaging means. Said mounting means may also be adapted to secure the fabric tensioner to a frame of a marquee by means of a pin, associated with said mounting means, which in use locates in a hole in said frame.
A second aspect of the present invention provides a method of using the aforementioned fabric tensioner, wherein the method comprises the steps of mounting the fabric tensioner to a frame of a marquee by means of the mounting means; moving the connecting means to a resiliently bent position; engaging the fabric engaging means with fabric to be tensioned; and moving the connecting means from the resiliently bent position so as to tension said fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described with reference to the accompanying drawings, in which:
FIG. 1 is a side view of a first embodiment of the present invention;
FIG. 2 is a perspective view of a mounting member of the first embodiment secured to a post shown with broken lines;
FIG. 3 is a plan view of the first embodiment secured to a post shown with broken lines;
FIG. 4 is a side view of the first embodiment in a non-tensioning configuration whilst secured to a post;
FIG. 5 is a side view of the first embodiment in a tensioning configuration whilst secured to a post; and
FIG. 6 is a perspective view of a second embodiment of the present invention in a tensioning configuration.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A first embodiment 2 of the present invention is schematically shown in FIGS. 1-5 of the accompanying drawings. The first embodiment 2 comprises three components 4 , 6 , 8 which are connected to one another by means of two pivots 10 , 12 .
The first of the three components is a mounting member 4 for mounting the first embodiment 2 to a post of a marquee. The configuration of the mounting member 4 is most clearly shown in the schematic perspective view of FIG. 2 . The mounting member 4 may be conveniently manufactured from sheet material by stamping a required profile from said sheet and bending the profile into an open box section for conforming with a marquee post as shown in FIG. 3 . The mounting member 4 may be stamped from 1.5 mm to 2.0 mm sheet steel. Appropriate materials and manufacturing techniques will be readily understood and apparent to a reader skilled in the art.
As will be seen from the accompanying drawings, the mounting member 4 takes the form of an open box section. An open end 14 thereof (see FIGS. 2 and 3 ) allows the mounting member 4 to the resiliently sprung-fitted about a marquee post. The open end 14 is defined by two parallel lobes 16 , 18 which are each provided with a circular aperture 20 for receiving a first pivot pin 22 . It will also be seen from the accompanying drawings that the side 24 of the mounting member 4 opposite the open end 14 is provided at its lower edge with a lobe 26 having a circular aperture 28 defined therein. In use, the circular aperture 28 receives a pin for fixing the position of the mounting member 4 relative to a marquee post.
The second component is a lever member 6 which may be fabricated from sheet metal so as to define an elongate member having a C-section. A first end 30 of the lever member 6 is provided with circular apertures (not shown) for aligning with the circular apertures 20 adjacent the open end 14 of the mounting member 4 and subsequent reception of the first pivot pin 22 . In the assembled embodiment 2, the first end 30 of the lever member 6 is received within the open end 14 of the mounting member 4 and pivotally secured thereto by means of the first pivot pin 22 . The first pivot pin 22 extends through the aforementioned aligned apertures and is itself secured in place by means of a nut (not shown) threadedly engaged with an end thereof. The nut, in combination with a flange provided on a distal end of the pin 22 , prevents the pivot pin 22 from falling from said aligned apertures.
Side walls of the C-section lever member 6 are provided with further circular apertures 32 which, in the assembled embodiment 2, receive a second pivot pin 34 . A second end 36 of the lever member 6 is appropriately shaped so as to allow a user to safely apply a tensioning force to said end 36 by hand.
The third component of the embodiment 2 is a telescopically extendible fabric connecting member 8 . The connecting member 8 comprises a metal bar 38 having external screw threads for threaded engagement with internal screw threads of a metal cylindrical member 40 . The bar 38 and cylindrical member 40 thereby cooperate to define the telescopically extendible connecting member 8 . The connecting member 8 is pivotally attached to the lever member 6 by means of circular apertures (not shown) provided in the cylindrical member 40 for aligning with the circular apertures 32 of the lever member 6 and subsequent reception of the second pivot pin 34 . The lever and connecting members 6 , 8 are dimensioned so that the connecting member 8 may pivot relative to the lever member 6 and lie in the C-section of the lever member 6 as shown in FIG. 5 . The second pivot pin 34 may be secured in position by means of a threaded nut as described in respect of the first pivot pin 22 . Alternative means of providing an appropriate pivot connection between the three components 4 , 6 , 8 will be readily apparent to a reader skilled in the art.
A fabric engaging member 42 is provided on the end of the connecting member 8 distal to the pivotal connection with the lever member 6 . The fabric engaging member 42 comprises a short rod 44 extending perpendicularly to the bar 38 . The end of the rod 44 is provided with a circular disc 46 . The disc 46 may be manufactured from metal or a more flexible material such as rubber. In use, the disc 46 and rod 44 are pressed through a custom made aperture in fabric to be tensioned. Once the engaging member 42 is in position, the circular disc 46 tends to prevent the engaging member 42 from falling from the custom made fabric aperture.
The three components 4 , 6 , 8 and pivots 10 , 12 of the first embodiment 2 are preferably made of galvanized steel so as to ensure acceptable durability in harsh weather conditions.
Operation of the first embodiment 2 is clearly shown in FIGS. 2-5 of the accompanying drawings. The embodiment 2 may be used to tension the fabric roof of a marquee by mounting the embodiment 2 to the top of a vertical side wall post 100 of a marquee frame. This may be achieved by resiliently expanding the open end 14 of the mounting member 4 so that the mounting member 4 may be pressed over a marquee post 100 prior to assembly of the first pivot 10 (see FIG. 2 ). Once the mounting member 4 has been positioned about a post 100 , the first pivot 10 may be assembled in accordance with the above (see FIG. 3 ). Although the spring fit of the mounting member 4 about the marquee post 100 may be sufficient to prevent the embodiment 2 from slipping relative to said post 100 , it is likely that means in addition to the friction fit between the mounting member 4 and post 100 will be desirable to prevent relative movement therebetween when tensioning. As shown in FIGS. 2-5 , this additional means comprises a post pin 102 which, by means of appropriate apertures, extends from one side of the post 100 to an opposite side thereof and may be pressed through the circular aperture 28 provided on the side 24 of the mounting member 4 . In this way, movement of the mounting member 4 relative to the post 100 is prevented. The post pin 102 may be bent at one end and provided with a laterally extending hole 104 at an opposite end for receiving a clip (not shown) so as to prevent accidental removal of the post pin 102 from the aforementioned apertures. The post pin 102 is preferably of a durable material such as galvanized steel. The arrangement is such that the embodiment 2 can be conveniently retro-fitted to existing marquee posts.
Once secured to a marquee post, the embodiment 2 may be used to tension fabric supported by said post. In FIGS. 4 and 5 in particular, a post 100 is shown supporting a roof beam 106 . The post 100 and roof beam 106 combine with similar components to provide a frame structure for supporting the fabric of a marquee. The fabric is attached to this frame by means of a bead and groove arrangement wherein beading integral with the fabric is slidably located within grooves 108 defined in the side wall post and roof beam members 100 , 106 .
With reference to FIGS. 4 and 5 , it will be seen that a tension force may be applied to roof fabric supported by the roof beam 106 by attaching the fabric engaging member 42 to said roof fabric and pressing the end 36 of the lever member 6 in the direction of arrow A (see FIG. 4 ) towards the position shown in FIG. 5 . The rod 44 and disc 46 of the fabric engaging member 42 may be inserted through a metal eye provided either in the roof fabric itself or a strap extending from said roof fabric. For the purposes of clarity, the fabric to be tensioned is not shown in FIGS. 2-5 .
In moving the lever member 6 in the direction of arrow A, the fabric engaging member 42 is moved in a downward direction. Roof fabric is thereby also pushed in a downward direction and tensioned as a consequence. Considerable tensioning force may be readily applied by a user who presses on the end 36 of the lever member 6 distal to the mounting member 4 . In this way, significant leverage can be generated.
The configuration of the embodiment 2 is such that an over-center arrangement is provided. Specifically, the first pivot 10 is sufficiently spaced from the vertical post 100 when in use for the lever member 6 to be able to pass from the stable position shown in FIG. 4 through an unstable position to a second stable position shown in FIG. 5 wherein the reaction force exerted by the tensioned fabric tends to pull the lever member 6 and fabric connecting member 8 in the direction of arrow B (see FIG. 5 ) and into abutment with the post 100 . The embodiment 2 may therefore be conveniently moved from a stable non-tensioning position (shown in FIG. 4 ) to a stable tensioning position (shown in FIG. 5 ) in a rapid and effective manner.
Furthermore, the amount of tension applied to the roof fabric when in the stable tensioning position may be adjusted by telescopically extending or retracting the bar 38 relative to the cylindrical member 40 prior to securing the fabric engaging member 42 to the roof fabric when in the non-tensioning position. In this way, the tension applied to the roof fabric may be increased by telescopically extending the length of the fabric connecting member 8 or, alternatively, decreased by telescopically reducing the length of the connecting member 8 .
The present invention is not limited to the specific embodiment or method described above. Alternative arrangements and suitable materials will be apparent to a reader skilled in the art. For example, in circumstances where the post 100 is too large for a mounting member 4 to be sprung fitted thereto, it will be necessary to provide the mounting member 4 as a two-piece component. Each piece will comprise a side 24 having a circular aperture 28 defined therein for receiving a post pin 102 . Each piece will also comprise a circular aperture 20 for receiving the first pivot pin 22 . In use, the two pieces will locate on opposite sides of a post 100 with the circular apertures 28 coaxially aligned for reception of the post pin 102 . The two apertures 20 will also be coaxially aligned for reception of the first pivot pin 22 which, once in position with a nut threadedly attached thereto, will retain the two pieces of the mounting member 4 together.
As a further alternative. FIG. 6 shows a schematic view of a second embodiment 50. The second embodiment 50 is identical to the first embodiment 2 except for modifications to the mounting member and to the end of the lever member connected to said mounting member. As will be seen from FIG. 6 , the second embodiment 50 comprises a mounting member 52 which allows for mounting of the second embodiment 50 to a gable tension bar 110 . The mounting member 52 comprises a section 54 stamped and folded from sheet metal. This section 54 comprises two axially aligned circular apertures 56 (corresponding to the circular apertures 20 of the mounting member 4 of the first embodiment 2) for receiving a pivot pin. 58 to which a lever member 60 is pivotally secured. The mounting member 52 is not required to fit around a post or other member of a marquee frame and, accordingly, is of a relatively slim design. This results in the apertures 56 being closer to one another than the corresponding apertures 20 of the first embodiment 2. As a consequence, the end of the lever member 60 attached to the mounting member 52 is narrower than the corresponding end of the lever member 6 of the first embodiment 2.
In addition to the aforementioned section 54 of the mounting member 52 , the mounting member 52 also comprises a metal rod 62 . The rod 62 extends perpendicularly to the aligned axes of the mounting member apertures 56 . The second embodiment 50 may be thereby mounting to a gable tension bar 110 by inserting the rod 62 through a hole in said bar 110 and securing the rod 62 in position by locating appropriate clips in holes 64 extending laterally through the end of the rod 62 distal to the section 54 of the mounting member 52 . Once the second embodiment 50 has been secured to a gable tension bar 110 , gable fabric 112 may be tensioned in the same manner as described for roof fabric in relation to the first embodiment 2.
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The present invention relates to a method and apparatus for tensioning fabric and particularly, but not exclusively, to a method and apparatus for tensioning a fabric support by a frame in a marquee. A tensioner ( 2 ) is provided with a mounting device ( 4 ) for mounting the tensioner to a frame ( 100 ) of a marquee and a connector ( 6, 8, 42 ), which connects the mounting device ( 4 ) to a fabric to be tensioned. The connector ( 6, 8, 42 ) includes a resiliently bendable elongate member, ( 6, 8 ) which is resiliently connected to the mounting device ( 4 ) and includes an engagement device ( 42 ) which engages the fabric so as to permit a transfer of force between the fabric and the mounting device ( 4 ). The tensioner thereby allows fabric to be tensioned in a convenient and rapid manner.
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FIELD OF THE INVENTION
This invention relates in general to devices for injecting medicines into animals and, more particularly, to devices which mark the animal concurrently upon injecting the animal.
BACKGROUND OF THE INVENTION
The days of farmers independently operating small family farms profitably are, for the most part, a distant memory. Today's successful farmers rely heavily on quantity, quality and efficiency to operate their businesses successfully. In the hog industry, for example, a successful business operation may include hundreds, if not thousands, of hogs. In such an operation, overhead is kept low by employing only a handful of people to perform all aspects of the maintenance of the hogs, including breeding, feeding, treating, and selling.
The recognized need to increase efficiency in the hog production industry has given rise to the development of numerous devices for assisting hog farming operations. Computers are heavily used to track information related to genetics, feed consumption, and environmental factors, often providing feedback information concerning the quality of the final product. Such feedback allows a farmer to modify production processes for better outcomes. The efforts of farmers to increase profitability and productivity have also been assisted by both the pharmaceutical and nutrition industries. Each of these industries has produced a vast array of nutrition supplements and medicinal regimens to keep hogs healthier and, ultimately, more valuable. The negative aspect of these new regimens is that they require increased man-hours to administer.
For instance, it is not uncommon for each hog in a herd to require 7-9 medicinal injections per year--which is nearly double the number required only a decade ago. In today's hog farming environment, both the number of injections per hog and the number of hogs in a typical operation are increasing at the same time the number of employees on hand to maintain the hogs is decreasing. Thus, the maximization of personnel resources and delivery methods becomes ever more critical.
Aside from sheer volume, the delivery of injectible medicines to animals is complicated by the temperaments and behavior of the animals themselves. As a rule, hogs are generally not pleased at the prospect of receiving injections. Furthermore, there is no practical way to restrict movement of the hogs during the injection process. As a result, a hog who is about to receive or has received his medicine may be difficult to control and may intermingle with hogs who have not yet been injected. Accordingly, the possibility exists that certain hogs may go without their intended injections while others mistakenly receive multiple doses. Either scenario-leaving an animal unvaccinated or overvaccinating an animal--carry significant downfalls. Such mistakes in the administration of medicines could, in one extreme, threaten the well-being of the animals. In another extreme, the result may be toxic levels of medicines in the end products.
Various methods and devices have been developed to combat these inefficiencies, although recent changes to industry standards and production methods for hogs have rendered many of these solutions obsolete. For instance, as recently as twenty years ago it was a standard practice for farmers to deliver injectible medicines without paying particular attention to the specific location of the injections, either on the hogs or relative to one another. Subsequent research has indicated that this practice resulted in problems such as the delivery of medicines to areas to which they were not optimally assimilated into the bloodstream of the hog. Just as bad, delivery of the medicines to a disadvantageous location could blemish or damage the surrounding tissue, thereby devaluating the final meat product.
A good example of an early medicine delivery device which manifested the above referenced problems can be found in U.S. Pat. No. 3,949,746 (the '746 patent) issued to Wollach. The medicine delivery device of the '746 patent comprises a hypodermic syringe apparatus and includes a contact member having an apertured front plate and a hydraulic cylinder reciprocated mounting plate supporting a group of hypodermic needles in slidable registry with the front plate openings. The needles pierce a liquid absorbing web backing the front plate. Each needle is connected by a flexible tube to an adjustable stroke piston pump and then to liquid injectible holding receptacles. The pistons are simultaneously actuated by a motor driven cam carrying shaft. The motor is controlled by a handle carried switch to rotate the shaft one turn. The shaft carrying cam also controls the flow of the liquid to the handle cylinder, and the absorbent pad is connected to a source of antiseptic. A marking pad is carried by the handle front wall to identify the puncture area.
Because of the complicated nature and resulting expense of the device of the '746 patent, it never found widespread use in the livestock industry, where profit margins are typically too low to support either the purchase or the continued maintenance required by such a complicated device. Additionally, the manner in which the injections are delivered by the '746 patent is now considered unacceptable for several reasons. First, livestock experts now agree that delivering a large number of treatments in essentially the same location may limit the effectiveness of some medicines and may even be detrimental to the animal. Secondly, the former practice of delivering injectible treatments to "high yield" meat areas such as the rump (as shown in the '746 patent) reduces the quality of the salable meat from that area and reduces the profitability of the animal.
More recently, individual syringes have been developed which allow the farmer to apply an injection in any desired location using a singlehandled manual syringe. One such syringe is the "Easy Vac" Automatic Syringe, manufactured by Forlong & Massey d/b/a Instrument Supplies of New Zealand and distributed in the United States by Vac-Pac Incorporated of Marietta, Ga. (1-800-793-1671). Typically, the Instrument Supplies Easy-Vac syringe is used in conjunction with a so-called "paint stick". In livestock operations, the paint stick is a well known device which resembles a large grease pencil and is used to mark the hog which has received the injection. If used properly, the farmer injects the animal with a syringe held in one hand and marks the injected animal with a paint stick held in the other hand. Proper use of the paint stick identifies the animal as one which has been injected. This method does not necessarily provide a visible indication of the location of the injection.
Even this improved method of delivering injections poses serious problems for the farmer. First, it is extremely easy for a low-paid manual laborer who is delivering the injections to take a shortcut by injecting the animal in an easily accessible but improper area (such as the rump), then use the paint stick to mark the animal where the injection should have been given, such as in the neck. Secondly, even if used properly, both of the hands of the farmer are occupied, making it extremely difficult to control the animal in any meaningful way. Often, an animal will escape control of the farmer after being injected and before being marked, resulting in the potential risk of an animal receiving multiple injections, or not receive an injection at all.
Accordingly, a need exists for an apparatus for injecting hogs and other livestock which delivers injections easily, accurately and reliably. There is an additional need for such an apparatus which will mark both the animal injected and the location of the injection on the animal concurrent with the delivery of the injection. Finally, there exists a need for such an apparatus which can be operated with one hand, leaving the farmer one hand free to control the animal, protect himself or deliver a second injection and mark with a second apparatus substantially simultaneously.
SUMMARY OF THE INVENTION
The present invention is a marking syringe which allows an individual using the marking syringe to inject a fluid such as a vaccine into an animal and, at the same time, mark the location of the injection on the animal and the animal being injected. More specifically, the marking syringe of the present invention include a vaccine syringe and an ink syringe which are respectively connected to a source of vaccine and a source of ink. A syringe handle is operatively connected to both the vaccine syringe and the ink syringe. After connection to the vaccine and ink sources, the syringe needle is inserted into the animal and the syringe handle is actuated. As the handle is actuated, the vaccine syringe and the ink syringe both simultaneously discharge their contents. The position of the ink syringe relative to the vaccine syringe is such that the discharged ink marks the animal in the approximate location of the vaccine injection through the needle.
The marking syringe of the present invention carries many advantages over current injecting and marking systems. First, because the handle activates both the vaccine syringe and the marking syringe simultaneously, the marking syringe of the present invention can be easily operated with one hand, leaving the user's other hand free to control the animal or to operate a second marking syringe. The operation of a second syringe poses obvious advantages, in that one user could apply twice as many injections in roughly the same amount of time, thereby cutting in half the number of man-hours needed to accomplish the task.
Another advantage of the marking syringe of the present invention is that it applies a mark to the animal in close proximity to the actual injection by the needle. Unlike current popular methods of marking, the user cannot apply the injection with the needle in one area of the animal and apply the mark to a different area.
Yet another advantage the marking syringe of the present invention is its simplicity of use. Specifically, the marking syringe of the present invention does not require power of any type and, thus, can be easily used in remote locations. Additionally, the marking syringe of the present invention is easily disassembled for cleaning or replacement of failed parts.
Accordingly, it is an object of the present invention to provide an apparatus for injecting hogs and other livestock which delivers injections easily, accurately and reliably. It is another object of the present invention to provide an apparatus which will mark both the animal injected and the location of the injection on the animal concurrent with the delivery of the vaccine injection. It is yet another object of the present invention to provide an apparatus which can accomplish the foregoing and be operated with one hand, leaving the user one hand free to control the animal, protect himself or deliver a second injection and mark with a second apparatus substantially simultaneously.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of an exemplary embodiment of the present invention in a typical operating environment.
DETAILED DESCRIPTION
Referring now to the drawings, FIG. 1 is an illustration of a preferred embodiment of the present invention, which shows a marking syringe for simultaneously injecting a vaccine or other substance into an animal while placing an identifying mark on the animal in the vicinity of the injection.
As can be seen in FIG. 1, the marking syringe 5 comprises, generally, a syringe handle 4 operatively connected to a vaccine syringe 50 and an ink syringe 70. The syringe handle 4 comprises a first syringe handle 10 pivotally connected to a second syringe handle 30. The first syringe handle 10 is elongated, having a first end 11 and a second end 13. The handle 10 is generally shaped for comfortable receipt into the palm portion of the hand of the user. A socket 15 is located adjacent the end 11, and a slot 16 is located between the socket 15 and the end 13. The handle 10 has a pivot hole at its second end 13.
The second syringe handle 30 of marking syringe 5 is also elongated and has a first end 31 and a second end 33. The first end 31 of the second syringe handle 30 securely receives a hook 90 for storage of the marking syringe 5 between uses. The second syringe handle 30 is configured to fit as a finger grip for the user. The second end 33 of the second syringe handle 30 is sized to slidably straddle the second end 13 of the first handle 10 and has a pivot hole through its thickness. The second handle 30 includes integral vaccine syringe collar 32 and integral ink syringe collar 34.
During assembly, the second end 33 of the second syringe handle 30 is positioned over the second end 13 of the first syringe handle 10 such that the pivot holes in the ends 13 and 33 are axially aligned. Thereafter, pivot pin 20 is inserted through the aligned holes and appropriately secured therein in any number of ways, including deforming distal ends of pivot pin 20 so that the diameter of the pivot pin 20 is larger at the points of deformation than the diameter of the pivot pin receiving holes, thereby preventing withdrawal of pivot pin 20 through the pivot pin receiving holes. After the pivot pin is properly positioned and secured, the second syringe handle 30 rotates about the axis of pivot pin 20 in a plane defined by second syringe handle 30 and first syringe handle 10. In use, the first and second handles 10 and 30 are initially in a spread position. The user can then grip the first and second handles 10 and 30 and squeeze them into a closed position as the handles 10 and 30 pivot about the pin 20.
The vaccine syringe 50 is mounted between the handles 10 and 30 by means of the collar 32 on handle 30 and the socket 15 on handle 10. The vaccine syringe 50 comprises a vaccine syringe head 52 with a ball 53, an extendible vaccine syringe shaft 51, vaccine syringe biasing spring 68, vaccine syringe plunger 60, vaccine dosage chamber 61, vaccine syringe needle fastener 62, and a needle 64. In order to connect the syringe 50 to the handle 4, the dosage chamber 61 is threaded into the handle collar 32 of handle 30, and the vaccine syringe head 52 is connected to the handle 10 by engaging the ball 53 of the head 52 into the socket 15 of the handle 10.
The head 52 is hollow and comprises the ball 53 for attaching the head 52 to the handle 10, a vaccine syringe nipple 56, and a spring stop 58. The vaccine syringe nipple 56 is integral to the hollow vaccine syringe head 52 and is sized to securely receive a syringe vaccine hose 6. Vaccine is delivered to the hollow interior cavity of the head 52 via vaccine hose 6 which is connected to a vaccine source (not shown). The vaccine syringe spring stop flange 58 extends laterally about the periphery of the vaccine syringe head 52.
The extendible vaccine syringe shaft 51 interconnects the syringe head 52 and the plunger 60. The shaft 51 has an interior axial conduit (not shown) which communicates a one end to the interior cavity of the head 52 and at the other end to an interior axial conduit (not shown) through the plunger 60. The syringe shaft 51 extends through a vaccine syringe collar 32 of the second syringe handle 30 and into the vaccine dosage chamber 61. In order to vary the amount of dosage, the shaft 51 has a vaccine dosage adjust valve 66. The dosage adjust valve 66 comprises a collar that engages the plunger 60 on one end and is threaded onto shaft 51.
The vaccine syringe plunger 60 slides within vaccine dosage chamber 61. An O-ring 63 creates a liquid tight seal between the periphery of plunger 60 and the interior wall of the dosage chamber 61. The plunger 60 has a check valve (not shown) within its interior axial conduit that allows liquid to pass only in the direction toward the needle end of the syringe 50.
The vaccine dosage chamber 61 is formed of a translucent or transparent material and is secured at its first end to the vaccine syringe collar 32. Vaccine dose chamber 61 may be scored with incremental graduations to assist a user in dosage measurements. At its second end, the vaccine dosage chamber 61 removably receives a vaccine syringe needle fastener 62. The vaccine syringe needle fastener 62 is fitted to capture a needle 64. A check valve (not shown) is fitted within the needle fastener 62 to allow liquid flow only out of the needle.
A vaccine syringe biasing spring 68 is disposed around the vaccine syringe shaft 51 between the vaccine syringe stop flange 58 and the vaccine dosage adjust valve 66. The biasing spring 68 is a compression spring which serves to return the handles 10 and 30 to their initial spread position after being squeezed closed by the user.
When the handles 10 and 30 are squeezed together, the plunger 60 moves within the dosage chamber 61. The movement of the plunger closes the check valve within the plunger 60 to force vaccine in the dosage chamber 61 through the check valve within the needle fastener 62 and out through the needle 64. When the handles 10 and 30 are released by the user, the check valve within the needle fastener 62 closes to preclude fluid or air being drawn into the dosage chamber 61 through the needle 64. Simultaneously, the check valve within the plunger 60 opens so that vaccine is drawn into dosage chamber 61 through the nipple 56, the hollow head 52, the conduit within the shaft 51, and the conduit with the plunger 60. By turning the dosage adjust valve 66, the length of the shaft 51 is changed. Changing the length of the shaft 51 changes the length of the plunger stroke, and the amount of medicine delivered through the needle 64 is accordingly changed.
Similarly, the ink syringe 70 is mounted between the handles 10 and 30 by means of the collar 34 on handle 30 and the slot 16 on the handle 10. The ink syringe 70 comprises a ink syringe head 72 with a pin 73 extending therefrom, an extendible ink syringe shaft 71, ink syringe biasing spring 88, ink syringe plunger 80, ink dosage chamber 81, and an ink discharge orifice 82. In order to connect the syringe 70 to the handle 4, the dosage chamber 81 is threaded into the handle collar 34 of handle 30, and the ink syringe head 72 is connected to the handle 10 by engaging the pin 73 of the head 72 into the slot 16 of the handle 10. The combination of the slot 16 and pin 73 assures axial alignment of the plunger 80 with the ink dosage chamber 81.
The head 72 is hollow and comprises the pin 73 for attaching the head 72 to the handle 10, an ink syringe nipple 76, and a spring stop 78. The ink syringe nipple 76 is integral to the hollow ink syringe head 72 and is sized to securely receive a syringe ink hose 7. Ink is delivered to the hollow interior cavity of the head 72 via ink hose 7 which is connected to a ink source (not shown). The ink syringe spring stop flange 78 extends laterally about the periphery of the ink syringe head 72.
The extendible ink syringe shaft 71 interconnects the syringe head 72 and the plunger 80. The shaft 71 has an interior axial conduit (not shown) which communicates a one end to the interior cavity of the head 72 and at the other end to an interior axial conduit (not shown) through the plunger 80. The syringe shaft 71 extends through a ink syringe collar 34 of the second syringe handle 30 and into the ink dosage chamber 81. In order to vary the amount of ink dispensed, the shaft 71 has a ink dosage adjust valve 86. The dosage adjust valve 86 comprises a collar that engages the plunger 80 on one end and is threaded onto shaft 71.
The ink syringe plunger 80 slides within ink dosage chamber 61. An O-ring 83 creates a liquid tight seal between the periphery of plunger 80 and the interior wall of the dosage chamber 81. The plunger 80 has a check valve (not shown) within its interior axial conduit that allows liquid to pass only in the direction toward the needle end of the syringe 70.
The ink dosage chamber 81 is formed of a translucent or transparent material and is secured at its first end to the ink syringe collar 34. Ink dose chamber 81 may be scored with incremental graduations to assist a user in dosage measurements. At its second end, the ink dosage chamber 81 has the discharge orifice 82. A check valve (not shown) is fitted within the discharge orifice 82 to allow ink flow only out of the discharge orifice 82. The discharge orifice has a body portion 83 and an end portion 85 which is set at angle to axis of the cylindrical dosage chamber 81. By rotating the discharge orifice on the cylindrical dosage chamber 81, the end portion may be aimed and thereby control the location of the resulting mark with respect to the needle 64.
An ink syringe biasing spring 88 is disposed around the ink syringe shaft 71 between the ink syringe stop flange 78 and the ink dosage adjust valve 86. The biasing spring 88 is a compression spring which serves to return the handles 10 and 30 to their initial spread position after being squeezed closed by the user.
When the handles 10 and 30 are squeezed together, the plunger 80 moves within the dosage chamber 81. The movement of the plunger closes the check valve within the plunger 80 to force ink in the dosage chamber 81 through the check valve within the discharge orifice 82 and out through the discharge orifice 82. When the handles 10 and 30 are released by the user, the check valve within the discharge orifice 82 closes to preclude fluid or air being drawn into the dosage chamber 81 through the discharge orifice 82. Simultaneously, the check valve within the plunger 80 opens so that ink is drawn into dosage chamber 81 through the nipple 76, the hollow head 72, the conduit within the shaft 71, and the conduit with the plunger 80. By turning the dosage adjust valve 86, the length of the shaft 71 is changed. Changing the length of the shaft 71 changes the length of the plunger stroke, and the amount of ink delivered through the discharge orifice 82 is accordingly changed.
In operation, an appropriately sized needle 64 is selected and received within vaccine syringe needle fastener 62. Automatic syringe vaccine hose 6 and syringe ink hose 7 are connected to their respective vaccine and ink sources. Next, the vaccine dose adjust valve 66 and the ink dose adjust valve 86 are rotated to achieve proper dosing. As each of the respective adjust valves is rotated, the functional connection between the adjust valves and their respective syringe shafts moves the initial position of the respective syringe plungers to determine dosage amounts. When adjusted according to dosing requirements, first syringe handle 10 is rotated about pivot pin 20 toward second syringe handle 30 to clear air from the respective hoses and prime the respective syringes.
Actuation of the first syringe handle 10 in such a fashion forces both the vaccine syringe shaft 51 and the ink syringe shaft 71 forward. As a result, both the vaccine syringe plunger 60 and ink syringe plunger 80 move toward the needle 64 and ink discharge orifice 82, respectively, thereby forcing substantially simultaneous expulsion of the contents of the vaccine dose chamber 61 and ink dose chamber 81. As the first syringe handle 10 is compressed, vaccine syringe biasing spring 68 and ink syringe biasing spring 88 are similarly compressed. Following completion of full compression of the first syringe handle 10 and subsequent release of same, compressed biasing springs 68 and 88 return the first syringe handle 10 to its original position.
The method of movement of vaccine and ink into their respective dosage chambers 61 and 81 is accomplished by any number of devices well known to those skilled in the art of syringes. For instance, an exemplary embodiment of the marking syringe 5 incorporates hollow vaccine and ink shafts 51 and 71 and unidirectional diaphragms or check valves within the respective plungers 60 and 80 and the respective needle fastener 62 and discharge orifice 82. After actuation of the first syringe handle 10 and injection of vaccine and ink, the return of the first syringe handle 10 to its original position by the respective biasing springs 68 and 88 creates a vacuum within the respective dosage chambers. The respective unidirectional diaphragms open and close as previously described under this circumstance to draw either vaccine or ink into its dosage chamber. As the first syringe handle reaches its initial position, the respective dosage chambers 61 and 81 are filled with their intended contents and the diaphragm closes, thereby allowing pressurized expulsion of the chamber contents upon actuation of the first syringe handle as previously described.
While the invention has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of and equivalents to these embodiments. Accordingly, the scope of the present invention should be assessed as that of the appended claims and any equivalents thereto and not limited to the specific embodiments articulated hereinabove.
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A marking syringe which allows an individual using the syringe to inject a fluid such as a vaccine into an animal and, at the same time, mark the location of the injection on the animal. More specifically, the marking syringe includes a vaccine syringe and an ink syringe connected to a handle. Activation of the handle simultaneously activates the vaccine syringe and the marking syringe. The vaccine syringe and the ink syringe are respectively connected to a source of vaccine and a source of ink. After connection to the vaccine and ink sources, the syringe needle is inserted into the animal and a syringe handle is actuated. As the handle is actuated, a vaccine syringe and an ink syringe both discharge their contents. The position of the ink syringe relative to the vaccine syringe is such that the discharged ink marks the animal in the approximate location of the vaccine injection.
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TECHNICAL FIELD
[0001] This invention relates to a polyester resin container made of a polyester resin composition containing a specific ultraviolet absorber. More particularly, it relates to a polyester resin container excellent in heat resistance, colorlessness, and weatherability which is obtained from a polyester resin composition containing a specific triazine compound as an ultraviolet absorber. The polyester resin container of the invention is suitable as a food packaging container requiring heat sterilization, such as a soft drink bottle.
BACKGROUND ART
[0002] Polyethylene terephthalate (PET) containers have been widely used as beverage bottles and containers for cosmetics, medicines, detergents, shampoos, and so on because of high transparency, gas barrier properties, and the like.
[0003] Although food packaging containers are rarely left outdoors for a long time and therefore not required to have high weatherability, they are usually kept on the grocery or supermarket shelves under sunlight or fluorescent lights and are required to have weatherability enough to keep the product's appeal to consumers.
[0004] Among known methods of light stabilizing various synthetic resins is addition of additives, such as ultraviolet absorbers, phenol or phosphorus antioxidants, and hindered amine stabilizers. Triazine compounds are known as highly effective ultraviolet absorbers and are disclosed, for example, in JP-A-2000-238857, JP-A-2001-302926, JP-A-2003-192830, and JP-A-2003-261725.
DISCLOSURE OF THE INVENTION
[0005] An object of the present invention is to provide a polyester resin container with improved weatherability and, in addition, sufficient colorlessness and excellent heat resistance.
[0006] As a result of extensive investigations, the present inventors have found that the above object is accomplished by adding to a polyethylene terephthalate resin a triazine ultraviolet absorber having a specific structure. The present invention has been reached based on this finding.
[0007] The present invention provides a polyester resin container made of a polyester resin composition comprising (A) 100 parts by weight of a polyester resin and (B) 0.01 to 10 parts by weight of a triazine ultraviolet absorber represented by formula (I):
wherein R 1 represents a straight-chain or branched alkyl group having 1 to 17 carbon atoms, which may have an alicyclic group at the terminal or in the chain thereof; and R 2 , R 2 ′, R 3 , and R 3 ′ each represent a hydrogen atom or a methyl group.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The polyester resin as component (A) that can be used in the present invention typically includes polyethylene terephthalate used as a general-purpose bottle material. Also included is polyethylene naphthalate that is expensive but known as a material of returnable/refillable bottles.
[0009] The polyethylene terephthalate for use in the invention can be obtained by, for example, using terephthalic acid and ethylene glycol as main monomer components and, if desired, other monomer components, including dicarboxylic acid components such as isophthalic acid and naphthalenedicarboxylic acid, oxycarboxylic acid components such as p-hydroxybenzoic acid and hydroxynaphthalenecarboxylic acid, and diol components such as cyclohexanedimethanol, bisphenol A ethylene oxide adducts, bisphenol S ethylene oxide adducts, and bis(4-β-hydroxyethoxyphenyl)sulfone. Using the other monomer components in too high a proportion can impair the physical properties of the resulting polyethylene terephthalate resin. A recommended amount of the other monomer components is less than 20% by weight, preferably less than 10% by weight, based on the total monomer components.
[0010] A polyethylene terephthalate resin for use in the invention can be prepared by any known polymerization method, such as interesterification of dimethyl terephthalate and ethylene glycol. A polyethylene terephthalate resin can also be prepared by directly esterifying terephthalic acid and ethylene glycol to prepare bis(2-hydroxyethyl) terephthalate as a precursor and melt-polymerizing the precursor in the presence of a polycondensation catalyst, such as a germanium compound. Considering that polyester resins of high degree of polymerization are preferred for bottles, it is preferred that the polymer obtained by melt polycondensation be further subjected to solid phase polymerization at temperatures lower than the melting point by 20° to 50° C.
[0011] Catalysts for direct esterification that can be used in the production of a polyethylene terephthalate resin include a methylate of sodium or magnesium; zinc borate; fatty acid salts or a carbonate of zinc, cadmium, manganese, cobalt, calcium or barium, such as zinc acetate; metallic magnesium; and an oxide of lead, zinc, antimony or germanium.
[0012] A polyethylene naphthalate resin for use in the invention is obtained in the same manner as for the polyethylene terephthalate resin, except for using naphthalenedicarboxylic acid in place of terephthalic acid.
[0013] In using a commercially available polyester resin as component (A), it is advisable to use those of container grade. The intrinsic viscosity (I.V.) of the polyester resin (A) preferably ranges from 0.5 to 1.5, still preferably from 0.6 to 1.1. The polyester resin (A) which is non-crystalline preferably has an I.V. of 0.65 to 0.75. The one which is crystalline preferably has an I.V. of 0.7 to 1.05. The one which is a copolymer preferably has an I.V. of 0.7 to 0.8.
[0014] In formula (I) representing the triazine ultraviolet absorber as component (B), the alkyl group represented by R 1 includes methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, tert-butyl, isobutyl, amyl, isoamyl, tert-amyl, hexyl, 2-hexyl, 3-hexyl, heptyl, 2-heptyl, 3-heptyl, isoheptyl, tert-heptyl, n-octyl, isooctyl, tert-octyl, 2-ethylhexyl, nonyl, isononyl, decyl, dodecyl (lauryl), tridecyl, tetradecyl (myristyl), pentadecyl, hexadecyl (palmityl), heptadecyl, cyclopentyl, 2-cyclopentylethyl, 3-cyclopentylpropyl, 4-cyclopentylbutyl 5-cyclopentylpentyl, cyclohexyl, 2-cyclohexylethyl, 3-cyclohexylpropyl, 4-cyclohexylbutyl, 5-cyclohexylpentyl, 8-cyclohexyloctyl, 10-cyclohexyldecyl, cycloheptyl, cyclooctyl, bicyclohexyl, bicycloheptyl, bicyclooctyl, 2-methylcyclohexyl, 3-methylcyclohexyl, 4-methylcyclohexyl, 2,4-dimethylcyclohexyl, 2,5-dimethylcyclohexyl, 2,6-dimethylcyclohexyl, 3,4-dimethylcyclohexyl, 4,5-dimethylcyclohexyl, 4-ethylcyclohexyl, 4-propylcyclohexyl, 4-isopropylcyclohexyl, 4-butylcyclohexyl, 4-tert-butylcyclohexyl, 4-hexylcyclooctyl, 4-cyclohexyldecyl, (4-methylcyclohexyl)methyl, 2-(4-ethylcyclohexyl)ethyl, and 3-(4-isopropylcyclohexyl)-propyl. Of these alkyl groups preferred are those having 1 to 10 carbon atoms.
[0015] Specific but non-limiting examples of the triazine ultraviolet absorbers represented by formula (I) include compound Nos. 1 to 9 listed below.
[0016] The triazine compound (I) is used as component (B) in an amount of 0.01 to 10 parts by weight, preferably 0.05 to 5 parts by weight, still preferably 0.1 to 3 parts by weight, per 100 parts by weight of the polyester resin (A). At amounts less than 0.01 parts, the compound fails to produce sufficient stabilizing effect. At amounts more than 10 parts, the compound bleeds out or reduces the physical properties of the resin composition, resulting in a reduction of merchantability of the container and the contents.
[0017] The triazine compound (I) is not limited by the process of preparation. Useful processes for preparing the triazine compound (I) include esterification or interesterification between 2-[2-hydroxy-4-(2-hydroxyethyloxy)phenyl]-4,6-diphenyl-1,3,5-triazine as an alcohol component and a monocarboxylic acid or an ester-forming derivative thereof (e.g., a halide or an ester). These reactions may be effected either successively or all at once.
[0018] Methods for molding a container from the polyester resin composition is not particularly restricted. Useful molding methods include single-stage molding processes, such as extrusion blow molding, injection blow molding, and injection biaxial stretch blow molding (hot parison method); two-stage molding processes, such as extruded preform blow molding and injected preform blow molding; biaxial stretch blow molding processes; and non-stretch molding processes.
[0019] Polyethylene terephthalate resin containers may sometimes have insufficient gas barrier properties against oxygen or carbon dioxide. Where there is a fear that liquid contents, e.g., juice undergoes color change or reduction of vitamins, the polyester resin container may be a co-extruded laminate container having an interlayer of an ethylene-vinyl alcohol copolymer (e.g., Eval available from Kuraray Co., Ltd.) or an aromatic polyamide (e.g., MX Nylon available from Mitsubishi Gas Chemical Co., Ltd.).
[0020] If desired, the polyester resin composition can contain compounding additives generally used in the art, such as a coloring inhibitor (hereinafter taken as component (C)), a hindered amine light stabilizer, an ultraviolet absorber other than the triazine compound of formula (I), a phosphorus, phenol or sulfur antioxidant, a nucleating agent, a flame retardant, a metal soap, a processing aid, a pigment, a filler, and a lubricant.
[0021] The coloring inhibitor as component (C) preferably includes phosphorus-containing antioxidants, particularly phosphorous ester compounds represented by formula (II):
wherein R 7 represents an alkyl group having 4 to 8 carbon atoms or an arylalkyl group having 7 to 12 carbon atoms; and R 8 and R 9 each represent a hydrogen atom, an alkyl group having 1 to 8 carbon atoms or an arylalkyl group having 7 to 12 carbon atoms.
[0022] Specific examples of the phosphorous ester compound of formula (II) include bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite, bis(2,6-di-tert-butyl-4-methylphenyl) pentaerythritol diphosphite, and bis(2,4-dicumylphenyl) pentaerythritol diphosphite. Further included in the coloring inhibitor (C) are phenol type antioxidants and sulfur-containing antioxidants. The coloring inhibitor (C) is preferably used in an amount of 0.01 to 10 parts by weight, still preferably 0.1 to 5 parts by weight, per 100 parts by weight of the polyester resin (A).
[0023] Examples of the hindered amine light stabilizer include 2,2,6,6-tetramethyl-4-piperidyl stearate, 1,2,2,6,6-pentamethyl-4-piperidyl stearate, 2,2,6,6-tetramethyl-4-piperidyl benzoate, bis(2,2,6,6-tetramethyl-4-piperidyl) sebacate, bis(1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, bis(1-octoxy-2,2,6,6-tetramethyl-4-piperidyl) sebacate, tetrakis(2,2,6,6-tetramethyl-4-piperidyl)-1,2,3,4-butanetetracarboxylate, tetrakis(1,2,2,6,6-pentamethyl-4-piperidyl)-1,2,3,4-butanetetracarboxylate, bis(2,2,6,6-tetramethyl-4-piperidyl) bis(tridecyl)-1,2,3,4-butanetetracarboxylate, bis(1,2,2,6,6-pentamethyl-4-piperidyl) bis(tridecyl)-1,2,3,4-butanetetracarboxylate, bis(1,2,2,6,6-pentamethyl-4-piperidyl)-2-butyl-2-(3,5-di-tert-butyl-4-hydroxybenzyl) malonate, 1-(2-hydroxyethyl)-2,2,6,6-tetramethyl-4-piperidinoVdiethyl succinate polycondensate, 1,6-bis(2,2,6,6-tetramethyl-4-piperidylamino)hexane/dibromoethane polycondensate, 1,6-bis(2,2,6,6-tetramethyl-4-piperidylamino)hexane/2,4-dichloro-6-morpholino-s-triazine polycondensate, 1,6-bis(2,2,6,6-tetramethyl-4-piperidylamino)hexane/2,4-dichloro-6-tert-octylamino-2-triazine polycondensate, 1,5,8,12-tetrakis[2,4-bis(N-butyl-N-(2,2,6,6-tetramethyl-4-piperidyl)amino)-s-triazin-6-yl]-1,5,8,12-tetraazadodecane, 1,5,8,12-tetrakis[2,4-bis(N-butyl-N-(1,2,2,6,6-pentamethyl-4-piperidyl)amino)-s-triazin-6-yl]-1,5,8,12-tetraazadodecane, 1,6,11-tris[2,4-bis(N-butyl-N-(2,2,6,6-tetramethyl-4-piperidyl)amino-s-triazin-6-ylamino]undecane, 1,6,11-tris[2,4-bis(N-butyl-N-(1,2,2,6,6-pentamethyl-4-piperidyl)amino-s-triazin-6-ylamino]undecane, 3,9-bis[1,1-dimethyl-2-[tris(2,2,6,6-tetramethyl-4-piperidyloxycarbonyloxy)butylcarbonyloxy]ethyl]-2,4,8,10-tetraoxaspiro[5.5]undecane, and 3,9-bis[1,1-dimethyl-2-[tris(1,2,2,6,6-pentamethyl-4-piperidyloxycarbonyloxy)butylcarbonyloxy] ethyl]-2,4,8,10-tetraoxaspiro[5.5]undecane.
[0024] Examples of the ultraviolet absorber other than the triazine compound of formula (I) include 2-hydroxybenzophenones, such as 2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone, 2-hydroxy-4-octoxybenzophenone, and 5,5′-methylenebis(2-hydroxy-4-methoxybenzophenone); 2-(2-hydroxyphenyl)benzo-triazoles, such as 2-(2-hydroxy-5-methylphenyl)benzotriazole, 2-(2-hydroxy-5-tert-octylphenyl)benzotriazole, 2-(2-hydroxy-3,5-di-tert-butylphenyl)-5-chlorobenzo-triazole, 2-(2-hydroxy-3-tert-butyl-5-methylphenyl)-5-chlorobenzotriazole, 2-(2-hydroxy-3,5-dicumylphenyl)benzotriazole, 2,2′-methylenebis(4-tert-octyl-6-benzo-triazolylphenol), polyethylene glycol ester of 2-(2-hydroxy-3-tert-butyl-5-carboxyphenyl)benzotriazole, 2-[2-hydroxy-3-(2-acryloyloxyethyl)-5-methylphenyl]-benzotriazole, 2-[2-hydroxy-3-(2-methacryloyloxyethyl)-5-tert-butylphenyl]benzo-triazole, 2-[2-hydroxy-3-(2-methacryloyloxyethyl)-5-tert-octylphenyl]benzotriazole, 2-[2-hydroxy-3-(2-methacryloyloxyethyl)-5-tert-butylphenyl]-5-chlorobenzotriazole, 2-[2-hydroxy-5-(2-methacryloyloxyethyl)phenyl]benzotriazole, 2-[2-hydroxy-3-tert-butyl-5-(2-methacryloyloxyethyl) phenyl]benzotriazole, 2-[2-hydroxy-3-tert-amyl-5-(2-methacryloyloxyethyl)phenyl] benzotriazole, 2-[2-hydroxy-3-tert-butyl-5-(3-methacryloyloxypropyl)phenyl]-5-chlorobenzotriazole, 2-[2-hydroxy-4-(2-methacryloyloxymethyl)phenyl]benzotriazole, 2-[2-hydroxy-4-(3-methacryloyloxy-2-hydroxypropyl)phenyl]benzotriazole, and 2-[2-hydroxy-4-(3-methacryloyl-oxypropyl)phenyl]benzotriazole; 2-(2-hydroxyphenyl)-4,6-diaryl-1,3,5-triazines, such as 2-(2-hydroxy-4-methoxyphenyl)-4,6-diphenyl-1,3,5-triazine, 2-(2-hydroxy-4-hexyloxyphenyl)-4,6-diphenyl-1,3,5-triazine, 2-(2-hydroxy-4-octoxyphenyl)-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, 2-[2-hydroxy-4-(3-C 12-13 mixed alkoxy-2-hydroxypropoxy)phenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, 2-[2-hydroxy-4-(2-acryloyloxyethoxy)phenyl]-4,6-bis(4-methylphenyl)-1,3,5-triazine, 2-(2,4-di-hydroxy-3-allylphenyl)-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and 2,4,6-tris(2-hydroxy-3-methyl-4-hexyloxyphenyl)-1,3,5-triazine; benzoates, such as phenyl salicylate, resorcinol monobenzoate, 2,4-di-tert-butylphenyl 3,5-di-tert-butyl-4-hydroxybenzoate, octyl (3,5-di-tert-butyl-4-hydroxy)benzoate, dodecyl (3,5-di-tert-butyl-4-hydroxy)benzoate, tetradecyl (3,5-di-tert-butyl-4-hydroxy)benzoate, hexadecyl (3,5-di-tert-butyl-4-hydroxy)benzoate, octadecyl (3,5-di-tert-butyl-4-hydroxy)benzoate, and behenyl (3,5-di-tert-butyl-4-hydroxy)benzoate; substituted oxanilides, such as 2-ethyl-2′-ethoxyoxanilide and 2-ethoxy-4′-dodecyloxanilide; cyanoacrylates, such as ethyl α-cyano-β,β-diphenylacrylate and methyl 2-cyano-3-methyl-3-(p-methoxyphenyl)acrylate; and metal salts or chelates, particularly nickel or chromium salts or chelates.
[0025] Examples of the phosphorus-containing antioxidant include triphenyl phosphite, tris(2,4-di-tert-butylphenyl) phosphite, tris(2,5-di-tert-butylphenyl) phosphite, tris(nonylphenyl) phosphite, tris(dinonylphenyl) phosphite, tris(mono-/di-mixed nonylphenyl) phosphite, diphenyl acid phosphite, 2,2′-methylenebis(4,6-di-tert-butylphenyl) octyl phosphite, diphenyl decyl phosphite, diphenyl octyl phosphite, di(nonylphenyl) pentaerythritol diphosphite, phenyl diisodecyl phosphite, tributyl phosphite, tris(2-ethylhexyl) phosphite, tridecyl phosphite, trilauryl phosphite, dibutyl acid phosphite, dilauryl acid phosphite, trilauryl trithiophosphite, bis(neopentyl glycol) 1,4-cyclohexanedimethyl diphosphite, bis(2,4-di-tert-butylphenyl) pentaerythritol diphosphite, bis(2,5-di-tert-butylphenyl) pentaerythritol diphosphite, bis(2,6-di-tert-butyl-4-methylphenyl) pentaerythritol diphosphite, bis(2,4-dicumylphenyl)pentaerythritol diphosphite, distearyl pentaerythritol diphosphite, tetra(C 12-15 -mixed alkyl)-4,4′-isopropylidenediphenyl phosphite, bis[2,2′-methylenebis(4,6-diamylphenyl)] isopropylidenediphenyl phosphite, tetratridecyl 4,4′-butylidenebis(2-tert-butyl-5-methylphenol) diphosphite, hexa(tridecyl)-1,1,3-tris(2-methyl-5-tert-butyl-4-hydroxyphenyl)butane-triphosphite, tetrakis(2,4-di-tert-butylphenyl) biphenylene diphosphonite, tris(2-[(2,4,7,9-tetrakis-tert-butyldibenzo[d,f][1,3,2]dioxaphosphepin-6-yl)oxy]ethyl)amine, 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide, and 2-butyl-2-ethylpropanediol 2,4,6-tri-tert-butylphenol monophosphite.
[0026] Examples of the phenol type antioxidant include 2,6-di-tert-butyl-p-cresol, 2,6-diphenyl-4-octadecyloxyphenol, stearyl (3,5-di-tert-butyl-4-hydroxyphenyl)propionate, distearyl (3,5-di-tert-butyl-4-hydroxybenzyl)phosphonate, tridecyl 3,5-di-tert-butyl-4-hydroxybenzyl thioacetate, thiodiethylenebis[(3,5-di-tert-butyl-4-hydroxyphenyl) propionate], 4,4′-thiobis(6-tert-butyl-m-cresol), 2-octylthio-4,6-di(3,5-di-tert-butyl-4-hydroxyphenoxy)-s-triazine, 2,2′-methylenebis(4-methyl-6-tert-butylphenol), bis[3,3-bis(4-hydroxy-3-tert-butylphenyl)butyric acid] glycol ester, 4,4′-butylidenebis(2,6-di-tert-butylphenol), 4,4′-butylidenebis(6-tert-butyl-3-methylphenol), 2,2′-ethylidenebis(4,6-di-tert-butylphenol), 1,1,3-tris(2-methyl-4-hydroxy-5-tert-butyl-phenyl)butane, bis[2-tert-butyl-4-methyl-6-(2-hydroxy-3-tert-butyl-5-methylbenzyl)-phenyl] terephthalate, 1,3,5-tris(2,6-dimethyl-3-hydroxy-4-tert-butylbenzyl) isocyanurate, 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl) isocyanurate, 1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)-2,4,6-trimethylbenzene, 1,3,5-tris[(3,5-di-tert-butyl-4-hydroxyphenyl)-propionyloxyethyl] isocyanurate, tetrakis[methylene-3-(3′,5′-di-tert-butyl-4′-hydroxyphenyl) propionate]methane, 2-tert-butyl-4-methyl-6-(2-acryloyloxy-3-tert-butyl-5-methylbenzyl)phenol, 3,9-bis[2-(3-tert-butyl-4-hydroxy-5-methylhydro-cinnamoyloxy)-1,1-dimethylethyl]-2,4,8,10-tetraoxaspiro[5.5]undecane, and triethylene glycol bis[β-(3-tert-butyl-4-hydroxy-5-methylphenyl)propionate].
[0027] Examples of the sulfur-containing antioxidant include dialkyl thiodipropionates, such as a dilauryl, dimyristyl, myristylstearyl or distearyl ester of thiodipropionic acid; and polyol β-alkylmercaptopropionic acid esters, such as pentaerythritol tetra(β-dodecylmercaptopropionate).
[0028] The amount of these additives to be added is preferably 0.001 to 10 parts by weight, still preferably 0.01 to 5 parts by weight, per 100 parts by weight of the polyester resin (A).
[0029] The polyester resin container of the present invention can have any desired shape and includes bottles, trays, and boxes. The polyester resin container of the invention finds the most application in food packaging. The container is especially suitable as a container of liquid foods including juices, carbonated beverages, teas, seasonings, edible oils, and alcoholic beverages. The container is also applicable to packaging non-foods such as detergents or as an industrial container.
[0030] The polyester resin container of the invention can be filled or stored not only under ambient temperature and atmospheric pressure conditions but under pressure or reduced pressure or at high temperature. The polyester resin container of the invention may be subjected to heat sterilization in a usual manner.
[0031] The polyester resin container of the invention preferably has a weatherability of at least 7,000 hours, still preferably 8,000 hours or longer, in a weathering test hereinafter described. A container with a weatherability shorter than 7,000 hours is liable to break before the expiration date due to the failure to maintain its mechanical strength or to lose its merchantability due to the failure to maintain its color tone. The polyester resin container of the invention is preferably water-white (colorless). Otherwise, the contents might look different from what they naturally are, which can impair the merchantability.
[0032] The present invention will now be illustrated in greater detail with reference to Examples, but it should be understood that the invention is not deemed to be limited thereto. Unless otherwise noted, all the percents are parts by weight.
[0033] The components used in Examples and Comparative Examples are shown below.
1) Polyester resin
Polyethylene terephthalate (TR-8550, available from Teijin Ltd.)
2) Coloring inhibitor
Bis(2,6-di-tert-butyl-4-methylphenyl) pentaerythritol diphosphite
3) Hindered amine light stabilizer (hereinafter abbreviated as HALS)
Tetrakis(1,2,2,6,6-pentamethyl-4-piperidyl) 1,2,3,4-butanetetracarboxylate
4) Ultraviolet absorber
The triazine compounds of formula (I) and comparative compound Nos. 1 to 4 shown below.
EXAMPLES 1 TO 8 AND COMPARATIVE EXAMPLES 1 TO 6
[0042] A hundred parts of the polyester resin, 0.1 parts of the ultraviolet absorber shown in Table 1 below, 0.1 parts of the HALS (in Examples 3 and 8 and Comparative Example 2), and 0.05 parts of the coloring inhibitor were compounded. The resulting compound was blown molded to obtain 700 ml volume bottles. Blow molding was carried out using a direct blow molding machine JEB-7/P50/WS60S supplied by The Japan Steel Works, Ltd. at a cylinder temperature of 280° C., a mold temperature of 15° C., and a cycle time of 13 seconds. The resulting bottles were evaluated for weatherability and colorlessness in accordance with the following test methods. The results obtained are shown in Table 1.
[0000] 1) Weathering test
[0043] Five pieces of 2 cm wide and 4 cm long were cut out of the side wall of the bottle and acceleratedly aged in a sunshine weatherometer. The time required until the haze became 50% was taken as a weatherability.
[0000] 2) Coloring test
[0044] The five cut pieces after being subjected to the weathering test were stacked up, and the color tone of the stack was observed with the naked eye.
TABLE 1 Weath- Wave- er- length* ability UV Absorber (nm) HALS (hr) Coloration Example 1 Compound No. 1 343, 280 no 10500 colorless Example 2 Compound No. 2 343, 292 no 9500 colorless Example 3 Compound No. 2 343, 292 yes 10500 colorless Example 4 Compound No. 3 340, 295 no 9200 colorless Example 5 Compound No. 5 343, 292 no 9500 colorless Example 6 Compound No. 7 343, 280 no 9200 colorless Example 7 Compound No. 9 343, 280 no 9800 colorless Example 8 Compound No. 9 343, 280 yes 10000 colorless Compara. — — no 400 yellow Example 1 Compara. — — yes 1700 yellow Example 2 Compara. Comparative 350, 305 no 8200 colorless Example 3 Compound No. 1 Compara. Comparative 357, 315 no 3200 colorless Example 4 Compound No. 2 Compara. Comparative 343, 280 no 3700 colorless Example 5 Compound No. 3 Compara. Comparative 343, 280 no 3800 colorless Example 6 Compound No. 4 *The absorption maximum wavelengths of the UV absorber
[0045] As is apparent from Table 1, the containers of Examples 1 to 8 containing the specific ultraviolet absorber of the invention are protected from coloration and exhibit superiority to comparative containers in weatherability and are therefore fit for use as containers.
[0046] The containers of Examples 1 to 8 were heat sterilized in a usual manner to be confirmed to have satisfactory heat resistance enough to withstand heat sterilization.
[0047] As described hereinabove, the present invention provides a sanitary polyester resin container exhibiting improved weatherability without causing coloring of polyester resin nor involving bleeding of additives and therefore suitable as a food container for packaging beverages, etc.
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A polyester resin container with improved weatherability as well as colorlessness and heat resistance, made of a polyester resin composition comprising (A) 100 parts by weight of a polyester resin and (B) 0.01 to 10 parts by weight of a triazine ultraviolet absorber represented by formula (I):
wherein R 1 represents a straight-chain or branched alkyl group having 1 to 17 carbon atoms, which may have an alicyclic group at the terminal or in the chain thereof; and R 2 , R 2 ′, R 3 , and R 3 ′ each represent a hydrogen atom or a methyl group.
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FIELD OF THE INVENTION
The invention relates to a resonator and more particularly to a multi-chamber resonator box for a vehicle air intake system, the resonator including serially arranged Helmholtz, expansion chamber, annular, and perforated type resonators.
BACKGROUND OF THE INVENTION
In an internal combustion engine for a vehicle, it is desirable to design an air induction system in which sound energy generation is minimized. Sound energy is generated as fresh air is drawn into the engine. Vibration is caused by the intake air in the air feed line which creates undesirable intake noise. Resonators of various types such as a Helmholtz type, for example, have been employed to reduce engine intake noise. Such resonators typically include a single chamber for dissipating the intake noise.
It would be desirable to produce a multi-chamber air resonator system which militates against the emission of sound energy caused by the intake air and minimizes underhood space requirements while maintaining desired underhood appearance.
SUMMARY OF THE INVENTION
Consistent and consonant with the present invention, a multi-chamber air resonator system, which militates against the emission of sound energy caused by the intake air and minimizes underhood space requirements while maintaining desired underhood appearance, has surprisingly been discovered.
The multi-chamber resonator system comprises:
a duct having an inlet and an outlet;
a main body surrounding at least a portion of the duct;
at least two resonators of a different type disposed in the main body, the at least two resonators in communication with the duct to attenuate noise travelling through the duct.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, as well as other objects, features, and advantages of the present invention will be understood from the detailed description of the preferred embodiments of the present invention with reference to the accompanying drawings, in which:
FIG. 1 is an exploded perspective view of a multi-chamber resonator incorporating the features of the present invention; and
FIG. 2 is a schematic perspective view of the multi-chamber resonator illustrated in FIG. 1 in an assembled state and including an automobile engine air cleaner attached thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, and particularly FIG. 1, there is shown generally at 10 a multi-chamber air resonator system incorporating the features of the invention. The air resonator system 10 includes a tray section 12 , an inner cover section 14 , a cover section 16 , and an outlet section 18 .
The tray section 12 is hollow and generally bell shaped with two open ends. In the embodiment shown, the tray section 12 is formed to include a smaller diameter air inlet 20 , an expanding section 22 , and a larger diameter main body 24 . The air inlet 20 is adapted to draw air from the atmosphere. The expanding section 22 connects the air inlet 20 and the main body 24 . A mounting lug 26 is disposed on the outer wall of the main body 24 for mounting the resonator system 10 as desired.
The inner cover section 14 is adapted to be inserted into the tray section 12 . In the embodiment shown, two types of resonators are included in the inner cover section 14 . A generally cylindrical hollow center tube 28 extends the length of the inner cover section 14 . A nose portion 30 of the tube 28 is adapted to be received in the air inlet 20 of the tray section 12 . An airtight fit is desired between the nose portion 30 of the tube 28 and the air inlet 20 , but is not critical to the operation of the resonator system 10 .
A radially outwardly extending annular plate 32 is disposed on the end of the tube 28 opposite the nose portion 30 . An array of radially outwardly extending hollow cylindrical extensions 34 are disposed on an outer wall of the tube 28 . In the embodiment shown, four extensions 34 are used. Additional or fewer extensions 34 can be used as desired. An array of apertures 36 are formed in the wall of the tube 28 and are aligned with the hollow interior of the extensions 34 .
A plurality of dividing walls 38 are disposed to separate each of the extensions 34 from one another and form a resonator chamber. Each chamber has one of the extensions 34 disposed therein. The walls 38 extend in a longitudinal direction with respect to the tube 28 . In the embodiment shown, the quantity of the walls 38 is equal to the quantity of the extensions 34 . Each of the walls 38 abut the plate 32 . An outer edge 40 of the walls 38 has a shape matching that of the inner surface of the main body 24 and the expanding section 22 . The walls 38 terminate adjacent the nose portion 30 of the tube 28 so as not to interfere with the insertion of the nose portion 30 into the air inlet 20 . The extensions 34 , the apertures 36 , and the walls 38 are arranged and sized as needed to form and tune each of the corresponding resonator chambers to the desired frequency for noise attenuation and/or improved sound quality.
A first annular ring 42 and a second annular ring 44 are disposed on the end of the tube 28 adjacent the nose portion 30 . The rings 42 , 44 cooperate with the walls 38 to form small chambers therebetween. A first annular array of perforations 46 is formed in the outer wall of the tube 28 between the nose portion 30 and the first ring 42 . A second annular array of perforations 48 is formed in the outer wall of the tube 28 between the first ring 42 and the second ring 44 . In the embodiment shown, two rings 42 , 44 and two arrays of perforations 46 , 48 are shown. It is understood that more or fewer rings and arrays of perforations could be used without departing from the scope and spirit of the invention.
The cover section 16 includes a generally cylindrical hollow center tube 50 . A bell section 52 is formed around the tube 50 . The bell 52 has an annular lip 54 which is adapted to be joined with the end of the main body 24 of the tray section 12 . One end of the tube 50 of the cover section 16 is adapted to abut the end of the tube 28 of the inner cover section 14 . Although an air tight fit is desired between the tube 50 of the cover section 16 and the tube 28 of the inner cover section 14 , it is not critical to the operation of the resonator system 10 . An outlet tube 56 is formed at the end of the cover section 16 opposite the end of the tube 50 of the cover section 16 which abuts the tube 28 of the inner cover section 14 . The tube 50 and the bell 52 of the cover section 16 cooperate to form a resonator volume, which in the embodiment shown has an annular entry for the noise.
The outlet section 18 is a hollow conduit having an inlet end 58 and an outlet end 60 . The inlet end 58 is adapted to receive the outlet tube 56 of the cover section 16 . Although an air tight fit is desired between the inlet end 58 of the outlet section 18 and the outlet tube 56 of the cover section 16 , it is not critical to the operation of the resonator system 10 . The outlet end 60 is adapted to be connected to an engine mounted air cleaner 62 , as illustrated in FIG. 2 . FIG. 2 shows the resonator system 10 in an assembled condition.
In its assembled condition, the air inlet 20 , the tube 28 , the tube 50 , and the outlet section 18 cooperate to form a conduit for air to travel through. Additionally, upon assembly, a series of resonators are formed within the resonator system 10 .
In the embodiment shown, the first annular ring 42 cooperates with the inner surface of the expanding section 22 , and the outer wall of the tube 28 to form a first chamber therebetween. The first chamber communicates with the hollow portion of the tube 28 through the first perforations 46 , thereby forming a first high frequency resonator section 66 . Similarly, the second annular ring 44 cooperates with the first annular ring 42 , the expanding section 22 , and the outer wall of the tube 28 to form a second chamber therebetween. The second chamber communicates with the hollow portion of the tube 28 through the second perforations 48 , thereby forming a second high frequency resonator section 68 . Although two high frequency resonator sections are illustrated, fewer or more high frequency resonator sections may be used without departing from the scope and spirit of the invention.
Four Helmholtz type resonators are formed in the embodiment shown in the drawings. The plate 32 cooperates with two of the walls 38 , the inner surface of the main body 24 of the tray section 12 , and the outer wall of the tube 28 to form a first Helmholtz resonator chamber. The first Helmholtz resonator chamber communicates with the hollow portion of the tube 28 through one of the apertures 36 , thereby forming a Helmholtz resonator. Three other Helmholtz resonators are similarly formed and cooperate to form a Helmholtz resonator section 70 . Fewer or more Helmholtz resonator sections may be used without departing from the scope and spirit of the invention.
An annular entry type resonator 72 is formed in the cover section 16 for attenuating low frequency noise. The tube 50 extends from the tube 28 and a desired distance into the tube 56 . A clearance exists between the outer wall of the tube 50 and the inner wall of the tube 56 . The annular entry into the chamber of the annular resonator 72 is formed by the clearance between the outer wall of the tube 50 and the inner wall of the tube 56 . The noise enters the chamber of the annular resonator 72 through the clearance.
It is understood that other resonator types could be used such as an expansion chamber type, for example, in place of the above resonator types without departing from the scope and spirit of the invention.
In operation, air enters the resonator system 10 through the air inlet 20 , as indicated by the arrow 64 . The air travels through the conduit formed by the air inlet 20 , the tube 28 , the tube 50 , and the outlet section 18 , through the air cleaner 62 , and into an associated engine 74 . Noise generated by the engine 74 travels outward through the air cleaner 62 , the outlet section 18 , the tube 50 , the tube 28 , and exits through the tube 20 in a direction opposite to the air flow. The first high frequency resonator section 66 , the second high frequency resonator section 68 , the Helmholtz resonator section 70 , and the annular resonator 72 receive the noise pulses at various frequencies and reduce the amplitude of the noise pulses. By reducing the amplitude of the noise pulses, a desired sound quality is reached.
Since each resonator section has a separate chamber volume, individual noise pulse frequencies can be attenuated. Adjustments to or tuning of the individual resonator sections can be made by adjusting the volume of the chambers, the inside diameter of the apertures 36 or perforations 46 , 48 , or the length of the extensions 34 . Tuning can also be accomplished by modifying the conduit formed by the tube 28 , the tube 50 , and the outlet 18 . The location of the walls 38 and the annular rings 42 , 44 can be altered to change the volume of the chambers of the Helmholtz resonators and the high frequency resonators, respectively. By using the multi-chamber design with the different types of resonators, complex tuning can be accomplished to reach desired sound quality. Additionally, the multi-chamber design facilitates an efficient use of space under the hood of an automobile.
From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.
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A multi-chamber resonator box for a vehicle air intake system, wherein the resonator includes a Helmholtz, an expansion chamber, an annular, and a perforated style resonator to militate against the emission of noise energy caused by intake air.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a chain configured by alternately arranging in a shifted position by a half pitch in a chain longitudinal direction first plate rows and second plate rows including a plurality of plates arranged in parallel in a chain width direction, with these rows being bendably coupled to one another, and also relates to a chain guide plate used for the chain.
[0003] 2. Description of the Related Art
[0004] There has been known a chain 500 configured by, as shown in FIG. 10 , alternately arranging in a shifted position by a half pitch in a chain longitudinal direction, first plate rows 510 including a plurality of plates 520 and 530 arranged in parallel in a chain width direction and second plate rows 540 including a plurality of plates 550 arranged in parallel in the chain width direction, with these rows being bendably coupled with one another with coupling pins 560 (see, for example, Japanese Patent Application Laid-Open No. H10-238597 (Patent Literature 1)).
[0005] As a guide method for the chain 500 , various methods are known. As one of the methods, there is known a method of setting an outer side guide on the outer side of a chain traveling track and bringing rear surfaces (end faces on a chain bending outer circumferential side) of the plates 520 , 530 , and 550 into slide contact with a shoe surface of the outer side guide. However, to set the outer side guide, it is necessary to secure an attachment space for the outer side guide on the outer side of the chain traveling track. Therefore, it is sometimes difficult to use the outer side guide depending on an environment of use of the chain 500 .
[0006] As another guide method for the chain 500 , it is also known to set an idler sprocket halfway in the chain traveling track. However, it is sometimes difficult to use the idler sprocket in terms of a setting space and costs because, for example, it is necessary to set a sprocket shaft and a bearing mechanism to set the idler sprocket.
[0007] Therefore, as a method of solving the problems of the setting space and the costs in using the outer side guide and the idler sprocket explained above, there is known a method of, as shown in FIG. 11 , setting an inner side guide G on the inner side of the chain traveling track, bringing guide slide contact sections 524 formed on a chain bending inner circumferential side of guide plates 520 into slide contact with a shoe surface G 1 of the inner side guide G, and guiding the chain 500 .
[0008] However, when the chain 500 is guided using the inner side guide G, in the conventional chain 500 , as shown in FIG. 11 , spaces D are formed among the guide slide contact sections 524 of the guide plates 520 . Therefore, during chain traveling, the plurality of guide slide contact sections 524 intermittently collide with the shoe surface G 1 of the inner side guide G. Noise occurs because of the intermittent collision.
SUMMARY OF THE INVENTION
[0009] The present invention has been devised to solve the problems and it is an object of the present invention to provide a chain and a chain guide plate that suppress occurrence of noise during chain traveling while attaining a reduction in costs and also attaining space saving.
[0010] According to an aspect of the present invention, there is provided a chain configured by alternately arranging in a shifted position by a half pitch in a chain longitudinal direction first plate rows and second plate rows including a plurality of plates arranged in parallel in a chain width direction, with these rows being bendably coupled to one another, wherein each of the first plate rows includes a guide plate including a pair of pin holes formed side by side in the chain longitudinal direction and a guide slide contact section for coming into slide contact with an inner side guide arranged on a chain bending inner circumferential side, the guide slide contact section extends in the chain longitudinal direction to be asymmetrical relative to an imaginary center line extending in a chain height direction through a center of the pair of pin holes, and during guiding by the inner side guide, lines drawn by the guide slide contact sections of a plurality of the guide plates are continuous in the chain longitudinal direction when viewed in the chain width direction. Consequently, the problems are solved.
[0011] According to another aspect of the present invention, there is provided a chain guide plate including a guide slide contact section for coming into slide contact with an inner side guide arranged on a chain bending inner circumferential side. The guide plate includes a pair of pin holes formed side by side in a chain longitudinal direction and the guide slide contact section. The guide slide contact section extends in the chain longitudinal direction to be asymmetrical relative to an imaginary center line extending in a chain height direction through the center of the pair of pin holes. Consequently, the problems are solved.
[0012] In inventions according to claims 1 and 7 , a guide slide contact section of a guide plate is formed to extend in a chain longitudinal direction to be asymmetrical relative to an imaginary center line. During guiding by an inner side guide, lines drawn by guide slide contact sections of a plurality of guide plates are made continuous in a chain longitudinal direction. Therefore, it is possible to suppress occurrence of noise due to intermittent collision of the plurality of guide plates with the inner side guide while avoiding an increase in the number of guide plates and complication of a chain structure.
[0013] In an invention according to claim 2 , each of the first plate rows includes two guide plates arranged in a state in which directions of the guide plates in the chain longitudinal direction are reversed each other. Therefore, it is possible to make, using the guide plates having the same shape, the lines drawn by the guide slide contact sections of the plurality of guide plates continuous in the chain longitudinal direction.
[0014] In an invention according to claim 3 , the guide plates are arranged on both outer sides, in the chain width direction, of each of the first plate rows. Consequently, it is possible to improve contact balance between the guide plates and the inner side guide. Further, it is possible to cause the guide plates to play a function of preventing disengagement of the chain and a sprocket.
[0015] In an invention according to claim 4 , the guide slide contact section includes a plurality of curved concave surface sections having different curvature radiuses. Therefore, when a plurality of inner side guides having different curvature radiuses are used, it is possible to satisfactorily maintain a contact state of the inner side guides and the guide plate.
[0016] In an invention according to claim 5 , a curvature center of a curved concave surface section formed in a position crossing the imaginary center line is located on the imaginary center line. Therefore, it is possible to satisfactorily set the entire surface of the curved concave surface section in contact with a curved shoe surface of the inner side guide.
[0017] In an invention according to claim 6 , a curvature radius of a second curved concave surface section arranged adjacent to the curved concave surface section formed in the position crossing the imaginary center line is set larger than a curvature radius of the curved concave surface section. Therefore, it is possible to prevent the second curved concave surface section from hindering slide contact of the curved concave surface and the inner side guide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view showing a chain in a first embodiment;
[0019] FIG. 2 is an explanatory diagram showing a use form of the chain in the first embodiment;
[0020] FIG. 3 is an explanatory diagram showing guide plates in the first embodiment;
[0021] FIG. 4 is an explanatory diagram showing a contact state of the guide plates and an inner side guide in the first embodiment;
[0022] FIG. 5 is a use form diagram showing a chain in a second embodiment;
[0023] FIG. 6 is an explanatory diagram showing guide plates in the second embodiment;
[0024] FIG. 7 is an explanatory diagram showing a contact state of the guide plates and an inner side guide in the second embodiment;
[0025] FIG. 8 is an explanatory diagram showing a first modification of the guide plates in the second embodiment;
[0026] FIG. 9 is an explanatory diagram showing a second modification of the guide plates in the second embodiment;
[0027] FIG. 10 is a perspective view showing a conventional chain; and
[0028] FIG. 11 is an explanatory diagram showing a use form of the conventional chain.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Embodiments
[0029] A chain 100 according to a first embodiment of the present invention is explained below with reference to FIGS. 1 to 4 .
[0030] The chain 100 in the first embodiment is configured as a timing chain incorporated in a timing system for an automobile engine. As shown in FIG. 2 , the chain 100 travels on a predetermined track in a state in which the chain 100 is wound around a plurality of sprockets (not shown in the figure) and a chain bending inner circumferential side is guided by an inner side guide G having a flat shoe surface G 1 . The inner side guide G is configured as a fixed guide fixed to a peripheral section or the like of an engine block or the like or a swinging guide swingably attached to the peripheral section and pressed to the chain 100 side by a tensioner.
[0031] In the chain 100 , as shown in FIG. 1 , a plurality of first plate rows 110 and a plurality of second plate rows 140 are shifted by a half pitch in a chain longitudinal direction, alternately arranged, and bendably coupled.
[0032] As shown in FIG. 1 , the first plate row 110 is configured from a pair of guide plates 120 arranged on both outer sides in a chain width direction and a plurality of first inner plates 130 arranged between the pair of guide plates 120 . The second plate row 140 is configured from a plurality of second inner plates 150 arranged in parallel in the chain width direction.
[0033] Each of the guide plate 120 , the first inner plate 130 , and the second inner plate 150 includes a pair of pin holes formed side by side in the chain longitudinal direction. The plurality of first plate rows 110 and the plurality of second plate rows 140 are bendably coupled by inserting coupling pins 160 into the pin holes of the first inner plates 130 and the second inner plates 150 in a loose fit state and fixing both end sides of the coupling pins 160 to pin holes 121 of the guide plates 120 . Each of the first inner plate 130 and the second inner plate 150 includes a pair of V-shaped link teeth for meshing with a sprocket (not shown in the figure) on a chain bending inner circumferential side.
[0034] A specific form of the guide plate 120 most characterizing the chain 100 in this embodiment is explained below.
[0035] The guide plate 120 includes, as shown in FIG. 3 , a plate base section 122 including a pair of pin holes 121 formed side by side in the chain longitudinal direction and a plate swelling section 123 swelling to the chain longitudinal direction side from one end edge in the chain longitudinal direction of the plate base section 122 . The plate base section 122 is formed in a symmetrical shape with respect to an imaginary center line L extending in a chain height direction through the center of the pair of pin holes 121 .
[0036] On the end face on the chain bending inner circumferential side of the guide plate 120 , as shown in FIG. 3 , a guide slide contact section 124 for coming into slide contact with the inner side guide G is formed. In this embodiment, the guide slide contact section 124 is configured from a flat surface section 124 a and formed over the plate base section 122 and the plate swelling section 123 . The guide slide contact section 124 extends in the chain longitudinal direction to be asymmetrical relative to the imaginary center line L.
[0037] As it is seen from FIGS. 1 and 4 , the pair of guide plates 120 included in each of the first plate rows 110 is arranged in a state in which directions in the chain longitudinal direction of the guide plates 120 (swelling directions of the plate swelling sections 123 ) are reversed each other. Consequently, as shown in FIG. 4 , lines drawn by the guide slide contact sections 124 of the plurality of guide plates 120 during guiding by the inner side guide G are continuous in the chain longitudinal direction when viewed in the chain width direction. Note that, in FIG. 4 , the guide plates 120 located on the paper surface front side are hatched and the guide plates 120 located on the paper surface inner side are not hatched.
[0038] A chain 200 according to a second embodiment of the present invention is explained with reference to FIGS. 5 to 9 . The second embodiment is the same as the first embodiment except a part of the configuration. Therefore, 100 series reference numerals described in the specification and the drawings concerning the first embodiment are replaced with 200 series reference numerals, whereby explanation of the components other than differences is omitted.
[0039] As shown in FIG. 5 , the chain 200 in the second embodiment travels in a state in which the chain 200 is guided by the inner side guide G including the shoe surface G 1 having a curved convex surface shape. Accordingly, a guide slide contact section 224 of a guide plate 220 is configured from a single curved concave surface section 224 b. The curved concave surface section 224 b is formed to be curved at a curvature radius same as the curvature radius of the shoe surface G 1 of the inner side guide G centering on a bending center located on the imaginary center line L.
[0040] The guide plate 220 according to a first modification of the second embodiment is explained with reference to FIG. 8 .
[0041] In the guide plate 220 in the first modification, as shown in FIG. 8 , the guide slide contact section 224 is configured from a first curved concave surface section 224 c and a second curved concave surface section 224 d having different curvature radiuses.
[0042] As shown in FIG. 8 , the first curved concave surface section 224 c is formed in a position crossing the imaginary center line L and formed to be curved at a curvature radius R 1 centering on a bending center C 1 located on the imaginary center line L. The second curved concave surface section 224 d is formed adjacent to the first curved concave surface section 224 c and formed to be curved at a curvature radius R 2 centering on a bending center C 2 located on the opposite side of a forming position of the second curved concave surface section 224 d with respect to the imaginary center line L. The curvature radius R 2 of the second curved concave surface section 224 d is larger than the curvature radius R 1 of the first curved concave surface section 224 c. By forming the first curved concave surface section 224 c and the second curved concave surface section 224 d in this way, it is possible to prevent ups and downs from being formed in the guide slide contact section 224 and smoothly connect the first curved concave surface section 224 c and the second curved concave surface section 224 d.
[0043] The guide plate 220 according to a second modification of the second embodiment is explained with reference to FIG. 9 .
[0044] In the guide plate 220 in the second modification, unlike the first modification, as shown in FIG. 9 , the bending center C 2 of the second curved concave surface section 224 d is located on the imaginary center line L. Consequently, when two inner side guides G having different bending radiuses of the shoe surface G 1 are used, even when the guide plate 220 comes into contact with the inner side guides G centering on any one of the curved concave surface sections 224 c and 224 d , it is possible to maintain a smooth slide contact state of the inner side guides G and the curved concave surface sections 224 c and 224 d.
[0045] Note that, as in the first modification and the second modification of the second embodiment, when a plurality of curved concave surface sections 224 c and 224 d having different curvature radiuses are formed in the guide slide contact section 224 , a slight gap is partially formed between the guide slide contact section 224 and the shoe surface G 1 of the inner side guide G. However, since lubricant is present between the guide slide contact section 224 and the shoe surface G 1 of the inner side guide G, the slight gap does not hinder the smooth slide contact.
[0046] In the embodiments, the chain is explained as the timing chain for the automobile engine. However, the use of the chain of the present invention is not limited to this. The chain may be any chain such as a chain for transmission and a chain for conveyance.
[0047] In the embodiments, the chain of the present invention is explained as a silent chain. However, a specific form of the chain may be any chain formed by alternately arranging in a shifted position by a half pitch in a chain longitudinal direction first plate rows and second plate rows including a plurality of plates arranged in parallel in a chain width direction, with these rows being bendably coupling with one another, and may be, for example, a roller chain and a bush chain.
[0048] In the embodiments, the guide plates are explained as being arranged one each on both the outer sides in the chain width direction of each of the first plate rows. However, specific arrangement, number, and the like of the guide plates may be any arrangement, number, and the like.
[0049] In the embodiments, the example in which the guide slide contact section of the guide plate is configured from only the flat surface section (the first embodiment), the example in which the guide slide contact section is configured from only the single curved concave surface section (the second embodiment), and the example in which the guide slide contact section is configured from the two curved concave surface section having the different curvature radiuses (the first modification and the second modification of the second embodiment) are explained. However, a specific form of the guide slide contact section is not limited to this and may be configured by combining the flat surface section and the curved concave surface section. The numbers of flat surface sections and curved concave surface sections to be combined only have to be arbitrarily determined.
[0050] The configurations of the embodiments and the modifications may be arbitrarily combined to configure a chain.
[0051] The materials of the components of the chain may be any materials such as metal and resin.
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The invention provides a chain and a chain guide plate that suppress occurrence of noise during chain traveling while attaining a reduction in costs and also attaining space saving. A chain includes first plate rows and second late rows. Each of the first plate rows includes a guide plate including a guide slide contact section for coming into slide contact with an inner side guide. The guide slide contact section extends in a chain longitudinal direction to be asymmetrical relative to an imaginary center line. During guiding by the inner side guide, lines drawn by the guide slide contact sections of a plurality of the guide plates are continuous in the chain longitudinal direction.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a table capable of tilting motion, more particularly, to a tilting rotary table device for subjecting a workpiece secured thereon to machining or scribing.
2. Description of the Prior Art
A conventional tilting rotary table device comprises a worm, which is rotatably disposed on a fixed base and provided with a handle at one end thereof, and a sector wheel, which is formed on the bottom frame of a tilting rotary table member and engaged with the worm. Such a device is adapted to set the tilting rotary table member rotatably supported on the fixed base to a desired inclination.
In a tilting rotary table device using such a worm gearing mechanism, however, shifts of the center of gravity of the workpiece secured on the table when the inclination is set cause the meshing part of the worm gearing to receive a part of the diagonal component of the load, thereby causing elastic strain and error in the set position of inclination. The mode of occurrence of error varies not only according to the magnitude of the table load and the inclination, but also according to the variation of cutting force as well as the variation of cutting direction. Furthermore, in cutting operations in which the loading direction is repeatedly reversed or in tilting operations in which the inclination of the table is changed, the change of the center of gravity of the workpiece secured on the table causes error in the inclination of the table corresponding to the backlash between the worm and the worm wheel.
Accordingly, the accuracy of engagement between the worm and the worm wheel of the worm gearing, the decisive factor behind accuracy of inclination of the tilting table, has had to be improved. This has been done through high precision machining and careful examination and selection of materials. Nevertheless, it has become increasingly difficult to attain satisfactory accurate inclination. This is because of the increasingly heavier, thereby larger, tables being used and the increasingly greater work loads. These have made the working surfaces of the worm gearing more susceptible to wear. This wear results in increased backlash in the worm gearing, causing error in the set inclination greater than tolerance.
Mechanical table tilting operations using worm gearing further require increased torque for operating the worm gearing along with increased table loads. Further, when a motor is employed to rotate the worm, the speed of the worm shaft varies, making the smooth control of the table tilting operation difficult.
BRIEF SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved tilting rotary table device. According to the present invention, the direct gear-drive system using worm gearing, employed in conventional tilting rotary table devices, is replaced by a driving system incorporating a hydraulic servocontrol system totally unaffected by the load applied to the tilting rotary table, thereby eliminating the aforementioned disadvantages of conventional tilting rotary table devices. In the tilting rotary table device of the present invention, the tilting rotary table is operated by the driving force of a power cylinder which is an integral component of the hydraulic servomechanism, while the operation of the power cylinder is controlled by a control valve device which is also a component of the servomechanism.
Other objects, features, and advantages of the present invention will become apparent from the following description of two different embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration for facilitating the explanation of the principle of a tilting rotary table device according to the present invention;
FIGS. 2 to 5 illustrate various portions of a first embodiment of the tilting rotary table device according to the present invention, wherein
FIG. 2 is a side elevation of the device incorporating a hydraulic servomechanism disposed on the base,
FIG. 3 is a sectional view showing a tilting-rotary-table clamping device employing a double-piston mechanism and showing a tilting-rotary-table pivoting mechanism,
FIGS. 4 and 5 are sectional views showing in detail the construction of a hydraulic worm shaft clamping device;
FIG. 6 is a schematic view showing a modified disposition of an operating arm and a stylus; and
FIG. 7 is a schematic illustration of a second embodiment of the tilting rotary table device according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, illustrating the skeleton of a first embodiment of the tilting rotary table device according to the present invention, the device generally comprises a base frame section adapted to support a tilting rotary table for tilting rotary motion, a tilting rotary table section, and a hydraulic servomechanism for tilting the tilting rotary table to a desired inclination. In FIG. 1, a tilting rotary table 1 is rotatably supported on bearings mounted on the base frame by means of trunnions 2 formed integrally on both sides of the tilting rotary table at a lower part thereof. A sector worm wheel 4 is fitted loosely on one of the trunnions 2 for rotation thereon. The sector worm wheel 4 is engaged with a worm 5. The worm shaft 6 of the worm 5 is rotatably received in a bearing device mounted on the frame 3 of the tilting rotary table for rotation by means of a manually operated handle 7. This allows, for instance, the sector wheel 4 to be rotated to set the tilting rotary table 1 to a desired inclination by means of a hydraulic servomechanism, described afterward. A table clamping cylinder device 20 is provided for locking the table to the base after the table 1 has been set to the desired inclination. A worm clamping cylinder device 21 is provided for checking the idle rotary movement of the worm shaft 6 during machining operations with the table fixed at an inclination.
Reference numeral 40 designates a hydraulic servomechanism constituting an essential component of the tilting rotary table device of the present invention. The hydraulic servomechanism 40 comprises a power cylinder 41 pivotally attached to the base at the pivotal mounting part 42, a servocontrol valve 50 adapted to supply hydraulic fluid selectively to the right and the left chambers of the power cylinder, and a stylus operating arm 8 connected to a stylus 58 attached to one end of the servocontrol valve in continuous abutment with the stylus. The stylus operating arm 8 and the sector worm wheel 4 are connected together for synchronous rotation. The free end of the stylus operating arm 8 causes minute detecting movement of the stylus in accordance with the rotary operation of the worm shaft 6. The servocontrol valve 50 selectively connects the output passages 53 or 54 thereof communicating with the left chamber or the right chamber, respectively, of the power cylinder to the source 51 of the pressurized hydraulic fluid for selectively supplying hydraulic fluid to the left or the right chamber of the power cylinder.
In FIG. 1, reference numerals 55 and 56 designate pilot check valves of a known type. The connecting circuit 63 of the pilot check valves is a hydraulic safety circuit for prevention of accidental tilting of the tilting rotary table due to an unforeseen drop of the supply pressure of the source 51 of the pressurized hydraulic fluid below a predetermined pressure. As mentioned earlier, the tilting rotary table device of the present invention further comprises two hydraulic clamping systems, namely, the table clamping cylinder device 20 for clamping the tilting rotary table 1 to the base thereof and the worm clamping cylinder device 21 for clamping the worm shaft 6 to the tilting rotary table 1. Pressurized hydraulic fluid is supplied from the same source 51 to those clamping cylinder devices 20 and 21 through a passage 61 arranged on the lefthand side as viewed in FIG. 1, a clamp control valve 24 having an operating handle, the output passage 62 of the clamp control valve 24, and passages 22 and 23, respectively, through the two-position operation of the clamp operating handle 60. The table clamping cylinder device 20 is formed as a double-piston type device capable of gripping the leg member of the table between two pistons to avoid straining the tilting rotary table by single-directional press-clamping action.
The operating mode of the tilting rotary table 1 will now be described in reference to FIG. 1.
1. In setting the tilting rotary table 1 to a predetermined inclination, first the clamp operating handle 60 is operated manually to a position (a). This causes the clamp control valve 24 to block the passage 61 supplying passages 62, 22, and 23 with pressurized hydraulic fluid from the source 51 and to connect the passages 62, 22, and 23 to a draining passage 64, thereby cancelling the table clamping action and the worm shaft clamping action.
2. Next, for example, the worm operating handle 7 is rotated to turn the stylus operating arm 8 minutely in the clockwise direction through the worm 5 and the sector worm wheel 4, thereby tilting the tilting rotary table 1 in a leftward declivity as viewed in FIG. 1. The stylus of the hydraulic servocontrol valve 50 in contact with the free end of the operating arm 8 is therefore shifted from its neutral position (wherein the hydraulic servocontrol valve 50 interrupts the pressurized hydraulic fluid supplying passage) to the left position by the resilient force of a compression spring contained within the hydraulic servocontrol valve 50. This connects the related passages to supply the pressurized hydraulic fluid to the power cylinder 41 through a circuit of the source 51 - the passage 52 - the servocontrol valve 50 - the passage 53 - the pilot check valve 55 - the left chamber of the power cylinder 41. Consequently, the intensive pressure of the hydraulic fluid drives the frame 3 of the tilting rotary table for counterclockwise rotation, namely, for tilting the tilting rotary table 1 in a leftward declivity, through the piston 44, the piston rod 43, and a rotary joint 45. The stylus operating arm 8 is rotated together with the tilting rotary table 1 according to the movement of the tilting rotary table 1, thereby continuously controlled the stylus operating arm 8 to return the servocontrol valve 50 to its neutral position. The supply of the pressurized hydraulic fluid to the power cylinder is therefore interrupted immediately after the supply of the hydraulic fluid to the power cylinder has started. Thus the tilting rotary table tilting operation continues as long as the worm shaft 6 is rotated.
3. After the tilting rotary table 1 has been tilted to the predetermined inclination, the worm shaft rotating operation is stopped. The clamp operating handle 60 is then shifted from position (a) to position (b), thereby shifting the clamp control valve 24 so as to connect the clamping cylinders to the source 51 of the pressurized hydraulic source through the circuit of the source 51 of pressurized hydraulic fluid - the passage 61 - the clamp control valve 24 - the passage 62 - (the passage 22 - table clamping cylinder device 20) - (passage 23 - worm shaft clamping cylinder device 21). Since the tilting rotary table 1 and the worm gearing 4-5 are firmly fixed by the hydraulic clamping system, the workpiece held on the tilting rotary table 1 can be accurately machined without being affected by the variation of the load.
Since the response characteristic of the servomechanism as described above is of a high sensitivity as well as of a high speed, the angle setting accuracy of the tilting rotary table device of the present invention is an angle of one minute or less. This compares with angle setting accuracy of conventional tilting rotary tables of a minimum 10 minutes. Furthermore, the servocontrol valve 50 has a displacement sensing and responding accuracy of a sensitivity of 5/1000 mm, which corresponds to an angle of rotation of tan 0.05/200=0.08 minutes of the stylus operating arm 8, assuming an effective working radius of the stylus operating arm 8 of 200 mm. Such high sensitivity and a high speed response characteristics of the servomechanism make the tilting rotary table device of the present invention applicable to continuous machining with continuously varying inclinations of the tilting rotary table, which has been impossible with conventional tilting rotary table devices.
The operating mode of machining with continuously varying inclinations of the tilting rotary table will now be described.
First, the clamp operating handle 60 is shifted to position (a) to disengage the hydraulic clamping system, as in the first step for setting the tilting rotary table to a fixed inclination. The worm shaft 6 is then rotated at a controlled variable rate, in accordance with a predetermined machining sequential program, by means of a known driving device, for example, a pulse motor, to control the tilting operation of the tilting rotary table. During the controlled tilting operation, the stylus of the servocontrol valve 50 accurately and rapidly detects the movement of the stylus operating arm 8 resulting from the rotation of the worm shaft 6 and causes the power cylinder 41 to provide a force corresponding to the minute angular displacement of the stylus operating arm 8, whereby the tilting rotary table 1 is continuously tilted. If the power cylinder is designed to have a strength sufficient to endure the load working on the power cylinder during machining, the inclination of the tilting rotary table can be secured. If, by any possibility, the inclination of the tilting rotary table should deviate from the set inclination, the servocontrol valve 50 detects the deviation of the inclination, through the movement of the stylus operating arm 8, and responds instantly to correct the inclination, thus maintaining a highly precise inclination setting.
FIG. 2 shows a first embodiment based on the principle as described hereinbefore with reference to FIG. 1.
Referring to FIGS. 2 and 3, base frames 101 and 102 are fixed upright on opposite sides of a base 100 functioning as a pedestal for the tilting rotary table 1. The trunnions 2 and 2' of the tilting rotary table 1 are rotatably supported on rolling bearings 103 and 103' mounted on the upper ends of the base frames 101 and 102. Flanges 105 and 105' formed on the trunnions 2 and 2' at the respective inner ends thereof are bolted to legs 104 and 104' which extend downward from the underside of the tilting rotary table 1. The trunnions 2 and 2' are disposed below the top surface of the tilting rotary table and extend horizontally. The right trunnion 2 on the right side as viewed in FIG. 3 extends longer than the left trunnion 2'. The sector worm wheel 4 and the stylus operating arm 8, each an essential component of the device of the present invention, are loosely rotatably fitted on the right trunnion 2. The sector worm wheel 4 and the stylus operating arm 8 are connected resiliently by means of an extension spring 81 with the stopper 82 of the sector wheel and the stopper 83 of the stylus operating arm 8 in abutment with each other so that the sector worm wheel 4 and the stylus operating arm 8 are rotatable as a single unit (FIG. 2). An inclination scale plate 9 for indicating the approximate inclination of the tilting rotary table is incorporated into the trunnion 2. A flanged sleeve 108 provided with a shoulder 106 and a key way 107 is keyed on the right trunnion 2 on the outside of the bearing 103. The inclination scale plate 9 is bolted to the flange of the flanged sleeve 108. A pair of thrust bearings 109 and combined bearings 110 are fitted on the sleeve portion of the flanged sleeve 108 so as to loosely and rotatably fit the stylus operating arm 8 and the sector wheel 4 on the flanged sleeve 108 at the respective predetermined positions thereon.
The sector worm wheel 4 is engaged with the worm 5. A handle 7 provided with vernier indexing graduations 71 for indicating accurate inclination is fixed to the outer end of the worm shaft 6 (FIGS. 2 and 4). The worm shaft 6 is supported on rolling bearings 73 within a housing 72 fixed on the surface of the scale plate 9.
A hydraulic servocontrol valve unit is disposed on the base 100 near the free end of the stylus operating arm 8. The servocontrol valve 50 of the hydraulic servocontrol unit is fixed on the base frame 111. The servocontrol valve 50 is disposed with the axis of its valve rod perpendicularly intersecting the radius of oscillation of the stylus operating arm 8, so that a stylus 85 attached to the free end of the valve rod is continuously in contact with the free end of the stylus operating arm 8 against the resilient force of a spring to transmit the minute movement of the stylus operating arm 8 to the stylus 85 (FIG. 2).
As described hereinbefore, when the servocontrol valve is in the neutral position, the application of hydraulic pressure to the power cylinder 41 is interrupted. When the servocontrol valve is shifted slightly rightward or leftward, the source of the pressurized hydraulic fluid is connected through a circuit to the power cylinder 41 to supply pressurized hydraulic fluid to the right or left chamber, respectively. The response accuracy of the stylus 85 is in the order of 5/1000 mm. Accordingly, the maximum stroke of the stylus 85 of around 3 mm is sufficient for accurately controlling the inclination of the tilting rotary table. A limiting pin 86 functioning as a stopper is provided on the base frame 111 near the stylus to limit the movement of the stylus to within a small range to prevent it from being damaged. As a result, when the rotation of the worm shaft 6 moves the stylus operating arm 8, engaged with the sector worm wheel 4, in toward the stylus at a speed faster than the speed of the tilting rotary table, for example, the limiting pin 86 checks the movement of the stylus operating arm 8. The rapid rotation of the worm 4 then stretches the extension spring 81 between the stylus operating arm 8 and the sector worm wheel 4, thus preventing breakage of the servocontrol valve and the worm gearing.
FIG. 6 shows a modified form of the stylus operating mechanism wherein the minute movement of a stylus 85 is caused by the rotary motion of a stylus operating arm 8. In this modified form, the direction of movement of the valve rod of the hydraulic servocontrol valve, namely, the axis of the valve rod, is directed toward the center of rotation of the stylus operating arm 8. A cam surface is formed along the periphery of the stylus operating arm. The cam surface is shaped by successive curved surfaces of different radii of rotation, namely, a circular surface 87 of a fixed smaller radius of rotation, a flat or curved cam surface 86 of a progressively increasing radius of rotation, and a circular surface 88 of a fixed larger radius of rotation. The fixed smaller radius and the fixed larger radius are selectively determined so as to make the difference therebetween, i.e., the effective lifts of the cam surface 86, correspond to the maximum limit of the stroke of the stylus 85. The stylus 85 is positioned at the neutral position thereof when it is in contact with the cam surface 86 at the central part thereof. The circular surface 88 of a fixed larger radius is formed preferably so as to extend leftward, as viewed in FIG. 6, extensively in order to prevent the stylus 85 from being pushed out from the valve body by the spring biasing the stylus 85 when the stylus operating arm 8 engaged with the sector worm wheel 4 in a single unit is rotated at a speed greater than that of the tilting rotary table 1. This design of the mechanism allows the sector worm wheel 4 and the stylus operating arm 8 to be formed as a single component, thereby allowing the omission of the above-mentioned extension spring 81, stoppers 82 and 83, and limiting pin 86.
Returning to FIGS. 2 and 3, trunnions 42 are formed to project horizontally at both sides from the outside surface of the central part of the power cylinder 41 of the hydraulic servocontrol mechanism. Trunnions 42 are supported rotatably on trunnion bearings 46 mounted on the base frame 112, whereby the power cylinder 41 is pivotally supported. A piston rod 43 for driving the tilting rotary table extends from the left end of the power cylinder 41. The left end of the piston rod 43 and the bottom parts of table frames 36 and 37 are joined by means of a rotary joint 45 for smooth tilting motion of the tilting rotary table 1. As shown partially in the central part of FIG. 3, the rotary joint 45 is formed in a rotatable cross head extending between the table frames 36 and 37. A leveling protrusion 91 for bringing the topside surface of the tilting rotary table 1 to a level is formed near the right-hand side (FIG. 2) of the underside of the tilting rotary table 1. An adjustable stopper 92 corresponding to the leveling protrusion 91 is fixed upright on the base 100.
Finally, the operation of the hydraulic clamping system will be described with respect to the function thereof in fixing the tilting rotary table 1 of the device of the present invention.
Reffering to FIG. 2, the rotary type of a clamp control valve assembly (24, 25, 60) for changing-over the clamp actuating circuits is fixed to the base 100. A clamp control valve element 24 fixed with a clamp control valve operating handle 60 is contained within the casing 25 of the clamp control valve. A conduit pipe 62 is the outlet passage of the casing 25 of the clamp control valve and corresponds to the passage 62 of FIG. 1. A pipe joint 57 receives a conduit pipe extending between the servocontrol valve and the power cylinder.
Shown within FIG. 3 is a table clamping cylinder device 20 for clamping the tilting rotary table 1 immovably. The table clamping cylinder device 20 is fixed on the base 100 and comprises two pistons 30 and 31 fitted in the cylinder body. The solid piston rod of the left piston 30 penetrates through and is slidable within a bore formed through the right piston 31 and its piston rod. Pressing surfaces 32 and 33 formed at the ends of the rods of pistons 30 and 31, respectively, are disposed at the right and left sides, respectively, of the table frame 36 extending downward from the underside of the tilting rotary table 1. An opening 34 of a circular arc is formed along the periphery of the table frame 36 for allowing the tilting motion of the tilting rotary table 1 with respect to the piston rod of the piston 30, which is disposed at a fixed position. When pressurized hydraulic fluid is supplied into the intermediate chamber formed between pistons 30 and 31 through an inlet port 35, pistons 30 and 31 are moved leftward and rightward, respectively, whereby the pressing surfaces 32 and 33 strongly clamping the table frame 36 to fix the tilting rotary table 1 relative to the base 100. This clamping action applies pressures of substantially the same magnitude to the right and the left sides of the table frame 36, with respect to the central plane of rotation, instead of applying a single-directional pressure to one side and thus bending the table frame. The table frame 36, hence the tilting rotary table 1, is not therefore subjected to strain, and successful precision machining of the workpiece is attained.
FIG. 4 shows a worm shaft supporting construction in the housing 72. A clamping ring 74 for clamping the worm shaft 6 is provided at the central part of the worm shaft 6.
FIG. 5 is a section taken on line V--V of FIG. 4 as seen in the arrow direction. FIG. 5 shows the worm shaft clamping cylinder device 21 for engaging and disengaging the clamping ring 74. The cylinder body 75 of the worm shaft clamping cylinder device 21 is fixed to the housing 72, and a piston 76 combined with a coil spring 78 for disengaging the clamping ring is fitted in the cylinder body 75. When pressurized hydraulic fluid is supplied into the cylinder device through a port 77, the piston 76 moves against the resilient force of the coil spring 78 to make the clamping ring 74 take a firm hold of the worm shaft 6. When the hydraulic fluid is drained from the cylinder, the piston 76 is returned by the resilient force of the coil spring 78 to disengage the clamping ring 74.
As described hereinbefore, the first embodiment of the present invention completely eliminates the variation of the load on the worm gearing, liable to occur during the tilting operation of conventional tilting rotary table devices, through the use of a hydraulic servomechanism of superior response characteristics and, furthermore, improves the accuracy of engagement and the durability of the worm gearing through allowing the worm shaft to be always rotated by a rotative operation of a constant torque. Furthermore, since the time lag between the rotation of the worm shaft and table tilting motion is extremely small, the tilting rotary table device of the present invention is suitable for continuous machining of a workpiece under varying inclinations of the tilting rotary table. Particularly, since the worm shaft can be rotated and kept at a uniform speed with a small torque, even with under varying loads working on the worm gearing during machining, automatic program control machining can be attained.
Still further, the tilting rotary table device of the present invention is capable of not only firm and reliable clamping of the tilting rotary table merely by operating the clamping control valve of the hydraulic clamping system, but also sequential control of the tilting rotary table clamping operation.
FIG. 7 shows a second embodiment of the tilting rotary table device according to the present invention. A tilting rotary table 201 is inclined at an angle of β to a horizontal plane. A sector worm wheel 202 is fixed to the underside of the tilting rotary table 201 by means of bolts or any other suitable means so that the tilting rotary table 201 and the sector worm wheel 202 form a single unit. The tilting rotary table 201 is supported rotatably by a bearing device disposed in the housing formed on a fixed base 200. In mounting the tilting rotaty table 201 on the base 200, the tilting rotary table 201 may be supported, for example, by trunnions, formed so as to protrude outward from both sides of the tilting rotary table 201 in alignment with the axis of rotation of the tilting rotary table 201, on the bearings of the bearing device. The sector worm wheel 202 is engaged with a worm 203. A worm shaft 204 fixed to the worm 203 is supported on bearings within a bearing housing and is rotatably operable. The worm shaft 204 is fixed with a thrust detecting disk 205 at the middle position thereof and with a handle 207 for tilting operation at the free end thereof. The worm shaft 204 is illustrated in FIG. 7 in the form adapted for manual operation, but can be designed, if necessary, in a form adaptable to a driving system employing a control motor, in which the worm shaft is driven under an electric automatic control system according to a sequential machining program. Limiting surfaces 208 for limiting the axial movement of the detecting disk 205 define the maximum stroke of the valve element of a servocontrol valve and contribute to preventing the breaking of the valve element. Reference numerals 250 and 241 designate a servocontrol valve unit and a hydraulic power cylinder unit belonging to the hydraulic servomechanism and a power cylinder also belonging to the hydraulic servomechanism. A stylus 211 attached to the free end of the valve element of a servocontrol valve 209 is kept in continuous contact with the thrust detecting disk 205 mounted on the worm shaft 204 to follow the axial movement of the thrust detection disk 205 and control the servocontrol valve 209. A pressure source 251 is formed usually in a hydraulic pump unit. Reference numeral 259 designates a reservoir for containing a hydraulic fluid. The hydraulic power cylinder 241 is mounted pivotally at one end on a supporting frame 242 disposed on the fixed base 200. The piston rod 243 of the hydraulically operated piston of the hydraulic power cylinder 241 slidingly reciprocates through an opening formed at the other end of the power cylinder 241. The free end of the reciprocative piston rod 243 is pivotally connected to the tilting rotary table 201 at a lower peripheral part thereof.
The operating mode of the second embodiment will now be described. Assume an initial state where the tilting rotary table 201 is positioned with its topside surface horizontal and is clamped relative to the fixed base 200. One first fixes the desired workpiece on the topside surface of the tilting rotary table, disengages the table clamping mechanism, then operates the worm shaft rotating handle 207 to set the tilting rotary table 201 to the desired angle of inclination of β. When the handle 207 is rotated against the load applied to the tilting rotary table 201, a thrust of a magnitude proportional to the intermeshing pressure between the sector worm wheel and the worm is applied axially to the worm shaft 204, since it is usual that the intermeshing pressure between a worm and a worm wheel produces thrusts axially of the worm and the worm wheel. Accordingly, the thrust detecting disk 205 fixed to the worm shaft 204 is moved in the direction of action of the thrust. The thrust detecting disk 205 actuates the valve element of the servocontrol valve 209 through the stylus 211, which is in continuous contact with the thrust detecting disk. The distance of movement of the thrust detecting disk controls the opening area of the ports of the servocontrol valve 209 to make the power cylinder produce a table driving force of a magnitude and a direction which counteracts the thrust. For example, when rotating the worm shaft 204 to turn the tilting rotary table 201 in a counterclockwise direction, a leftward thrust is applied to the worm shaft 204, therefore, the thrust detecting disk 205 is biased leftward. Accordingly, a slight elastic deformation of the meshing surface of the worm 203 is unavoidable for allowing the axial displacement of the worm shaft 204. It is obvious that such an elastic deformation can be kept below a fixed limit, and the displacement of the disc due to the deformation is less than the maximum stroke of the stylus. The valve element of the servocontrol valve 209 moves leftward, corresponding to the leftward movement of the detecting disk 205, to appropriately control the ports of the servocontrol valve 209. In this case, the right chamber of the power cylinder 241 is connected to the pressure source 251 through the circuit of the pressure source 251 - the passage 252 - the servocontrol valve 209 - the passage 219 - power cylinder 241, whereas the left chamber of the power cylinder 241 is connected to the reservoir 259 through the circuit of the power cylinder 241 - the passage 218 - the servocontrol valve 209 - the return passage 220 - the reservoir 259. Consequently, the tilting rotary table 201 is turned on its trunnions due to a moment of force produced by the driving force of the power cylinder 241 acting in a direction to counteract the thrust working on the worm shaft, thereby relieving the elastic deformation of the meshing surface of the worm. The operating mode as described hereinbefore is continued until the rotative operation of the worm shaft 204 is stopped, wherein at any stop positions of the table the detecting disc and the servocontrolled valve are in their neutral positions respectively. The tilting rotary table is clamped relative to the fixed base 200 after the tilting rotary table has been tilted in the angle of inclination of β.
The second embodiment of the tilting rotary table device according to the present invention is not only capable of allowing light rotative operation of the worm shaft in tilting the tilting rotaty table independently of the load working on the tilting rotary table, but is also capable of keeping the elastic deformation of the tooth surface of a meshing tooth of the worm below a small fixed limit. Therefore, the inclination error resulting from the elastic deformation of the worm can be minimized, thus improving the accuracy of inclination and improving the operation of the tilting rotary table. Furthermore, even if breakage occurs in the hydraulic system, the tilting rotary table will not unduely and suddenly change in inclination, since the tilting rotary table is safely restrained at its position by the engagement of the sector worm wheel with the worm. In such a case, the table's reacting force counteracts on one of either limiting walls disposed opposite to the detecting disk 205 with a small gap.
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A tilting table for machining works is of the worm and worm wheel type incorporating a hydraulic servomechanism. A displacement of a stylus operating lever effected by the drive worm shaft moves the servocontrol valve out of its neutral position, thereby causing a tilting motion of the table in a desired direction via a hydraulic power unit of the mechanism. Due to a linkage connection between the table and the lever, the movement of the table always follows the lever so as to compensate the initial displacement, resulting in light and accurate positioning of the inclined table.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a 371 of WO 97/45449.
FIELD OF THE INVENTION
This invention relates to dendritic cell receptors. In particular, it relates to human DEC-205, to the production and use thereof, and to ligands which bind to it. Human DEC-205 and its ligands are useful in prophylaxis and therapy.
BACKGROUND OF THE INVENTION
Dendritic cells perform important immunoregulatory functions by presenting antigens in the form of peptides bound to cell-surface major histocompatibility complex (MHC) molecules to T cells. Identification of the mechanism by which this antigen presentation function is achieved therefore has important implications in manipulating immune response in prophylaxis and therapy, particularly in humans.
Jiang et al, Nature 375: 151-155 (1995) disclose a murine dendritic cell receptor having a molecular weight of 205 kDa (murine DEC-205). However, they do not disclose a receptor on human dendritic cells.
The applicant has now identified a receptor on human dendritic cells. It is broadly to this receptor (likely to be the human homolog of murine DEC-205) that the present invention is directed.
SUMMARY OF THE INVENTION
The present invention has a number of aspects. In a first aspect, the invention provides isolated human DEC-205 which has an approximate molecular weight of 198-205 kDa and which includes the following amino acid sequences:
(i) TVDCNDNQPGAICYYSGNETEKEVKPVDSVKCPSPVLNTPWIPF QNCCYNFIITKNRHMATTQDEVQSTCEKLHPKSHILSIRDEKE NNFVLEQLLYFNYMASWVMLGITYRNNSL (amino acids at positions 1208-1323 of SEQ ID NO:1) and
(ii) SQHRLFHLHSQKCLGLDITKSVNELRMFSCDSSAML (amino acids at positions 71-106 of SEQ ID NO:1)
or a functionally equivalent fragment thereof.
In a further aspect, the invention provides isolated human DEC-205 which comprises the amino acid sequence shown in FIG. 11 or a functionally equivalent fragment thereof
In a still further aspect, the invention provides isolated mature human DEC-205, which comprises the amino acids 27 to 1722 shown for human DEC-205 in FIG. 11 .
In yet a further aspect, the invention provides an extracellular domain of human DEC-205 or a functionally-equivalent fragment thereof.
In a preferred embodiment, the extracellular domain fragment includes at least a portion of carbohydrate recognition domain (CRD7), spacer, and a portion of carbohydrate recognition domain (CRD8) of human DEC-205 (amino acids 1208 to 1323 of the amino acid sequence of FIG. 11 ).
In a still further aspect, the invention provides a polynucleotide encoding human DEC-205 or its extracellular domain as defined above. This polynucleotide is preferably DNA, more preferably cDNA, but can also be RNA.
In a specific embodiment, the polynucleotide coding for human DEC-205 includes the following nucleotide sequences (SEQ ID NOS:3& 4, respectively, in order of appearance):
(iii) A ACA GTT GAT TGC AAT GAC AAT CAA CCA GGT GCT ATT TGC
TAC TAT TCA GGA AAT GAG ACT GAA AAA GAG GTC AAA CCA GTT
GAC AGT GTT AAA TGT CCA TCT CCT GTT CTA AAT ACT CCG TGG
ATA CCA TTT CAG AAC TGT TGC TAC AAT TTC ATA ATA ACA AAG
AAT AGG CAT ATG GCA ACA ACA CAG GAT GAA GTT CAT ACT AAA
TGC CAG AAA CTG AAT CCA AAA TCA CAT ATT CTG AGT ATT CGA
GAT GAA AAG GAG AAT AAC TTT GTT CTT GAG CAA CTG CTG TAC
TTC AAT TAT ATG GCT TCA TGG GTC ATG TTA GGA ATA ACT TAT
AGA AAT AAX TCT CTT;and
(iv) ATT AAT ATG CTG TGG AAG TGG GTG TCC CAG CAT CGG CTC TTT
CAT TTG CAC TCC CAA AAG TGC CTT GGC CTC GAT ATT ACC AAA
TCG GTA AAT GAG CTG AGA ATG TTC AGC TGT GAC TCC AGT GCC
ATG CTG TGG TGG AAA TGC GAG CAC CA
where X is T or G.
In a further embodiment, the polynucleotide comprises part or all of the nucleotide sequence of FIG. 10 .
In yet a further aspect, the invention provides a vector including a polynucleotide as defined above.
In still a flrter aspect, the invention provides a method of producing human DEC-205, the extracellular domain thereof or a fimctional fragment comprising the steps of:
(a) culturing a host cell which has been transformed or transfected with a vector as defined above to express the encoded human DEC-205, extracelhular domain or fragment; and
(b) recovering the expressed human DEC-205, extracellular domain or fragment.
As yet an additional aspect, the invention provides a ligand that binds to human DEC-205 or its extracellular domain as defined above.
Preferably, the ligand is an antibody or antibody binding fragment or carbohydrate bearing protein.
The antibody or antibody binding fragment can be used in methods for extracting or isolating activated dendritic cells.
In still a further aspect, the invention provides a construct for use in therapy or prophylaxis. The construct will usually be a ligand-antigen construct or a DEC-205-antigen construct although ligand-toxin and DEC-205-toxin constructs are also contemplated. The ligand-antigen construct preferably consists of an antibody or antibody binding fragment which binds to human DEC-205 and a host-protective antigen. The DEC-205-antigen construct preferably consists of at least the extra-cellular domain of human DEC-205 and a host-protective antigen.
In yet further aspects, the invention contemplates methods of therapy or prophylaxis which employ human DEC-205, ligands or constructs containing them.
In yet a further aspect, the invention provides a molecule (hapten) which may be used to generate antibodies for identifying or puring human dendritic cells, which includes a peptide based upon part or all of the sequence of FIG. 11 .
DESCRIPTION OF THE DRAWINGS
While the invention is broadly as defined above, it will be appreciated by those persons skilled in this art that it is not limited thereto and that it includes embodiments more particularly described below. It will also be better understood by reference to the accompanying drawings, in which
FIG. 1 shows the structure of human DEC-205;
FIG. 2 shows the strategy for isolation of human DEC-205 cDNA. A. A schematic presentation of human DEC-205 mRNA with the regions corresponding to DEC-205 domains. The positions of the primers used for the cDNA cloning and analysis are indicated with arrows. The positions of reverse transcriptase-polymerase chain reaction (RT-PCR) fragments 1 to 6 and the clone pBK14-1 are indicated with bars: B. RT-PCR amplification of fragment 1 and 2 from L428 and HEL cell line RNA. L428 and HEL cells were subjected to RT-PCR with two pairs of degenerate primers (DEC-a/-b, and DEC-d/-e), fractionated by electrophoresis through 2% agarose gel, and stained with ethidium bromide. C. RT-PCR and 3′-RACE amplification of fragment 3 and 4 from L428 cells using the primers 028/023 and 029/019, respectively. A cDNA pool of L428 cells was subjected to 3′-RACE and RT-PCR, electrophoresed through 0.8% agarose gel, and stained with ethidium bromide. The numbers on the top correspond to the name of fragment in FIG. 2 A. The positions of DNA molecular size standard are indicates to the right. The estimated molecular size of the RT-PCR products are indicated to the left;
FIG. 3 shows protein similarity between human and mouse DEC-205.
A. The predicted amino acid sequence of human DEC-205 (SEQ ID NO:1) is aligned with the mouse homolog (SEQ ID NO:31). The regions corresponding to DEC-205 domain structure are bracketed. The positions of amino acids are shaded where there are identical or conservatively replaced amino acids between the sequences, and the asterisks indicates conserved cysteines. The diamonds indicates potential N-glycosylation sites conserved between the sequences. The arrow indicates one amino acid deletion in CRD-5 of human DEC-205. The circles indicate conserved potential serine-phosphorylation sites by protein kinase C (open circle) or casein kinase (closed circle). B. The % identity between human and mouse DEC-205 is indicated above each domain (boxed, See FIG. 2A for key);
FIG. 4 shows that human DEC-205 is probably a one-copy gene. Genomic DNA isolated from the peripheral blood of four individuals was digested with the restriction enzymes BgIII, BamHI, HindIII or EcoRI and subjected to Southern blot analysis with the [ 32 P]cysteine-rich domain probe. The final wash was 0.3×SSC at 65° C. The positions of the DNA molecular size standards are indicated to the right;
FIG. 5 shows that human DEC-205 gene localizes on chromosome 2. A somatic cell hybrid panel blot (restriction-digested with PstI) was subjected to Southern blot analysis with the [ 32 P]cysteine-rich domain probe. The final wash was 0.3×SSC at 65° C. The positions of the DNA molecular size standards are indicated to the right. The estimated molecular size of the probe-specific bands are indicated to the left. The asterisk indicates weakly hybridized bands. M, male; F, female;
FIG. 6 shows that human DEC-205 gene maps to chromosome band 2q24. A. A metaphase spread of human chromosomes were subjected to fluorescent in situ hybridization (FISH) with 6.6 kb human DEC-205 cDNA probe. The final wash was 0.1×SSC at 60° C. The FISH image was overlaid with a DAPI-stained chromosome image. The DEC-205 specific signals are indicated by the arrowheads. B. An inverted image of chromosome 2 containing DEC-205-specific signal (see FIG. 6A) is aligned with an ideogram of chromosome 2. The chromosome band corresponding to DEC-205 gene is indicated to the right;
FIG. 7 shows that expression of DEC-205 transcripts within human hematopoetic cell lines. Total RNA prepared from the cell lines were subjected to Northern blot analysis with the [ 32 P]fragment 3 (A and B), or [ 32 P]-actin (C) probes. The final wash was 0.1×SSC at 65° C. The positions of the RNA molecular size standards are indicated to the right. The estimated molecular size of DEC-205 transcripts are indicated to the left. A, 24 h exposure; B, 72 h exposure;
FIG. 8 shows RT-PCR analysis of DEC-205 mRNA in human DC preparations. Specific product is seen using lineage negative; fresh DC (lane 2) and a stronger signal with CMRF44 + low density cultured DC (lane 3). CD8 + T lymphocytes (lane 1) contain no DEC-205 mRNA Ethidium stain.
FIG. 9 represents the result of an ELISA assay showing a monoclonal antibody binding specifically to DEC-205 peptide 1 and not peptide 3. Positive control binding of a hyperimmunized rabbit anti-DEC-205-peptide 1 serum and hyperimmunized rabbit anti-DEC-205-peptide 2 serum are shown;
FIG. 10 gives the DNA sequence (SEQ ID NO:1) for human DEC-205 (coding region only);
FIG. 11 gives the human DEC-205 amino acid sequence (SEQ ID NO:2).
DETAILED DESCRIPTION OF THE INVENTION
A. Human DEC-205
The human DEC-205 of the invention is believed to be the human homolog of murine DEC-205 and has an approximate molecular weight of 198 to 205 kDa. It has the structure shown in FIGS. 1 and 2A. It also has the deduced amino acid sequence shown in FIG. 11 .
Human DEC-205 can usefully be provided in a number of different forms. These include human DEC-205 itself the “mature” form of human DEC-205, and the extracellular receptor domain of human DEC-205.
The “mature” form of human DEC-205 of the invention is human DEC-205 less its native amino-terminus leader or signal sequence, whereas the extracellular receptor domain is human DEC-205 lacking the signal sequence, the transmembrane region and cytoplasmic domain (where present).
The extracellular domain may be identified through commonly recognised criteria of extracellular amino acid sequences. The determination of appropriate criteria is known to those skilled in the at, and has been described, for example by Hopp et al., Proc. Natl. Acad. Sci. USA 78, 3824-3828 (1991); Kyte et al., J. Mol. Biol . 157 105-132 (1982); Emini, J. Virol 55, 836-839 (1985); Jameson et al. CA BIOS 4 181-186 (1988); and Karplus et al. Naturwissenschaften 72, 212-213 (1985). Amino acid domains predicted by these criteria to be surface exposed. are characteristic of extracellular domains.
The amino acid sequences of the predicted regions for human DEC-205 are shown in FIG. 3 A. These include the amino acid sequences for the signal peptide, cysteine-rich domain, fibronectin type II domain, Carbohydrate Recognition Domain-1, (CRD-1), CRD-2, CRD-3, CRD-4, CRD-5. CRD-6, CRD-7, CRD-8, CRD-9, CRD-10, transmembrane domain and cytoplasmic domain.
Human DEC-205 of the invention or its extracellular receptor domain (or parts thereof) may be prepared by methods known in the art. Such methods include protein synthesis from individual amino acids as described by Stuart and Young in “Solid Phase Peptide Synthesis”, Second Edition, Pierce Chemical Company (1984). It is however preferred that human DEC-205 and/or its extracellular receptor domain or parts thereof be prepared by recombinant methods as will be detailed hereinafter.
Example 1 provides further details of human DEC-205.
EXAMPLE 1
Langerhans cells were prepared from human skin. Epidermal cell suspensions were prepared from split thickness normal human breast skin by 30 min dispase (Boehringer-Mannheir, Mannheim, Germany; 0.5% in PBS) treatment at 37° C., followed by 10 min disaggregation in the presence of trypsin (0.25% in PBS), DNase I (5U/ml in PBS) and 5 mM EDTA at room temperature. Langerhans cells were then enriched by Ficoll/Metrizoate gradient separation (d=1.077g/cm 3 ). Final cell suspensions contained 3-15% Langerhans cells as determined by HLA-DR positivity. Total RNA was extracted using Trizol reagent according to the manufacturer's instructions.
Degenerate primers were prepared on an Applied Biosystems DNA Synthesizer with the primer sequences (d) and (e) as set out below (SEQ ID NOS:5 & 6, respectively, in order of appearance):
(d) 5′-GAX ACY GAX GGY TTX TGG AA-3′
(e) 3′-GCY GTX TTZ TCZ AAC CAC AT-5′
wherein X is C or T, Y is A, C, G or T, and Z is G or A.
Single stranded cDNA was prepared using total RNA and reverse transcribed by AMV reverse transcriptase using the 3′ primer (e). Subsequently, the cDNA was amplified using the 5′(d) and 3′(e) primer using PCR amplification according to techniques known in the art.
The amplified products were run on a 2% agarose gel and visualized with ethidium bromide staining.
The DNA was purified and ligated into the T tailed pGEM vector (available from Promega) using standard techniques. The ligation mixture was transformed into competent E. coli JM 109 bacteria (available from Promega) which were grown on agar plates with appropriate antibiotic selection. Two colonies were isolated. DNA was prepared and digested with restriction enzymes. Two inserts of the same size as the PCR product were sequenced by double-stranded DNA sequencing techniques using a Sequence Kit (Sequence 2.0 USB Lab Supply, Pierce). The two clones corresponded to human DEC-205.
The amino acid sequence of human DEC-205 was determined to include the following amino acid sequences (portions of SEQ ID NO:1):
(i) TVDCNDNQPGAICYYSGNETEKEVKPVDSVKCPSPVLNTPWIPF QNCCYNFIITKNRHMATTQDEVQSTCEKLHPKSHILSIRDEKE NNFVLEQLLYFNYMASWVMLGITYRNNSL; and
(ii) SQHRLFHLHSQKCLGLDITKSVNELRMFSCDSSAML.
Determination of these sequences was fundamental to isolating the cDNA for human DEC-205 detailed below.
In the partial sequences given above, individual amino acids are represented by the single letter code as follows:
Three-letter
One-letter
Amino Acid
abbreviation
symbol
Alanine
Ala
A
Arginine
Arg
R
Asparagine
Asn
N
Aspartic acid
Asp
D
Asparagine or
Asx
B
aspartic acid
Cysteine
Cys
C
Glutamine
Gln
Q
Glutamic Acid
Glu
E
Glutamine or
Glx
Z
glutamic acid
Glycine
Gly
G
Histidine
His
H
Isoleucine
Ile
I
Leucine
Leu
L
Lysine
Lys
K
Methionine
Met
M
Phenylalanine
Phe
F
Proline
Pro
P
Serine
Ser
S
Threonine
Thr
T
Tryptophan
Trp
W
Tyrosine
Tyr
Y
Valine
Val
V
Unidentified
X
This code also applies to the predicted full sequence of FIG. 11, deduced from the cDNA encoding human DEC-205 isolated as described below.
B. Polynucleotides Encoding Human DEC-205
In another aspect of this invention, the applicants provide polynucleotides encoding human DEC-205 or its extracellular domain. These polynucleotides may be DNA (isolated from nature, synthesised or cDNA) or RNA. Most often, the polynucleotides will be DNA.
The polynucleotides of the invention specifically include those which include the nucleotides (SEQ ID NOS 3 & 4, respectively, in order of appearance)
(iii) A ACA GTT GAT TGC AAT GAC AAT CAA CCA GGT GCT ATT TGC
TAC TAT TCA GGA AAT GAG ACT GAA AAA GAG GTC AAA CCA GTT
GAC AGT GTT AAA TGT CCA TCT CCT GTT CTA AAT ACT CCG TGG
ATA CCA TTT CAG AAC TGT TGC TAC AAT TTC ATA ATA ACA AAG
AAT AGG CAT ATG GCA ACA ACA CAG GAT GAA GTT CAT ACT AAA
TGC CAG AAA CTG AAT CCA AAA TCA CAT ATT CTG AGT ATT CGA
GAT GAA AAG GAG AAT AAC TTT GTT CTT GAG CAA CTG CTG TAC
TTC AAT TAT ATG GCT TCA TGG GTC ATG TTA GGA ATA ACT TAT
AGA AAT AAX TCT CTT; and
(iv) ATT AAT ATG CTG TGG AAG TGG GTG TCC CAG CAT CGG CTC TTT
CAT TTG CAC TCC CAA AAG TGC CTT GGC CTC GAT ATT ACC AAA
TCG GTA AAT GAG CTG AGA ATG TTC AGC TGT GAC TCC AGT GCC
ATG CTG TGG TGG AAA TGC GAG CAC CA
where X is T or G,
as well as the full nucleotide sequence shown in FIG. 10, but are not limited thereto.
The invention also includes within its scope functional equivalents of these polynucleotides.
This aspect of the invention will now be illustrated by the following Examples.
EXAMPLE 2
EXPERIMENTAL PROCEDURES
Cell culture—The cell lines, HEL, K562, KG-1, THP-1, U937, Mann and Jurkat were obtained from the American Type Culture Collection (Rockville, Md.). L428 cells were provided by V. Diehl (Klinik for lnnere Medizin, Cologne, Germany). HDLM2 and KMH2 cells were obtained from the German Collection of Micro-organisms and Cell Culture (Braunscfweig, Germany). Mono Mac 6 cells (Bufler et al (1995) Eur. J. Immunol . 25, 604-610) were provided by H. Engelmann (Institute for Immunology, Munchen, Germany). All cell lines were maintained in RPMI 1640, 10% fetal calf serum, 100 U/ml penicillin, 100 ug/ml streptomycin except that HDLM2 cells were with 20% fetal calf serum.
Isolation of Leukocytes—Leukocyte populations were isolated using standard laboratory procedures.
Isolation of cDNA encoding for human DEC-205—A set of degenerate oligonucleotide primers were designed based on the published amino acid sequence of mouse DEC-205 (Jiang etal (1995), above) and synthesized in house or by Life Technologies (Auckland, New Zealand) (see FIG. 2 A). These primers were (SEQ ID NOS:7-10 respectively, in order of appearance)
DEC-a (5′-AAYATGCTNTGGAARTGGGT-3′),
DEC-b (5′-TGRTGYTCRCAYTTCCACCA-3′),
DEC-d (5′-GAYACNGAYGGNTTYTGGAA-3′) and
DEC-e (5′-GCNGTYTTRTCRAACCACAT-3′),
where Y=C or T, R=A or G, N=A or C or G or T. Total RNA isolated from L428 or HEL cells was reverse transcribed with avian myeloblastosis virus reverse transcriptase (Promega, Madison, Wis.) at 55° C. for 1 h using the primers DEC-b or DEC-e. PCR was performed using the resultant cDNA and Taq polymerase (Boebrunger Mannheim, Auckland, New Zealand) with the primers DEC-a/-b for DEC-b-primed or DEC-d/-e for DEC-e-primed cDNAs. The PCR conditions used were the initial denaturation at 94° C. for 5 min, 35 cycles of denaturation at 94° C. for 1 min, annealing at 54° C. for 1 min, extension at 72° C. for 1 min, and the final extension at 72° C. for 5 min. The PCR reactions were fractionated with 2% agarose gel in 40 mM Tris-acetate, pH 8.3, 1 mM EDTA (TAE) buffer, and stained with 0.5 ug/ml ethidium bromide. The PCR fragments (fragment 1 and 2, see FIG. 2A and 2B) were cloned into pGEM-T vector (Promega), and sequenced manually using Sequenase DNA sequencing kit (Amersham Life Science, Auckland, New Zealand).
A set of oligonucleotide primers nested within the DNA sequence of fragment 1 and 2 were synthesized (see FIG. 2 A). These primers were (SEQ ID NOS:11-13, respectively, in order of appearance):
023(5′-GCTCTAGAAACATGACCCATGAAGCC-3′ containing a XbaI site),
028(5′-GCTCTAGACATCGGCTCTTTCATTTGT-3′ containing a XbaI site) and.
029(5′-CGGGATTCACAGTTGATTGCAATGACA-3′ containing a EcoRI site)
where incorporated restriction sites are underlined. Two ug of poly(A) RNA from L428 cells was reverse transcribed with 200 U of SuperScriptII (Life Technologies) at 45° C. for 1 h using an oligo d(T) adaptor primer (SEQ ID NO:14)
018(5′-GACTAGTCTGCAGAATTCTTTTTTTTTTTTTTTTT-3′, containing a SpeI, PstI, and EcoRI sites). After heat-inactivation at 70° C. for 15 min, the reaction was incubated with 1 U RNaseH (Life Technologies) at 37° C. for 30 min, heat-inactivated at 70° C. for 15 min, and diluted to 1 ml with 10 mM Tris-HCI, pH 8.0,1 mM EDTA (L428 cDNA pool). In order to isolate the fragment 3 (connecting the fragment 1 and 2) (see FIG. 2 A), PCR was performed with 5 ul of L428 cDNA pool, the primers 028 and 023, and 2.5 U of Expand enzyme mix (Boehringer Mannheim). The PCR conditions were the initial denaturation at 94° C. for 2 min, 10 cycles of 10 cycles of denaturation at 94° C. for 15 sec, annealing at 53° C. for 30 sec, and extension at 68° C. for 4 min, followed by 20 cycles of denaturation at 94° C. for 15 sec. annealing at 53° C. for 30 sec, and extension at 68° C. for 4 min plus additional 20 sec for each cycle, and the final extension at 68° C. for 15 min. 3′-rapid amplification of cDNA ends (3′-RACE) (Frohman et al (1988) Proc. Natl. Acad. Sci. USA 85, 8998-9002) was performed in order to isolate the fragment 4 (connecting the fragment 1 and the 3′-untranslated region of DEC-205) (see FIG. 2 A). PCR was performed with 5 ul of L428 cDNA pool and the primer 029 and an adaptor primer 019 (SEQ ID NO:15) (5′-GACTAGTCTGCAGAATTC, containing a SpeI, PstI and EcoRI site), in the same conditions for the fragment 3. The PCR reactions were fractionated with 0.8% agarose gel in TAE buffer, and stained with ethidium bromide. Both the fragment.3 and 4 were restriction digested with XbaI and EcoRI, respectively, and cloned into pBluescript 11 (Stratagene, La Jolla, Calif.). The representative clones from the fragment 3 (pB38fl) and 4 (pb30-3) were sequenced with a LI-COR automated sequencer (LI-COR, Lincoln, Neb.) using SequiTherm cycle sequencing kit (Epicentre Technologies, Madison, Wis.). If required, these plasmids were subjected to exonucleaseIII-nested deletion using Erase-A-Base system (Promega), and used for sequencing.
An oligo dT-primed L428 cDNA library was prepared using ZAP Express cDNA Gigapack Cloning kit (Stratagene) according to manufacturers instruction. The fragment 3 was labeled with [α-32P]dCTP (NEN) using Multiprime system (Amersham Life Science). The library was screened by plaque hybridization with the [ 32 P]fragment 3 using standard techniques (Sambrook, J., Fritsch, E. F., and Maniatis, T. (1989) Molecular Cloning. A Laboratory Manual , 2Ed., Cold Spring Harbour Laboratory, New York, USA). The specific activity of the probe was 0.8×10 9 cpm/ug DNA and used at 1×10 6 cpml/ml. The final wash was in 0.1×SSC, 0.5% SDS at 65° C. (1×SSC is 0.15 M NaCl, 15 mMM Na-citrate, pH7.0). Positive clones were converted to phagemid pBK-CMV (Stratagene) and sequenced using an automated sequencer.
In order to verify the DNA sequence obtained from the PCR clones, pB38f for fragment 3 and pB30-3 for fragment 4, the fragment 5 was PCR-amplified from a L428 cDNA pool using primers 058 (SEQ ID NO:16) (5′-CGGGATCCCTCTGGCCGCGCACTAATGA-3′ containing a BamHl site) and 050 (SEQ ID NO:17)(5′-CCGCTCGAGCTGTGGATACCAGCACATGCCT-3′ containing a XhoI site) (see FIG. 2 A). The PCR conditions were identical to that for the fragment 3 except using longer extension period (6 min) for cycling. The fragment 5 was sequenced directly using the IRD 40 -labeled custom primers (MWG-Biotech, Ebersberg, Germany) and a LI-COR automated sequencer without cloning. These primers were (SEQ ID NOS:18-25, respectively, in order of appearance): IRD001 (5′-GATGGGAACTCTTATGGGAGACCT-3′ at nucleotide 523-555), IRD002 (5′-TGATGCAGGCTGGCTGCCAAATAA-3′ at nucleotide 1134-1157), IRD003 (5′-AACTGGGCAACTGTTGGTGGAAGA-3′ at nucleotide 1759-1782), IRD004 (5′-ATGGCGAAGAGGCTGGCATTTCTA-3′ at nucleotide 2334-2357), IRD005 (5′-CTCAAGCAAGCGATACCTGTCACT-3′ at nucleotide 2972-2995), IRD006 (5′-TGGGCAACTCGAAGACTGTGTAGT-3′ at nucleotide 3624-3647), IRD007 (5′-CACCAGCACAGCATTCTTGCTTGT-3′ at nucleotide 4168-4191) and IRD008 (5′ATTTGTGAGCAGACTGATGAGGGA-3′ at nucleotide 4797-4820). The sequences of these primers were based on those of pb38fl and pb30-3, and they were positioned as 540-650 bp apart, ensuring the generation of contigs overlapping by at least 100 bp after automated sequencing.
Southern Blot Analysis—Genomic DNA was prepared from peripheral blood of patients with hematological disorders (each patient was karyotyped at Canterbury Health Laboratories, Christchurch, New Zealand). Approximately 8 ug of genomic DNA was digested with BgIII, BamHI, EcoRI, or HindIII, fractionated in 0.8% agarose gel in 89 mM Tris-borate, pH 8.3, 2 mM EDTA, and transferred to Hybond N+ by capillary reaction. A PCR-fragment corresponding to the cyteine-rich domain was PCR-amplified from pBK14-1 using the primers 058 and 059 (SEQ ID NO:26) (5′-CGGAATTCGATCTCATGATAAGGCTGGTCACA-3′ containing a EcoRI site) (see FIG. 2 A). Briefly, PCR was performed with 2 ng of pBK14-1, the primer 058 and 059, and Taq polymerase. The PCR conditions used were the initial denaturation at 94° C. for 2 min, 30 cycles of denaturation at 94° C. for 15 sec, annealing at 55° C. for 15 sec. extension at 72° C. for 30 sec, and the final extension at 72° C. for 5 min. The 450 bp PCR product was labeled with [α- 32 P]dCTP using Multiprime labeling system (Amersham Life Science). The blot was hybridized with the probe using standard technique (Sambrook et al, (1989), above). The specific activity of the probe was 0.8×10 9 cpm/ug DNA and used at 1×10 6 cpm/ml. The final wash was in 0.3×SSC, 0.5% SDS at 65° C., and exposed to X-OMAT AR film (Kodak) with an intensifying screen at −70° C.
A blot containing PstI-digested genomic DNA from a human-rodent somatic hybrid cell panel was obtained from Oncor (Gaithersburg, Md.), and probed with the [ 32 P]cysteine-rich domain fragment as described above.
Fluorescent in Situ Hybridization—Metaphase spreads were prepared from phytohaemagluttinin-stimulated peripheral blood lymphocytes of a 46,XY male donor using standard cytogenetic procedures. The fragment 6 was amplified by recombinant PCR with the fragment 3 and 4 (see FIG. 2 A). PCR was performed with each of the fragment 3 and 4 and the primers 028 and 019 in the same conditions for the fragment 3 except using longer extension period (7 min) for cycling. The fragment 6 was labelled with biotin-14-dCTP using a BioPrime random prime labelling kit (Bethesda Research Laboratories, Gathersberg, Md.), and hybridized to metaphase cells on slides. Conditions for hybridization and immununofluorescent detection were essentially as described (Morris et al, (1993) Human Genetics , 91, 31-36), except that Cot 1 suppression was not required, slides were washed to a stringency of 0.1×SSC, 60° C. after hybridization, and an additional amplification step was needed because of the small size of the probe. For precise chromosome band localization, DAPI and FITC images were captured separately for each metaphase from the fluorescent microscope to computer using a Photometrics KAF1400 CCD camera and IPLAB Spectrum software (Signal Analytics, Va.), and colour-joined using Multiprobe extension software.
Northern Blot Analysis—Approximately 10 ug of total RNA from cultured cells were fractionated in formaldehyde-denatured 1% agarose gel and transferred to Hybond N+ (Amersham) using 3 M NaCl, 8 mM NaOH, 2 mM sarkosyl with Turboblotter (Schleicher & Schuell, Keene, N.H.) for 3 h. The membrane was UV-crosslinked (Stratalinker, Stratagene), and hybridized with [ 32 P]fragment 3 or [ 32 P]human §-actin probe using standard techniques (Sambrook et al (1989), above). The specific activity of the probes were 0.9-1.1×10 9 cpm/ug DNA and used at 0.7-1.1×10 6 cpm/ml. The final wash was in 0.1×SSC, 0.5% SDS at 68° C., and exposed to X-OMAT AR film (Kodak) with intensifying screen at −70° C.
Reverse Transcription-PCR Analysis—Total RNA from isolated leukocytes was incubated with RNase-free DNasel (Life Technologies), and was reverse transcribed using Superscriptll with the oligo dT adaptor primer 018. PCR was performed using a pair of DEC-205 specific primers 060 (SEQ ID NO:27) (GTGGATCCAGTACAAGGGTCA at nucleotide 4655-4686) and 056 (SEQ ID NO:28) (ACCAAATCAGTCCGCCCATGA at nucleotide 5116-5096) with Taq polymerase in the presence of a PCR additive, Q buffer (Qiagen) by touch down PCR (Don, R. H., Cox, P. T., Wainwright, B. J., Baker, K., and Mattick, J. S., (1991) Nucleic Acid Res . 19, 4008). PCR conditions used were the initial denaturation at 92° C. for 2 min, 21 cycles of denaturation at 92 20 C. for 15 sec, annealing at 60° C. minus 0.5° C./cycle for 15 sec, extension at 68° C. for 30 sec, 15 cycles of denaturation at 92° C., annealing at 50° C., extension at 68° C. for 1 min and the final extension at 68° C. for 5 min. Human glycelaldehyde-3-phosphate dehydrogenase (GAPDH) (Tokunaga, K., Nakamura, Y., Sakata, K., Fujimori, K., Ohkubo, M., Sawada, K., and Sakiyama, S. (1987) Cancer Res . 47, 5616-5619) was used for normalization. The primers for GAPDH were 053 (SEQ ID NO:29) (ATGGGGAAGGTGAAGGTCGGA-3′ at nucleotide 61-81), and 055 (SEQ ID NO: 30) (AGGGGCCATCCACAGTCTTCT-3′ at nucleotide 634-614). The PCR reactions were fractionated with 1.5 % agarose gel in TAE buffer, and stained with 0.5 ug/ml ethidium bromide.
Sequence Data Analysis
The National Center of Biotechnology Information (NCBI) Center electronic mail server BLAST was used to search for homologous sequences. Sequence alignments and motif search were done using Bestfit and Motifs programs, respectively, of GCG computer package (Madison, Wis.).
RESULTS
Isolation of CDNA for human DEC-205. —Based on the amino acid sequence of mouse DEC-205, a set of degenerate primers were synthesized and used to perform RT-PCR using the Hodgkin's disease-derived L428 cell line and the myeloid HEL cell lines (FIG. 2 ). The two pair of primers (DEC-d/-e, and DEC-a/-b) gave rise to the specific RT-PCR products, fragment 1 (390 bp) and 2 (150 bp), respectively (FIG. 2 A and 2 B). These specific fragments were cloned and sequenced (data not shown). The deduced amino acid sequences of fragment 1 and 2 were ˜80% identical to that of mouse DEC-205, indicating that these fragments were derived from the cDNA of human DEC-205.
Primers nested within these fragments were synthesized and further RT-PCR and 3′-RACE performed using a L428 cDNA pool reverse transcribed with an oligo dT adapter primer 018. A 3.8 kb RT-PCR product (fragment 3) was obtained using primer 028 and 023 (FIG. 2 A and 2 C). A 3.2 kb 3′-RACE product (fragment 4) was obtained using primer 029 and an adaptor primer 019 (FIG. 2 A and 2 C). The fragment 3 was cloned and several identical clones were identified by restriction enzyme map analysis (data not shown), and one of which, pb38fl, was fully sequenced: The DNA sequence of the fragment 3 (pB38fl) extending from the middle of cysteine-rich domain to the middle of CRD-8 (FIG. 2 A), was 82% identical to the published mouse DEC-205 cDNA sequence. The fragment 4 was cloned and two distinct clones identified by restriction enzyme map analysis. Both clones were partially sequenced and the 3′ end DNA sequence of one clone (eg. pb30-3) was found to contain a poly A tail and with 72% identical to 3′-untranslated region of mouse DEC-205 (data not shown). Therefore, the pb30-3 was sequenced to obtain the DNA sequence of the coding region of DEC-205 plus partial 3′-untranslated region. The resulting DNA sequence for the coding region was ˜80% identical to that of mouse DEC-205 spanning from the middle of CRD-8 to the end of cytoplasmic domain (FIG. 2 A). The DNA sequences obtained from pb38fl and pb30-3 overlapped by 320 bp, covering 95% of human DEC-205 coding region.
In order to complete the 5′ end of the DEC-205 cDNA sequences a L428 cDNA library was screened by plaque hybridization using 32 P-labeled fragment 3 as a probe. A clone (pBKI4-1) was isolated, and the 1.5 kb insert of this clone was sequenced (FIG. 2 A). The sequence was 18 80% identical to the mouse sequence and corresponded to the signal peptide, cysteine-rich domain, fibronectin type II domain, CRD-1 and part of the CRD-2. The pBK14-1 contained 51 bp 5′-untranslated region, and overlapped with fragment 3 by ˜1.2 kb.
To validate the DNA sequence obtained from the PCR clones, a further RT-PCR fragment (fragment 5) amplified with primers 058 (nested in the cysteine-rich domain) and 050 (located ˜130 bp downstream of the stop codon) was prepared (FIG. 2 A). The fragment 5 PCR product was sequenced directly using MRD 41 -labeled custom primers without cloning. A total of 10 point mutations, presumably generated because of the low fidelity of thermostable polymerases were found and corrected in the PCR clone-derived DNA sequence. The complete cDNA sequence for human DEC-205 is 5166 bp in size, and encodes for a predicted 198 kDa type I transmembrane protein with 1722 amino acids before post translational modification.
The deduced amino acid sequence of human DEC-205 showed 77% overall identity with the homologous mouse protein (FIG. 3 A). All the cysteines, and putative N-glycosylation sites in the extracellular domain of mouse DEC-205, were conserved in the human sequence. In the cytoplasmic domain the putative serine phosphorylation sites by protein kinase C or casein kinase, and a tyrosine, which appears to be important for coated pit-mediated internalization (Ezekowitz, R. A. B., Sastry, K., Bailly, P., and Warner, A. (1990) J. Exp. Med . 172, 1785-1794; and Zvaritch, E., Lambeau, G., and Lazdunski, M. (1996) J. Biol. Chem . 271, 250-257), were also conserved. There was one amino acid deletion within the CRD-5 in human DEC-205. All the extracelluar domains, including the cysteine-rich domain, fibronectin type II domain, and CRD1-10 were 74-87% identical between human and mouse sequences (FIG. 3 B), suggesting the importance of these domains for the function of DEC-205. In contrast, the two hydrophobic domains, including the signal peptide and transmembrane domain, showed much lower identity (57% and 52%, respectively (FIG. 3 B)) with the mouse protein, confirming the observation that these hydrohobic domains are more variable, and rapidly evolved structures (Von Heijne, G. (1990) J. Membrane Biol . 115, 195-201).
DEC-205 is a Single Copy Gene with Polymorphism—Peripheral blood-derived genomic DNA from 4 individuals was restriction enzyme-digested with BglII, BamHI, HindIII or EcoRI, and subjected to Southern blot analysis. The cysteine-rich domain of the macrophage mannose receptor (Kim, S. J., Ruiz, N., Bezouska, K, and Drickamer, K. (1992) Genomics 14, 721-727; and Harris, N., Peters, L. L., Eicher, E. M., Rits, M., Raspberry, D., Eichbaum, Q. G., Super, M., and Ezekowitz, R. A. B. (1994) Biochem. Biophys. Res. Com . 198, 682-692) and phospholipase A2 receptor (Ancian, P., Lambeau, G., Mattei, M. G., and Lazdunski, M. (1995) 270, 8963-8970) is encoded by one exon. Therefore, we amplified the cysteine-rich domain of human DEC-205 using primers 058 and 059 as a potential single exon probe (450 bp), and used this to probe the Southern blot in high stringency. A single band appeared in BglII-, BamHI- or HindIII-digested genomic DNA from all individuals, indicating that DEC-205 is a single copy gene (FIG. 4 ). The EcoRI digests, however, produced a single band in two individuals and double bands in another, indicating that the DEC-205 gene is polymorphic. Further Southern blot analysis with larger panel of individuals showed identical results (data not shown). Therefore, DEC-205 is a single copy gene with at least one polymorphic site.
DEC-205 Gene Maps to Chromosome Band 2q24-In order to map the human DEC—205 gene, a somatic cell hybrid panel Southern blot (PstI-digested) was probed with the [ 32 P]cysteine-rich domain as described above (FIG. 5 ). A 3.0 kb band in human genomic DNA was found to hybridize strongly, and the identical band appeared in chromosome 2-containing somatic human-mouse hybrid cells, indicating that DEC-205 gene localizes on chromosome 2. The probe also hybridized weakly with hamster DNA, suggesting the presence of DEC-205 homolog in hamster as well as in the mouse (which also hybridized strongly). The origin of the weakly hybridized bands with apparent polymorphism in the human DNA-containing lanes is not known. The identical band appeared in chromosome 2, and may either be related to an alternative exon structure for this region of DEC-205 or result from weak cross hybridization to another gene on chromosome 2.
Fluorescent in situ hybridization then was used to map the DEC-205 gene in detail (FIGS. 6 A and 6 B). The 6.4 kb recombinant PCR fragment (fragment 6) (FIG. 2A) was prepared from fragment 3 and 4, labeled with biotinylated nucleotides, and used as a probe in a high stringency (FIG. 6 A). Ninety-one (80%) of a combined total 114 metaphase cells analysed from three experiments showed fluorescent signals on one (27) or both (64) chromosomes 2 in the middle of the long arm, specifically in band q24 (FIG. 6 B). High resolution banding analysis provided a more precise location of signals (not shown). No additional site-specific signals were detected on any other chromosome.
DEC-205 Exhibits Multiple Transcripts in Cell Lines—A panel of human cell lines, including myeloid, B lymphoid, T lymphoid and Hodgkin's desease-derived cell lines, were analyzed for the expression of DEC-205 transcripts by Northern blot analysis with the [ 32 P]fragment 3 as a probe (FIG. 7 A and 7 B). Two DEC-205 transcripts, 7.8 and 9.5 kb in size, were detected, and the 7.8 kb transcript was the most abundant. The expression level varied between cell lines, however the myeloid cell line THP-1, the B lymphoid cell line Mann and the Hodgkin's desease cell line KMH2 showed the highest level of expression. Even with longer exposure, DEC-205 transcripts were not detectable in K562, KG-1, Monomac and Jurkat cells, suggesting these cells are DEC-205 negative (FIG. 7 B). Interestingly all Hodgkin's disease-derived cell lines tested express the transcripts. Semiquantitative RT-PCR studies also support these results (data not shown).
C. Recombinant Expression of Human DEC-205
In yet another aspect, the present invention relates to the recombinant expression of human DEC-205 or of its extracellular domain.
The Polynucleotides that encode human DEC-205 or the extracellular domain of the invention may be inserted into known vectors for use in standard recombinant DNA techniques. Standard recombinant DNA techniques are those such as are described in Sambrook et al.; “Molecular Cloning” 2nd Edition Cold Spring Harbour Laboratory Press (1987) and by Ausubel et al., Eds, “Current Protocols in Molecular Biology” Greene Publishing Associates and Wiley-Interscience, New York (1987).
Vectors for expressing proteins in bacteria, especially E. coli , are known. Such vectors include the PATH vectors described by Dieckmann and Tzagoloff in J. Biol. Chem . 260, 1513-1520 (1985). These vectors contain DNA sequences that encode anthranilate synthetase (TrpE) followed by a polylinker at the carboxy terminus. Other expression vector systems are based on beta-galactosidase (pGEX); lambda P maltose binding protein (pMAL); and gluthathione S-transferase (pGST)—see Gene 67, 31 (1988) and Peptide Research 3, 167 (1990).
Vectors useful in yeast and insect cells are available and well known. A suitable example of a yeast vector is the 2μ plasmid.
Suitable vectors for use in mammlian cells are also known. Such vectors include well-known derivatives of SV-40, adenovirus, retrovirus-derived DNA sequences and vectors derived from combination of plasmids and phage DNA.
Further eucaryotic expression vectors are known in the art (e.g. P. J. Southern and P. Berg, J. Mol. Appl. Genet . 1, 327-341 (1982); S. Subramani et al, Mol. Cell. Biol . 1. 854-864 (1981); R. J. Kaufinann and P. A. Sharp, “Amplification And Expression of Sequences Cotransfected with a Modular Dihydrofolate Reductase Complementary DNA Gene,” J. Mol. Biol . 159, 601-621 (1982); R. J. Kaufmann and P. A. Sharp, Mol. Cell. Biol . 159 601-664 (1982); S. I. Scahill et al, “Expression And Characterization Of The Product Of A Human Imnune Interferon DNA Gene In Chinese Hamster Ovary Cells,” Proc. Natl. Acad. Sci. USA 80 4654-4659 (1983); G. Urlaub and L. A. Chasin, Proc. Natl. Acad. Sci. USA 77, 4216-4220, (1980).
The expression vectors useful in the present invention contain at least one expression control sequence that is operatively linked to the DNA sequence or fragment to be expressed. The control sequence is inserted in the vector in order to control and to regulate the expression of the cloned DNA sequence. Examples of useful expression control sequences are the lac system, the trp system, the tac stem, the trc system, major operator and promoter regions of phage lambda, the control region of fd coat protein, the glycolytic promoters of yeast, e.g. the promoter for 3-phosphoglycerate kinase, the promoters of yeast acid phosphatase, e.g. Pho5, the promoters of the yeast alpha-mating factors, and promoters derived from polyoma, adenovirus, retrovirus, and simian virus, e.g. the early and late promoters or SV40, and other sequences known to control the expression of genes of prokaryotic and eucaryotic cells and their viruses or combinations thereof.
Vectors containing the receptor-encoding DNA and control signals are inserted into a host cell for expression of the receptor. Some useful expression host cells include well-known prokaryotic and eucaryotic cells. Some suitable prokaryotic hosts include, for example, E. coli . such as E. coli SG-936 , E. coli HB 101 , E. coli W3110 , E. coli X1776 , E. coli X2282 , E. coli DHT, and E. coli MR01, Pseudomonas, Bacillus, such as Bacillus subtilis , and Streptomyces. Suitable eucaryotic cells include yeast and other fungi, insect, animal cells, such as COS cells and CHO cells, human cells and plant cells in tissue culture.
D. Ligands
The invention also includes ligands that bind to human DEC-205 of the invention.
The ligand will usually be an antibody or an antibody binding fragment raised against human DEC-205 or its extracellular domain, or against fragments thereof.
Such antibodies may be polyclonal but are preferably monoclonal. Monoclonal antibodies may be produced by methods known in the art. These methods include the immunological method described by Kohler and Milstein in Nature 256, 495-497 (1975) and Campbell in “Monoclonal Antibody Technology, the Production and Characterization of Rodent and Human Hybridomas” in Burdon et al. Eds, Laboratory Techniques in Biochemistry and Molecular Biology, Volume 13, Elsevier Science Publishers, Amsterdam (1985); as well as by the recombinant DNA method described by Huse et al. in Science 246 1275-1281 (1989).
In yet another form, the ligand may also be a non-protein, probably carbohydrate containing, molecule that acts as a ligand when it binds to, or otherwise comes into contact with, human DEC-205.
In addition, ligands may be of two fimctional types. The first functional type of ligand is a molecule which binds to human DEC-205 and stimulates it in performing its normal function (a “stimulant ligand”). The second functional type of ligand is a molecule which binds to human DEC-205 and inhibits or prevents it performing its normal function (an “antagonistic ligand”).
Both types of ligand will find application in either therapeutic or prophylactic treatments as described below.
Example 3 describes the production of anti-DEC-205 antibodies.
EXAMPLE 3
Production of Anti-DEC-205 Antibodies
A BALB/c mouse was immunized ip/sc with L428 cells and boosted SC with two peptides derived from the DEC-205 cDNA sequence. DEC-205 peptide 1 ATTQDEVHTKC [amino acids at positions 267-277 of SEQ ID NO:1] and DEC-205-peptide 2 TEKEVKPVDSVKC [amino acids at positions 1227-1239 of SEQ ID NO:1] were synthesized by Chiron Mimotopes Pty Ltd (Clayton, Victoria, Australia). After a third immunization with the two DEC-205 peptides sc/ip/IV the mouse was sacrificed and a spleen cell suspension prepared. The spleen cells were fused with the NS-1 myeloma cell line using standard techniques (Hock et al, Immunology 1994;83:573). A hybridoma was subsequently isolated, 2F5, which produced monoclonal antibody binding to the DEC-205-peptide 1 but not the DEC-205-peptide 2 or a third control DEC-205-peptide 3 (KCLGLDITKSVNELR) [amino acids at positions 82-96 of SEQ ID NO:1]. This is shown by FIG. 9 .
E. Constructs
The invention also provides constructs. The constructs will generally include antigens against which an immune response is desired but can also include other products to be delivered specifically to dendritic cells. Toxins, such as the ricin A chain are not excluded. The other component of the construct will vary, being either a ligand as described above or at least the extracellular domain of human DEC-205. Both constructs will have the potential to manipulate the immune system of the host.
In the ligand-antigen constructs, ligands which bind to human DEC-205 (usually antibodies, antibody-binding fragments or carbohydrates expressing proteins) can be coupled or otherwise associated with the antigen against which an immune response is desired. An example of such antigens are sugar-coated antigens such as tumour-associated antigens In use, the ligand component binds to human DEC-205 and the dendritic cell is ‘primed’ with the associated antigen. This ‘priming’ action will assist in the induction of an immediate immune response against the antigen.
The ligand-antigen construct can take any appropriate form for administration to the dendritic cells. Such forms may differ depending upon whether the therapeutic protocol involves isolation of the patients dendritic cells (so that the priming action can take place in vitro) or whether the construct is to be administered to a patient in vivo.
The construct can be directly administered to a patient for in vivo treatment. It can also be administered in a form which allows the construct to be expressed within the patient.
One example of such a form for administration to a patient in vivo is a live recombinant viral vaccine. Such a vaccine includes a polynucleotide encoding the DEC-205 ligand (or a portion thereof) and the antigen. The vaccine is administered to the patient and, once within the patient, expresses the encoded ligand and antigen to bind to the patients dendritic cells (via human DEC-205).
A number of such live recombinant viral vaccine systems are known. An example of such a system is the Vaccinia virus system (U.S. Pat. No. 4,603,112; Brochier el al., Nature 354:520 (1991)).
Administration can be via intravenous, intramuscular, subcutaneous, topical, oral, intra nasal, rectal or intracerebroventricular routes, as appropriate.
F. Applications
Human DEC-205, its ligands and the constructs discussed above can be employed therapeutically or prophylactically in accordance with this invention to promote or inhibit any of the known actions of dendritic cells and/or to manipulate the immune system.
Thus, the antagonistic ligands per se have potential application inter alia blocking or inhibiting the immune response during transplantation procedures.
Ligands also have application in delivering other products with which they are associated directly to dendritic cells. This can be for therapeutic purposes (where the delivered product is an immunogenic antigen) as discussed above. It can also be to target a toxin (such as the ricin A-chain specifically to dendritic cells to selectively destroy them as part of an immunosuppressive process.
G. The Use of Human DEC-205 to Detect Dendritic Cells in Cell Suspensions on Tissues and to Purify Dendritic Cells
Monoclonal antibodies or other ligands binding to DEC-205 may be used to identify or isolate DC for scientific study or therapeutic application. For this application, the antibodies or ligands can be used in conjunction with conventional identification/separation systems. An example of such a system is the avidin-biotin immunoaffinity system available from Cell-Pro Inc, Washington, USA (see U.S. Pat. No. 5,215,927, U.S. Pat. No. 5,225,353, U.S. Pat. No. 5,262,334 and U.S. pat. No. 5,240,856).
This system employs directly or indirectly a biotinylated monoclonal antibody directed against a target cell and a column containing immunobilized avidin and can be readily adapted to extract activated human dendritic cells, in this case from human peripheral blood, using the anti-DEC-205 antibody as follows:
1. A sample of human peripheral blood containing the human dendritic cells is mixed with biotinylated anti-DEC-205 antibody and incubated to allow formation of antibody/human DC complexes.
2. Following incubation, the mixture is introduced into a CellPro continuous-flow imnuunoadsorption column filled with avidin-coated beads, the strong affinity between biotin and avidin causing the biotin-coated antibodies (together with the human DC to which they have bound) to adhere to the avidin-coated beads.
3. After unwanted cells present in the mixture are washed away, captured activated human DC are removed from the column by gentle agitation and are available for use.
Variations on this theme using the anti-DEC-205 antibody as primary antibody (to bind to activated DC) and a biotinylated secondary antibody (to bind to the anti-DEC-205 antibody) can also be employed.
It will be appreciated that before admixture with the anti-DEC-205 antibody in accordance with the above protocol, the human peripheral blood sample should be treated to ensure that the DC the sample contains are activated. This can easily be achieved by, for example, overnight incubation of the sample.
H. Functional Equivalents
The invention includes functional equivalents of human DEC-205, extracellular domains and nucleic acid molecules described above.
Human DEC-205 and its extracellular domain are or include proteins. A protein is considered a functional equivalent of another protein for a specific function if the equivalent protein is immunologically cross-reactive with, and has the same function as, the original protein. The equivalent may, for example, be a fragment of the protein, or a substitution, addition or deletion mutant of the protein.
For example, it is possible to substitute amino acids in a sequence with equivalent amino acids using conventional techniques. Groups of amino acids known normally to be equivalent are:
(a) Ala(A) Ser(S) Thr(T) Pro(P) Gly(G);
(b) Asn(N) Asp(D) Glu(E) Gln(Q);
(c) His(H) Arg(R) Lys(K);
(d) Met(M) Leu(L) Ile(I) Val(V); and
(e) Phe(F) Tyr(Y) Trp(W).
Substitutions, additions and/or deletions in human DEC-205 may be made as long as the resulting equivalent protein is immunologically cross-reactive with, and have the same function as, the native human DEC-205.
The equivalent human DEC-205 will normally have substantially the same amino acid sequence as the native human DEC-205. An amino acid sequence that is substantially the same as another sequence, but that differs from the other sequence by means of one or more substitutions, additions and/or deletions is considered to be an equivalent sequence. Preferably, less than 25%, more preferably less tan 10%, and most preferably less than 5% of the number of amino acid residues in the amino acid sequence of the native human DEC-205 are substituted for, added to, or deleted from.
Equivalent nucleic acid molecules include nucleic acid sequences that encode proteins equivalent to human DEC-205 as defined above. Equivalent nucleic acid molecules also include nucleic acid sequences that, due to the degeneracy of the nucleic acid code, differ from native nucleic acid sequences in ways that do not affect the corresponding amino acid sequences.
Those persons skilled in the art will of course appreciate that the above description is provided by way of example only and that the invention is limited only by the lawful scope of the appended claims.
31
1
1722
PRT
Homo sapiens
1
Met Arg Thr Gly Trp Ala His Pro Ser Pro Pro Gly Gly Ala Pro His
1 5 10 15
Ala Ala Leu Leu Val Leu Arg Ser Arg Gly Ala Leu Trp Pro Arg Thr
20 25 30
Asn Asp Pro Phe Thr Ile Val His Gly Asn Thr Gly Lys Cys Ile Lys
35 40 45
Pro Val Tyr Gly Trp Ile Val Ala Asp Asp Cys Asp Glu Thr Glu Asp
50 55 60
Lys Leu Trp Lys Trp Val Ser Gln His Arg Leu Phe His Leu His Ser
65 70 75 80
Gln Lys Cys Leu Gly Leu Asp Ile Thr Lys Ser Val Asn Glu Leu Arg
85 90 95
Met Phe Ser Cys Asp Ser Ser Ala Met Leu Trp Trp Lys Cys Glu His
100 105 110
His Ser Leu Tyr Gly Ala Ala Arg Tyr Trp Leu Ala Leu Lys Asp Gly
115 120 125
His Gly Thr Ala Ile Ser Asn Ala Ser Asp Val Trp Lys Lys Gly Gly
130 135 140
Ser Glu Glu Ser Leu Cys Asp Gln Pro Tyr His Glu Ile Tyr Thr Arg
145 150 155 160
Asp Gly Asn Ser Tyr Gly Arg Pro Cys Glu Phe Pro Phe Leu Ile Asp
165 170 175
Gly Thr Trp His His Asp Cys Ile Leu Asp Glu Asp His Ser Gly Pro
180 185 190
Trp Cys Ala Thr Thr Leu Asn Tyr Glu Tyr Asp Arg Lys Trp Gly Ile
195 200 205
Cys Leu Lys Pro Glu Asn Gly Cys Glu Asp Asn Trp Glu Lys Asn Glu
210 215 220
Gln Phe Gly Ser Cys Tyr Gln Phe Asn Thr Gln Thr Ala Leu Ser Trp
225 230 235 240
Lys Glu Ala Tyr Val Ser Cys Gln Asn Gln Gly Ala Asp Leu Leu Ser
245 250 255
Ile Asn Ser Ala Ala Glu Leu Thr Tyr Leu Lys Glu Lys Glu Gly Ile
260 265 270
Ala Lys Ile Phe Trp Ile Gly Leu Asn Gln Leu Tyr Ser Ala Arg Gly
275 280 285
Trp Glu Trp Ser Asp His Lys Pro Leu Asn Phe Leu Asn Trp Asp Pro
290 295 300
Asp Arg Pro Ser Ala Pro Thr Ile Gly Gly Ser Ser Cys Ala Arg Met
305 310 315 320
Asp Ala Glu Ser Gly Leu Trp Gln Ser Phe Ser Cys Glu Ala Gln Leu
325 330 335
Pro Tyr Val Cys Arg Lys Pro Leu Asn Asn Thr Val Glu Leu Thr Asp
340 345 350
Val Trp Thr Tyr Ser Asp Thr Arg Cys Asp Ala Gly Trp Leu Pro Asn
355 360 365
Asn Gly Phe Cys Tyr Leu Leu Val Asn Glu Ser Asn Ser Trp Asp Lys
370 375 380
Ala His Ala Lys Cys Lys Ala Phe Ser Ser Asp Leu Ile Ser Ile His
385 390 395 400
Ser Leu Ala Asp Val Glu Val Val Val Thr Lys Leu His Asn Glu Asp
405 410 415
Ile Lys Glu Glu Val Trp Ile Gly Leu Lys Asn Ile Asn Ile Pro Thr
420 425 430
Leu Phe Gln Trp Ser Asp Gly Thr Glu Val Thr Leu Thr Tyr Trp Asp
435 440 445
Glu Asn Glu Pro Asn Val Pro Tyr Asn Lys Thr Pro Asn Cys Val Ser
450 455 460
Tyr Leu Gly Glu Leu Gly Gln Trp Lys Val Gln Ser Cys Glu Glu Lys
465 470 475 480
Leu Lys Tyr Val Cys Lys Arg Lys Gly Glu Lys Leu Asn Asp Ala Ser
485 490 495
Ser Asp Lys Met Cys Pro Pro Asp Glu Gly Trp Lys Arg His Gly Glu
500 505 510
Thr Cys Tyr Lys Ile Tyr Glu Asp Glu Val Pro Phe Gly Thr Asn Cys
515 520 525
Asn Leu Thr Ile Thr Ser Arg Phe Glu Gln Glu Tyr Leu Asn Asp Leu
530 535 540
Met Lys Lys Tyr Asp Lys Ser Leu Arg Lys Tyr Phe Trp Thr Gly Leu
545 550 555 560
Arg Asp Val Asp Ser Cys Gly Glu Tyr Asn Trp Ala Thr Val Gly Gly
565 570 575
Arg Arg Arg Ala Val Thr Phe Ser Asn Trp Asn Phe Leu Glu Pro Ala
580 585 590
Ser Pro Gly Gly Cys Val Ala Met Ser Thr Gly Lys Ser Val Gly Lys
595 600 605
Trp Glu Val Lys Asp Cys Arg Ser Phe Lys Ala Leu Ser Ile Cys Lys
610 615 620
Lys Met Ser Gly Pro Leu Gly Pro Glu Glu Ala Ser Pro Lys Pro Asp
625 630 635 640
Asp Pro Cys Pro Glu Gly Trp Gln Ser Phe Pro Ala Ser Leu Ser Cys
645 650 655
Tyr Lys Val Phe His Ala Glu Arg Ile Val Arg Lys Arg Asn Trp Glu
660 665 670
Glu Ala Glu Arg Phe Cys Gln Ala Leu Gly Ala His Leu Ser Ser Phe
675 680 685
Ser His Val Asp Glu Ile Lys Glu Phe Leu His Phe Leu Thr Asp Gln
690 695 700
Phe Ser Gly Gln His Trp Leu Trp Ile Gly Leu Asn Lys Arg Ser Pro
705 710 715 720
Asp Leu Gln Gly Ser Trp Gln Trp Ser Asp Arg Thr Pro Val Ser Thr
725 730 735
Ile Ile Met Pro Asn Glu Phe Gln Gln Asp Tyr Asp Ile Arg Asp Cys
740 745 750
Ala Ala Val Lys Val Phe His Arg Pro Trp Arg Arg Gly Trp His Phe
755 760 765
Tyr Asp Asp Arg Glu Phe Ile Tyr Leu Arg Pro Phe Ala Cys Asp Thr
770 775 780
Lys Leu Glu Trp Val Cys Gln Ile Pro Lys Gly Arg Thr Pro Lys Thr
785 790 795 800
Pro Asp Trp Tyr Asn Pro Asp Arg Ala Gly Ile His Gly Pro Pro Leu
805 810 815
Ile Ile Glu Gly Ser Glu Tyr Trp Phe Val Ala Asp Leu His Leu Asn
820 825 830
Tyr Glu Glu Ala Val Leu Tyr Cys Ala Ser Asn His Ser Phe Leu Ala
835 840 845
Thr Ile Thr Ser Phe Val Gly Leu Lys Ala Ile Lys Asn Lys Ile Ala
850 855 860
Asn Ile Ser Gly Asp Gly Gln Lys Trp Trp Ile Arg Ile Ser Glu Trp
865 870 875 880
Pro Ile Asp Asp His Phe Thr Tyr Ser Arg Tyr Pro Trp His Arg Phe
885 890 895
Pro Val Thr Phe Gly Glu Glu Cys Leu Tyr Met Ser Ala Lys Thr Trp
900 905 910
Leu Ile Asp Leu Gly Lys Pro Thr Asp Cys Ser Thr Lys Leu Pro Phe
915 920 925
Ile Cys Glu Lys Tyr Asn Val Ser Ser Leu Glu Lys Tyr Ser Pro Asp
930 935 940
Ser Ala Ala Lys Val Gln Cys Ser Glu Gln Trp Ile Pro Phe Gln Asn
945 950 955 960
Lys Cys Phe Leu Lys Ile Lys Pro Val Ser Leu Thr Phe Ser Gln Ala
965 970 975
Ser Asp Thr Cys His Ser Tyr Gly Gly Thr Leu Pro Ser Val Leu Ser
980 985 990
Gln Ile Glu Gln Asp Phe Ile Thr Ser Leu Leu Pro Asp Met Glu Ala
995 1000 1005
Thr Leu Trp Ile Gly Leu Arg Trp Thr Ala Tyr Glu Lys Ile Asn Lys
1010 1015 1020
Trp Thr Asp Asn Arg Glu Leu Thr Tyr Ser Asn Phe His Pro Leu Leu
1025 1030 1035 1040
Val Ser Gly Arg Leu Arg Ile Pro Glu Asn Phe Phe Glu Glu Glu Ser
1045 1050 1055
Arg Tyr His Cys Ala Leu Ile Leu Asn Leu Gln Lys Ser Pro Phe Thr
1060 1065 1070
Gly Thr Trp Asn Phe Thr Ser Cys Ser Glu Arg His Phe Val Ser Leu
1075 1080 1085
Cys Gln Lys Tyr Ser Glu Val Lys Ser Arg Gln Thr Leu Gln Asn Ala
1090 1095 1100
Ser Glu Thr Val Lys Tyr Leu Asn Asn Leu Tyr Lys Ile Ile Pro Lys
1105 1110 1115 1120
Thr Leu Thr Trp His Ser Ala Lys Arg Glu Cys Leu Lys Ser Asn Met
1125 1130 1135
Gln Leu Val Ser Ile Thr Asp Pro Tyr Gln Gln Ala Phe Leu Ser Val
1140 1145 1150
Gln Ala Leu Leu His Asn Ser Ser Leu Trp Ile Gly Leu Phe Ser Gln
1155 1160 1165
Asp Asp Glu Leu Asn Phe Gly Trp Ser Asp Gly Lys Arg Leu His Phe
1170 1175 1180
Ser Arg Trp Ala Glu Thr Asn Gly Gln Leu Glu Asp Cys Val Val Leu
1185 1190 1195 1200
Asp Thr Asp Gly Phe Trp Lys Thr Val Asp Cys Asn Asp Asn Gln Pro
1205 1210 1215
Gly Ala Ile Cys Tyr Tyr Ser Gly Asn Glu Thr Glu Lys Glu Val Lys
1220 1225 1230
Pro Val Asp Ser Val Lys Cys Pro Ser Pro Val Leu Asn Thr Pro Trp
1235 1240 1245
Ile Pro Phe Gln Asn Cys Cys Tyr Asn Phe Ile Ile Thr Lys Asn Arg
1250 1255 1260
His Met Ala Thr Thr Gln Asp Glu Val His Thr Lys Cys Gln Lys Leu
1265 1270 1275 1280
Asn Pro Lys Ser His Ile Leu Ser Ile Arg Asp Glu Lys Glu Asn Asn
1285 1290 1295
Phe Val Leu Glu Gln Leu Leu Tyr Phe Asn Tyr Met Ala Ser Trp Val
1300 1305 1310
Met Leu Gly Ile Thr Tyr Arg Asn Asn Ser Leu Met Trp Phe Asp Lys
1315 1320 1325
Thr Pro Leu Ser Tyr Thr His Trp Arg Ala Gly Arg Pro Thr Ile Lys
1330 1335 1340
Asn Glu Lys Phe Leu Ala Gly Leu Ser Thr Asp Gly Phe Trp Asp Ile
1345 1350 1355 1360
Gln Thr Phe Lys Val Ile Glu Glu Ala Val Tyr Phe His Gln His Ser
1365 1370 1375
Ile Leu Ala Cys Lys Ile Glu Met Val Asp Tyr Lys Glu Glu His Asn
1380 1385 1390
Thr Thr Leu Pro Gln Phe Met Pro Tyr Glu Asp Gly Ile Tyr Ser Val
1395 1400 1405
Ile Gln Lys Lys Val Thr Trp Tyr Glu Ala Leu Asn Met Cys Ser Gln
1410 1415 1420
Ser Gly Gly His Leu Ala Ser Val His Asn Gln Asn Gly Gln Leu Phe
1425 1430 1435 1440
Leu Glu Asp Ile Val Lys Arg Asp Gly Phe Pro Leu Trp Val Gly Leu
1445 1450 1455
Ser Ser His Asp Gly Ser Glu Ser Ser Phe Glu Trp Ser Asp Gly Ser
1460 1465 1470
Thr Phe Asp Tyr Ile Pro Trp Lys Gly Gln Thr Ser Pro Gly Asn Cys
1475 1480 1485
Val Leu Leu Asp Pro Lys Gly Thr Trp Lys His Glu Lys Cys Asn Ser
1490 1495 1500
Val Lys Asp Gly Ala Ile Cys Tyr Lys Pro Thr Lys Ser Lys Lys Leu
1505 1510 1515 1520
Ser Arg Leu Thr Tyr Ser Ser Arg Cys Pro Ala Ala Lys Glu Asn Gly
1525 1530 1535
Ser Arg Trp Ile Gln Tyr Lys Gly His Cys Tyr Lys Ser Asp Gln Ala
1540 1545 1550
Leu His Ser Phe Ser Glu Ala Lys Lys Leu Cys Ser Lys His Asp His
1555 1560 1565
Ser Ala Thr Ile Val Ser Ile Lys Asp Glu Asp Glu Asn Lys Phe Val
1570 1575 1580
Ser Arg Leu Met Arg Glu Asn Asn Asn Ile Thr Met Arg Val Trp Leu
1585 1590 1595 1600
Gly Leu Ser Gln His Ser Val Asp Gln Ser Trp Ser Trp Leu Asp Gly
1605 1610 1615
Ser Glu Val Thr Phe Val Lys Trp Glu Asn Lys Ser Lys Ser Gly Val
1620 1625 1630
Gly Arg Cys Ser Met Leu Ile Ala Ser Asn Glu Thr Trp Lys Lys Val
1635 1640 1645
Glu Cys Glu His Gly Phe Gly Arg Val Val Cys Lys Val Pro Leu Gly
1650 1655 1660
Pro Asp Tyr Thr Ala Ile Ala Ile Ile Val Ala Thr Leu Ser Ile Leu
1665 1670 1675 1680
Val Leu Met Gly Gly Leu Ile Trp Phe Leu Phe Gln Arg His Arg Leu
1685 1690 1695
His Leu Ala Gly Phe Ser Ser Val Arg Tyr Ala Gln Gly Val Asn Glu
1700 1705 1710
Asp Glu Ile Met Leu Pro Ser Phe His Asp
1715 1720
2
5169
DNA
Homo sapiens
CDS
(1)..(5166)
2
atg agg aca ggc tgg gcg cac ccc tcg ccg ccc ggc ggg gct cct cat 48
Met Arg Thr Gly Trp Ala His Pro Ser Pro Pro Gly Gly Ala Pro His
1 5 10 15
gct gct ctt ctg gtt ctt cga tct cgc gga gcc ctc tgg ccg cgc act 96
Ala Ala Leu Leu Val Leu Arg Ser Arg Gly Ala Leu Trp Pro Arg Thr
20 25 30
aat gac ccc ttc acc atc gtc cat gga aat acg ggc aag tgc atc aag 144
Asn Asp Pro Phe Thr Ile Val His Gly Asn Thr Gly Lys Cys Ile Lys
35 40 45
cca gtg tat ggc tgg ata gta gca gac gac tgt gat gaa act gag gac 192
Pro Val Tyr Gly Trp Ile Val Ala Asp Asp Cys Asp Glu Thr Glu Asp
50 55 60
aag tta tgg aag tgg gtg tcc cag cat cgg ctc ttt cat ttg cac tcc 240
Lys Leu Trp Lys Trp Val Ser Gln His Arg Leu Phe His Leu His Ser
65 70 75 80
caa aag tgc ctt ggc ctc gat att acc aaa tcg gta aat gag ctg aga 288
Gln Lys Cys Leu Gly Leu Asp Ile Thr Lys Ser Val Asn Glu Leu Arg
85 90 95
atg ttc agc tgt gac tcc agt gcc atg ctg tgg tgg aaa tgt gag cac 336
Met Phe Ser Cys Asp Ser Ser Ala Met Leu Trp Trp Lys Cys Glu His
100 105 110
cac tct ctg tac gga gct gcc cgg tac tgg ctg gct ctg aag gat gga 384
His Ser Leu Tyr Gly Ala Ala Arg Tyr Trp Leu Ala Leu Lys Asp Gly
115 120 125
cat ggc aca gca atc tca aat gca tct gat gtc tgg aag aaa gga ggc 432
His Gly Thr Ala Ile Ser Asn Ala Ser Asp Val Trp Lys Lys Gly Gly
130 135 140
tca gag gaa agc ctt tgt gac cag cct tat cat gag atc tat acc aga 480
Ser Glu Glu Ser Leu Cys Asp Gln Pro Tyr His Glu Ile Tyr Thr Arg
145 150 155 160
gat ggg aac tct tat ggg aga cct tgt gaa ttt cca ttc tta att gat 528
Asp Gly Asn Ser Tyr Gly Arg Pro Cys Glu Phe Pro Phe Leu Ile Asp
165 170 175
ggg acc tgg cat cat gat tgc att ctt gat gaa gat cat agt ggg cca 576
Gly Thr Trp His His Asp Cys Ile Leu Asp Glu Asp His Ser Gly Pro
180 185 190
tgg tgt gcc acc acc tta aat tat gaa tat gac cga aag tgg ggc atc 624
Trp Cys Ala Thr Thr Leu Asn Tyr Glu Tyr Asp Arg Lys Trp Gly Ile
195 200 205
tgc tta aag cct gaa aac ggt tgt gaa gat aat tgg gaa aag aac gag 672
Cys Leu Lys Pro Glu Asn Gly Cys Glu Asp Asn Trp Glu Lys Asn Glu
210 215 220
cag ttt gga agt tgc tac caa ttt aat act cag acg gct ctt tct tgg 720
Gln Phe Gly Ser Cys Tyr Gln Phe Asn Thr Gln Thr Ala Leu Ser Trp
225 230 235 240
aaa gaa gct tat gtt tca tgt cag aat caa gga gct gat tta ctg agc 768
Lys Glu Ala Tyr Val Ser Cys Gln Asn Gln Gly Ala Asp Leu Leu Ser
245 250 255
atc aac agt gct gct gaa tta act tac ctt aaa gaa aaa gaa ggc att 816
Ile Asn Ser Ala Ala Glu Leu Thr Tyr Leu Lys Glu Lys Glu Gly Ile
260 265 270
gct aag att ttc tgg att ggt tta aat cag cta tac tct gct aga ggc 864
Ala Lys Ile Phe Trp Ile Gly Leu Asn Gln Leu Tyr Ser Ala Arg Gly
275 280 285
tgg gaa tgg tca gac cac aaa cca tta aac ttt ctc aac tgg gat cca 912
Trp Glu Trp Ser Asp His Lys Pro Leu Asn Phe Leu Asn Trp Asp Pro
290 295 300
gac agg ccc agt gca cct act ata ggt ggc tcc agc tgt gca aga atg 960
Asp Arg Pro Ser Ala Pro Thr Ile Gly Gly Ser Ser Cys Ala Arg Met
305 310 315 320
gat gct gag tct ggt ctg tgg cag agc ttt tcc tgt gaa gct caa ctg 1008
Asp Ala Glu Ser Gly Leu Trp Gln Ser Phe Ser Cys Glu Ala Gln Leu
325 330 335
ccc tat gtc tgc agg aaa cca tta aat aat aca gtg gag tta aca gat 1056
Pro Tyr Val Cys Arg Lys Pro Leu Asn Asn Thr Val Glu Leu Thr Asp
340 345 350
gtc tgg aca tac tca gat acc cgc tgt gat gca ggc tgg ctg cca aat 1104
Val Trp Thr Tyr Ser Asp Thr Arg Cys Asp Ala Gly Trp Leu Pro Asn
355 360 365
aat gga ttt tgc tat ctg ctg gta aat gaa agt aat tcc tgg gat aag 1152
Asn Gly Phe Cys Tyr Leu Leu Val Asn Glu Ser Asn Ser Trp Asp Lys
370 375 380
gca cat gcg aaa tgc aaa gcc ttc agt agt gac cta atc agc att cat 1200
Ala His Ala Lys Cys Lys Ala Phe Ser Ser Asp Leu Ile Ser Ile His
385 390 395 400
tct cta gca gat gtg gag gtg gtt gtc aca aaa ctc cat aat gag gat 1248
Ser Leu Ala Asp Val Glu Val Val Val Thr Lys Leu His Asn Glu Asp
405 410 415
atc aaa gaa gaa gtg tgg ata ggc ctt aag aac ata aac ata cca act 1296
Ile Lys Glu Glu Val Trp Ile Gly Leu Lys Asn Ile Asn Ile Pro Thr
420 425 430
tta ttt cag tgg tca gat ggt act gaa gtt act cta aca tat tgg gat 1344
Leu Phe Gln Trp Ser Asp Gly Thr Glu Val Thr Leu Thr Tyr Trp Asp
435 440 445
gag aat gag cca aat gtt ccc tac aat aag acg ccc aac tgt gtt tcc 1392
Glu Asn Glu Pro Asn Val Pro Tyr Asn Lys Thr Pro Asn Cys Val Ser
450 455 460
tac tta gga gag cta ggt cag tgg aaa gtc caa tca tgt gag gag aaa 1440
Tyr Leu Gly Glu Leu Gly Gln Trp Lys Val Gln Ser Cys Glu Glu Lys
465 470 475 480
cta aaa tat gta tgc aag aga aag gga gaa aaa ctg aat gac gca agt 1488
Leu Lys Tyr Val Cys Lys Arg Lys Gly Glu Lys Leu Asn Asp Ala Ser
485 490 495
tct gat aag atg tgt cct cca gat gag ggc tgg aag aga cat gga gaa 1536
Ser Asp Lys Met Cys Pro Pro Asp Glu Gly Trp Lys Arg His Gly Glu
500 505 510
acc tgt tac aag att tat gag gat gag gtc cct ttt gga aca aac tgc 1584
Thr Cys Tyr Lys Ile Tyr Glu Asp Glu Val Pro Phe Gly Thr Asn Cys
515 520 525
aat ctg act atc act agc aga ttt gag caa gaa tac cta aat gat ttg 1632
Asn Leu Thr Ile Thr Ser Arg Phe Glu Gln Glu Tyr Leu Asn Asp Leu
530 535 540
atg aaa aag tat gat aaa tct cta aga aaa tac ttc tgg act ggc ctg 1680
Met Lys Lys Tyr Asp Lys Ser Leu Arg Lys Tyr Phe Trp Thr Gly Leu
545 550 555 560
aga gat gta gat tct tgt gga gag tat aac tgg gca act gtt ggt gga 1728
Arg Asp Val Asp Ser Cys Gly Glu Tyr Asn Trp Ala Thr Val Gly Gly
565 570 575
aga agg cgg gct gta acc ttt tcc aac tgg aat ttt ctt gag cca gct 1776
Arg Arg Arg Ala Val Thr Phe Ser Asn Trp Asn Phe Leu Glu Pro Ala
580 585 590
tcc ccg ggc ggc tgc gtg gct atg tct act gga aag tct gtt gga aag 1824
Ser Pro Gly Gly Cys Val Ala Met Ser Thr Gly Lys Ser Val Gly Lys
595 600 605
tgg gag gtg aag gac tgc aga agc ttc aaa gca ctt tca att tgc aag 1872
Trp Glu Val Lys Asp Cys Arg Ser Phe Lys Ala Leu Ser Ile Cys Lys
610 615 620
aaa atg agt gga ccc ctt ggg cct gaa gaa gca tcc cct aag cct gat 1920
Lys Met Ser Gly Pro Leu Gly Pro Glu Glu Ala Ser Pro Lys Pro Asp
625 630 635 640
gac ccc tgt cct gaa ggc tgg cag agt ttc ccc gca agt ctt tct tgt 1968
Asp Pro Cys Pro Glu Gly Trp Gln Ser Phe Pro Ala Ser Leu Ser Cys
645 650 655
tat aag gta ttc cat gca gaa aga att gta aga aag agg aac tgg gaa 2016
Tyr Lys Val Phe His Ala Glu Arg Ile Val Arg Lys Arg Asn Trp Glu
660 665 670
gaa gct gaa cga ttc tgc caa gcc ctt gga gca cac ctt tct agc ttc 2064
Glu Ala Glu Arg Phe Cys Gln Ala Leu Gly Ala His Leu Ser Ser Phe
675 680 685
agc cat gtg gat gaa ata aag gaa ttt ctt cac ttt tta acg gac cag 2112
Ser His Val Asp Glu Ile Lys Glu Phe Leu His Phe Leu Thr Asp Gln
690 695 700
ttc agt ggc cag cat tgg ctg tgg att ggt ttg aat aaa agg agc cca 2160
Phe Ser Gly Gln His Trp Leu Trp Ile Gly Leu Asn Lys Arg Ser Pro
705 710 715 720
gat tta caa gga tcc tgg caa tgg agt gat cgt aca cca gtg tct act 2208
Asp Leu Gln Gly Ser Trp Gln Trp Ser Asp Arg Thr Pro Val Ser Thr
725 730 735
att atc atg cca aat gag ttt cag cag gat tat gac atc aga gac tgt 2256
Ile Ile Met Pro Asn Glu Phe Gln Gln Asp Tyr Asp Ile Arg Asp Cys
740 745 750
gct gct gtc aag gta ttt cat agg cca tgg cga aga ggc tgg cat ttc 2304
Ala Ala Val Lys Val Phe His Arg Pro Trp Arg Arg Gly Trp His Phe
755 760 765
tat gat gat aga gaa ttt att tat ttg agg cct ttt gct tgt gat aca 2352
Tyr Asp Asp Arg Glu Phe Ile Tyr Leu Arg Pro Phe Ala Cys Asp Thr
770 775 780
aaa ctt gaa tgg gtg tgc caa att cca aaa ggc cgt act cca aaa aca 2400
Lys Leu Glu Trp Val Cys Gln Ile Pro Lys Gly Arg Thr Pro Lys Thr
785 790 795 800
cca gac tgg tac aat cca gac cgt gct gga att cat gga cct cca ctt 2448
Pro Asp Trp Tyr Asn Pro Asp Arg Ala Gly Ile His Gly Pro Pro Leu
805 810 815
ata att gaa gga agt gaa tat tgg ttt gtt gct gat ctt cac cta aac 2496
Ile Ile Glu Gly Ser Glu Tyr Trp Phe Val Ala Asp Leu His Leu Asn
820 825 830
tat gaa gaa gcc gtc ctg tac tgt gcc agc aat cac agc ttt ctt gcg 2544
Tyr Glu Glu Ala Val Leu Tyr Cys Ala Ser Asn His Ser Phe Leu Ala
835 840 845
act ata aca tct ttt gtg gga cta aaa gcc atc aaa aac aaa ata gca 2592
Thr Ile Thr Ser Phe Val Gly Leu Lys Ala Ile Lys Asn Lys Ile Ala
850 855 860
aat ata tct ggt gat gga cag aag tgg tgg ata aga att agc gag tgg 2640
Asn Ile Ser Gly Asp Gly Gln Lys Trp Trp Ile Arg Ile Ser Glu Trp
865 870 875 880
cca ata gat gat cat ttt aca tac tca cga tat cca tgg cac cgc ttt 2688
Pro Ile Asp Asp His Phe Thr Tyr Ser Arg Tyr Pro Trp His Arg Phe
885 890 895
cct gtg aca ttt gga gag gaa tgc ttg tac atg tct gcc aag act tgg 2736
Pro Val Thr Phe Gly Glu Glu Cys Leu Tyr Met Ser Ala Lys Thr Trp
900 905 910
ctt atc gac tta ggt aaa cca aca gac tgt agt acc aag ttg ccc ttc 2784
Leu Ile Asp Leu Gly Lys Pro Thr Asp Cys Ser Thr Lys Leu Pro Phe
915 920 925
atc tgt gaa aaa tat aat gtt tct tcg tta gag aaa tac agc cca gat 2832
Ile Cys Glu Lys Tyr Asn Val Ser Ser Leu Glu Lys Tyr Ser Pro Asp
930 935 940
tct gca gct aaa gtg caa tgt tct gag caa tgg att cct ttt cag aat 2880
Ser Ala Ala Lys Val Gln Cys Ser Glu Gln Trp Ile Pro Phe Gln Asn
945 950 955 960
aag tgt ttt cta aag atc aaa ccc gtg tct ctc aca ttt tct caa gca 2928
Lys Cys Phe Leu Lys Ile Lys Pro Val Ser Leu Thr Phe Ser Gln Ala
965 970 975
agc gat acc tgt cac tcc tat ggt ggc acc ctt cct tca gtg ttg agc 2976
Ser Asp Thr Cys His Ser Tyr Gly Gly Thr Leu Pro Ser Val Leu Ser
980 985 990
cag att gaa caa gac ttt att aca tcc ttg ctt ccg gat atg gaa gct 3024
Gln Ile Glu Gln Asp Phe Ile Thr Ser Leu Leu Pro Asp Met Glu Ala
995 1000 1005
act tta tgg att ggt ttg cgc tgg act gcc tat gaa aag ata aac aaa 3072
Thr Leu Trp Ile Gly Leu Arg Trp Thr Ala Tyr Glu Lys Ile Asn Lys
1010 1015 1020
tgg aca gat aac aga gag ctg acg tac agt aac ttt cac cca tta ttg 3120
Trp Thr Asp Asn Arg Glu Leu Thr Tyr Ser Asn Phe His Pro Leu Leu
1025 1030 1035 1040
gtt agt ggg agg ctg aga ata cca gaa aat ttt ttt gag gaa gag tct 3168
Val Ser Gly Arg Leu Arg Ile Pro Glu Asn Phe Phe Glu Glu Glu Ser
1045 1050 1055
cgc tac cac tgt gcc cta ata ctc aac ctc caa aaa tca ccg ttt act 3216
Arg Tyr His Cys Ala Leu Ile Leu Asn Leu Gln Lys Ser Pro Phe Thr
1060 1065 1070
ggg acg tgg aat ttt aca tcc tgc agt gaa cgc cac ttt gtg tct ctc 3264
Gly Thr Trp Asn Phe Thr Ser Cys Ser Glu Arg His Phe Val Ser Leu
1075 1080 1085
tgt cag aaa tat tca gaa gtt aaa agc aga cag acg ttg cag aat gct 3312
Cys Gln Lys Tyr Ser Glu Val Lys Ser Arg Gln Thr Leu Gln Asn Ala
1090 1095 1100
tca gaa act gta aag tat cta aat aat ctg tac aaa ata atc cca aag 3360
Ser Glu Thr Val Lys Tyr Leu Asn Asn Leu Tyr Lys Ile Ile Pro Lys
1105 1110 1115 1120
act ctg act tgg cac agt gct aaa agg gag tgt ctg aaa agt aac atg 3408
Thr Leu Thr Trp His Ser Ala Lys Arg Glu Cys Leu Lys Ser Asn Met
1125 1130 1135
cag ctg gtg agc atc acg gac cct tac cag cag gca ttc ctc agt gtg 3456
Gln Leu Val Ser Ile Thr Asp Pro Tyr Gln Gln Ala Phe Leu Ser Val
1140 1145 1150
cag gcg ctc ctt cac aac tct tcc tta tgg atc gga ctc ttc agt caa 3504
Gln Ala Leu Leu His Asn Ser Ser Leu Trp Ile Gly Leu Phe Ser Gln
1155 1160 1165
gat gat gaa ctc aac ttt ggt tgg tca gat ggg aaa cgt ctt cat ttt 3552
Asp Asp Glu Leu Asn Phe Gly Trp Ser Asp Gly Lys Arg Leu His Phe
1170 1175 1180
agt cgc tgg gct gaa act aat ggg caa ctc gaa gac tgt gta gta tta 3600
Ser Arg Trp Ala Glu Thr Asn Gly Gln Leu Glu Asp Cys Val Val Leu
1185 1190 1195 1200
gac act gat gga ttc tgg aaa aca gtt gat tgc aat gac aat caa cca 3648
Asp Thr Asp Gly Phe Trp Lys Thr Val Asp Cys Asn Asp Asn Gln Pro
1205 1210 1215
ggt gct att tgc tac tat tca gga aat gag act gaa aaa gag gtc aaa 3696
Gly Ala Ile Cys Tyr Tyr Ser Gly Asn Glu Thr Glu Lys Glu Val Lys
1220 1225 1230
cca gtt gac agt gtt aaa tgt cca tct cct gtt cta aat act ccg tgg 3744
Pro Val Asp Ser Val Lys Cys Pro Ser Pro Val Leu Asn Thr Pro Trp
1235 1240 1245
ata cca ttt cag aac tgt tgc tac aat ttc ata ata aca aag aat agg 3792
Ile Pro Phe Gln Asn Cys Cys Tyr Asn Phe Ile Ile Thr Lys Asn Arg
1250 1255 1260
cat atg gca aca aca cag gat gaa gtt cat act aaa tgc cag aaa ctg 3840
His Met Ala Thr Thr Gln Asp Glu Val His Thr Lys Cys Gln Lys Leu
1265 1270 1275 1280
aat cca aaa tca cat att ctg agt att cga gat gaa aag gag aat aac 3888
Asn Pro Lys Ser His Ile Leu Ser Ile Arg Asp Glu Lys Glu Asn Asn
1285 1290 1295
ttt gtt ctt gag caa ctg ctg tac ttc aat tat atg gct tca tgg gtc 3936
Phe Val Leu Glu Gln Leu Leu Tyr Phe Asn Tyr Met Ala Ser Trp Val
1300 1305 1310
atg tta gga ata act tat aga aat aat tct ctt atg tgg ttt gat aag 3984
Met Leu Gly Ile Thr Tyr Arg Asn Asn Ser Leu Met Trp Phe Asp Lys
1315 1320 1325
acc cca ctg tca tat aca cat tgg aga gca gga aga cca act ata aaa 4032
Thr Pro Leu Ser Tyr Thr His Trp Arg Ala Gly Arg Pro Thr Ile Lys
1330 1335 1340
aat gag aag ttt ttg gct ggt tta agt act gac ggc ttc tgg gat att 4080
Asn Glu Lys Phe Leu Ala Gly Leu Ser Thr Asp Gly Phe Trp Asp Ile
1345 1350 1355 1360
caa acc ttt aaa gtt att gaa gaa gca gtt tat ttt cac cag cac agc 4128
Gln Thr Phe Lys Val Ile Glu Glu Ala Val Tyr Phe His Gln His Ser
1365 1370 1375
att ctt gct tgt aaa att gaa atg gtt gac tac aaa gaa gaa cat aat 4176
Ile Leu Ala Cys Lys Ile Glu Met Val Asp Tyr Lys Glu Glu His Asn
1380 1385 1390
act aca ctg cca cag ttt atg cca tat gaa gat ggt att tac agt gtt 4224
Thr Thr Leu Pro Gln Phe Met Pro Tyr Glu Asp Gly Ile Tyr Ser Val
1395 1400 1405
att caa aaa aag gta aca tgg tat gaa gca tta aac atg tgt tct caa 4272
Ile Gln Lys Lys Val Thr Trp Tyr Glu Ala Leu Asn Met Cys Ser Gln
1410 1415 1420
agt gga ggt cac ttg gca agc gtt cac aac caa aat ggc cag ctc ttt 4320
Ser Gly Gly His Leu Ala Ser Val His Asn Gln Asn Gly Gln Leu Phe
1425 1430 1435 1440
ctg gaa gat att gta aaa cgt gat gga ttt cca cta tgg gtt ggg ctc 4368
Leu Glu Asp Ile Val Lys Arg Asp Gly Phe Pro Leu Trp Val Gly Leu
1445 1450 1455
tca agt cat gat gga agt gaa tca agt ttt gaa tgg tct gat ggt agt 4416
Ser Ser His Asp Gly Ser Glu Ser Ser Phe Glu Trp Ser Asp Gly Ser
1460 1465 1470
aca ttt gac tat atc cca tgg aaa ggc caa aca tct cct gga aat tgt 4464
Thr Phe Asp Tyr Ile Pro Trp Lys Gly Gln Thr Ser Pro Gly Asn Cys
1475 1480 1485
gtt ctc ttg gat cca aaa gga act tgg aaa cat gaa aaa tgc aac tct 4512
Val Leu Leu Asp Pro Lys Gly Thr Trp Lys His Glu Lys Cys Asn Ser
1490 1495 1500
gtt aag gat ggt gct att tgt tat aaa cct aca aaa tct aaa aag ctg 4560
Val Lys Asp Gly Ala Ile Cys Tyr Lys Pro Thr Lys Ser Lys Lys Leu
1505 1510 1515 1520
tcc cgt ctt aca tat tca tca aga tgt cca gca gca aaa gag aat ggg 4608
Ser Arg Leu Thr Tyr Ser Ser Arg Cys Pro Ala Ala Lys Glu Asn Gly
1525 1530 1535
tca cgg tgg atc cag tac aag ggt cac tgt tac aag tct gat cag gca 4656
Ser Arg Trp Ile Gln Tyr Lys Gly His Cys Tyr Lys Ser Asp Gln Ala
1540 1545 1550
ttg cac agt ttt tca gag gcc aaa aaa ttg tgt tca aaa cat gat cac 4704
Leu His Ser Phe Ser Glu Ala Lys Lys Leu Cys Ser Lys His Asp His
1555 1560 1565
tct gca act atc gtt tcc ata aaa gat gaa gat gag aat aaa ttt gtg 4752
Ser Ala Thr Ile Val Ser Ile Lys Asp Glu Asp Glu Asn Lys Phe Val
1570 1575 1580
agc aga ctg atg agg gaa aat aat aac att acc atg aga gtt tgg ctt 4800
Ser Arg Leu Met Arg Glu Asn Asn Asn Ile Thr Met Arg Val Trp Leu
1585 1590 1595 1600
gga tta tct caa cat tct gtt gac cag tct tgg agt tgg tta gat gga 4848
Gly Leu Ser Gln His Ser Val Asp Gln Ser Trp Ser Trp Leu Asp Gly
1605 1610 1615
tca gaa gtg aca ttt gtc aaa tgg gaa aat aaa agt aag agt ggt gtt 4896
Ser Glu Val Thr Phe Val Lys Trp Glu Asn Lys Ser Lys Ser Gly Val
1620 1625 1630
gga aga tgt agc atg ttg ata gct tca aat gaa act tgg aaa aaa gtt 4944
Gly Arg Cys Ser Met Leu Ile Ala Ser Asn Glu Thr Trp Lys Lys Val
1635 1640 1645
gaa tgt gaa cat ggt ttt gga aga gtt gtc tgc aaa gtg cct ctg ggc 4992
Glu Cys Glu His Gly Phe Gly Arg Val Val Cys Lys Val Pro Leu Gly
1650 1655 1660
cct gat tac aca gca ata gct atc ata gtt gcc aca cta agt atc tta 5040
Pro Asp Tyr Thr Ala Ile Ala Ile Ile Val Ala Thr Leu Ser Ile Leu
1665 1670 1675 1680
gtt ctc atg ggc gga ctg att tgg ttc ctc ttc caa agg cac cgt ttg 5088
Val Leu Met Gly Gly Leu Ile Trp Phe Leu Phe Gln Arg His Arg Leu
1685 1690 1695
cac ctg gcg ggt ttc tca tca gtt cga tat gca caa gga gtg aat gaa 5136
His Leu Ala Gly Phe Ser Ser Val Arg Tyr Ala Gln Gly Val Asn Glu
1700 1705 1710
gat gag att atg ctt cct tct ttc cat gac taa 5169
Asp Glu Ile Met Leu Pro Ser Phe His Asp
1715 1720
3
349
DNA
Homo sapiens
3
aacagttgat tgcaatgaca atcaaccagg tgctatttgc tactattcag gaaatgagac 60
tgaaaaagag gtcaaaccag ttgacagtgt taaatgtcca tctcctgttc taaatactcc 120
gtggatacca tttcagaact gttgctacaa tttcataata acaaagaata ggcatatggc 180
aacaacacag gatgaagttc atactaaatg ccagaaactg aatccaaaat cacatattct 240
gagtattcga gatgaaaagg agaataactt tgttcttgag caactgctgt acttcaatta 300
tatggcttca tgggtcatgt taggaataac ttatagaaat aaktctctt 349
4
152
DNA
Homo sapiens
4
attaatatgc tgtggaagtg ggtgtcccag catcggctct ttcatttgca ctcccaaaag 60
tgccttggcc tcgatattac caaatcggta aatgagctga gaatgttcag ctgtgactcc 120
gtgccatgc tgtggtggaa atgcgagcac ca 152
5
20
DNA
Artificial Sequence
Description of Artificial Sequence Primer
5
gaycangayg gnttytggaa 20
6
20
DNA
Artificial Sequence
Description of Artificial Sequence Primer
6
tacaccaarc trttytgncg 20
7
20
DNA
Artificial Sequence
Description of Artificial Sequence Primer
7
aayatgctnt ggaartgggt 20
8
20
DNA
Artificial Sequence
Description of Artificial Sequence Primer
8
tgrtgytcrc ayttccacca 20
9
20
DNA
Artificial Sequence
Description of Artificial Sequence Primer
9
gayacngayg gnttytggaa 20
10
20
DNA
Artificial Sequence
Description of Artificial Sequence Primer
10
gcngtyttrt craaccacat 20
11
26
DNA
Artificial Sequence
Description of Artificial Sequence Primer
11
gctctagaaa catgacccat gaagcc 26
12
27
DNA
Artificial Sequence
Description of Artificial Sequence Primer
12
gctctagaca tcggctcttt catttgt 27
13
27
DNA
Artificial Sequence
Description of Artificial Sequence Primer
13
cgggattcac agttgattgc aatgaca 27
14
35
DNA
Artificial Sequence
Description of Artificial Sequence Oligo d(T)
adaptor primer
14
gactagtctg cagaattctt tttttttttt ttttt 35
15
18
DNA
Artificial Sequence
Description of Artificial Sequence Adaptor
primer
15
gactagtctg cagaattc 18
16
28
DNA
Artificial Sequence
Description of Artificial Sequence Primer
16
cgggatccct ctggccgcgc actaatga 28
17
31
DNA
Artificial Sequence
Description of Artificial Sequence Primer
17
ccgctcgagc tgtggatacc agcacatgcc t 31
18
24
DNA
Artificial Sequence
Description of Artificial Sequence Primer
18
gatgggaact cttatgggag acct 24
19
24
DNA
Artificial Sequence
Description of Artificial Sequence Primer
19
tgatgcaggc tggctgccaa ataa 24
20
24
DNA
Artificial Sequence
Description of Artificial Sequence Primer
20
aactgggcaa ctgttggtgg aaga 24
21
24
DNA
Artificial Sequence
Description of Artificial Sequence Primer
21
atggcgaaga ggctggcatt tcta 24
22
24
DNA
Artificial Sequence
Description of Artificial Sequence Primer
22
ctcaagcaag cgatacctgt cact 24
23
24
DNA
Artificial Sequence
Description of Artificial Sequence Primer
23
tgggcaactc gaagactgtg tagt 24
24
24
DNA
Artificial Sequence
Description of Artificial Sequence Primer
24
caccagcaca gcattcttgc ttgt 24
25
24
DNA
Artificial Sequence
Description of Artificial Sequence Primer
25
atttgtgagc agactgatga ggga 24
26
32
DNA
Artificial Sequence
Description of Artificial Sequence
PCR-fragment
26
cggaattcga tctcatgata aggctggtca ca 32
27
21
DNA
Artificial Sequence
Description of Artificial Sequence Primer 060
27
gtggatccag tacaagggtc a 21
28
21
DNA
Artificial Sequence
Description of Artificial Sequence Primer 056
28
accaaatcag tccgcccatg a 21
29
21
DNA
Artificial Sequence
Description of Artificial Sequence Primer 053
29
atggggaagg tgaaggtcgg a 21
30
21
DNA
Artificial Sequence
Description of Artificial Sequence Primer 053
30
aggggccatc cacagtcttc t 21
31
1723
PRT
Murine sp.
31
Met Arg Thr Gly Arg Val Thr Pro Gly Leu Ala Ala Gly Leu Leu Leu
1 5 10 15
Leu Leu Leu Arg Ser Phe Gly Leu Val Glu Pro Ser Glu Ser Ser Gly
20 25 30
Asn Asp Pro Phe Thr Ile Val His Glu Asn Thr Gly Lys Cys Ile Gln
35 40 45
Pro Leu Ser Asp Trp Val Val Ala Gln Asp Cys Ser Gly Thr Asn Asn
50 55 60
Met Leu Trp Lys Trp Val Ser Gln His Arg Leu Phe His Leu Glu Ser
65 70 75 80
Gln Lys Cys Leu Gly Leu Asp Ile Thr Lys Ala Thr Asp Asn Leu Arg
85 90 95
Met Phe Ser Cys Asp Ser Thr Val Met Leu Trp Trp Lys Cys Glu His
100 105 110
His Ser Leu Tyr Thr Ala Ala Gln Tyr Arg Leu Ala Leu Lys Asp Gly
115 120 125
Tyr Ala Val Ala Asn Thr Asn Thr Ser Asp Val Trp Lys Lys Gly Gly
130 135 140
Ser Glu Glu Asn Leu Cys Ala Gln Pro Tyr His Glu Ile Tyr Thr Arg
145 150 155 160
Asp Gly Asn Ser Tyr Gly Arg Pro Cys Glu Phe Pro Phe Leu Ile Gly
165 170 175
Glu Thr Trp Tyr His Asp Cys Ile His Asp Glu Asp His Ser Gly Pro
180 185 190
Trp Cys Ala Thr Thr Leu Ser Tyr Glu Tyr Asp Gln Lys Trp Gly Ile
195 200 205
Cys Leu Leu Pro Glu Ser Gly Cys Glu Gly Asn Trp Glu Lys Asn Glu
210 215 220
Gln Ile Gly Ser Cys Tyr Gln Phe Asn Asn Gln Glu Ile Leu Ser Trp
225 230 235 240
Lys Glu Ala Tyr Val Ser Cys Gln Asn Gln Gly Ala Asp Leu Leu Ser
245 250 255
Ile His Ser Ala Ala Glu Leu Ala Tyr Ile Thr Gly Lys Glu Asp Ile
260 265 270
Ala Arg Leu Val Trp Leu Gly Leu Asn Gln Leu Tyr Ser Ala Arg Gly
275 280 285
Trp Glu Trp Ser Asp Phe Arg Pro Leu Lys Phe Leu Asn Trp Asp Pro
290 295 300
Gly Thr Pro Val Ala Pro Val Ile Gly Gly Ser Ser Cys Ala Arg Met
305 310 315 320
Asp Thr Glu Ser Gly Leu Trp Gln Ser Val Ser Cys Glu Ser Gln Gln
325 330 335
Pro Tyr Val Cys Lys Lys Pro Leu Asn Asn Thr Leu Glu Leu Pro Asp
340 345 350
Val Trp Thr Tyr Thr Asp Thr His Cys His Val Gly Trp Leu Pro Asn
355 360 365
Asn Gly Phe Cys Tyr Leu Leu Ala Asn Glu Ser Ser Ser Trp Asp Ala
370 375 380
Ala His Leu Lys Cys Lys Ala Phe Gly Ala Asp Leu Ile Ser Met His
385 390 395 400
Ser Leu Ala Asp Val Glu Val Val Val Thr Lys Leu His Asn Gly Asp
405 410 415
Val Lys Lys Glu Ile Trp Thr Gly Leu Lys Asn Thr Asn Ser Pro Ala
420 425 430
Leu Phe Gln Trp Ser Asp Gly Thr Glu Val Thr Leu Thr Tyr Trp Asn
435 440 445
Glu Asn Glu Pro Ser Val Pro Phe Asn Lys Thr Pro Asn Cys Val Ser
450 455 460
Tyr Leu Gly Lys Leu Gly Gln Trp Lys Val Gln Ser Cys Glu Lys Lys
465 470 475 480
Leu Arg Tyr Val Cys Lys Lys Lys Gly Glu Ile Thr Lys Asp Ala Glu
485 490 495
Ser Asp Lys Leu Cys Pro Pro Asp Glu Gly Trp Lys Arg His Gly Glu
500 505 510
Thr Cys Tyr Lys Ile Tyr Glu Lys Glu Ala Pro Phe Gly Thr Asn Cys
515 520 525
Asn Leu Thr Ile Thr Ser Arg Phe Glu Gln Glu Phe Leu Asn Tyr Met
530 535 540
Met Lys Asn Tyr Asp Lys Ser Leu Arg Lys Tyr Phe Trp Thr Gly Leu
545 550 555 560
Arg Asp Pro Asp Ser Arg Gly Glu Tyr Ser Trp Ala Val Ala Gln Gly
565 570 575
Val Lys Gln Ala Val Thr Phe Ser Asn Trp Asn Phe Leu Glu Pro Ala
580 585 590
Ser Pro Gly Gly Cys Val Ala Met Ser Thr Gly Lys Thr Leu Gly Lys
595 600 605
Trp Glu Val Lys Asn Cys Arg Ser Phe Arg Ala Leu Ser Ile Cys Lys
610 615 620
Lys Val Ser Glu Pro Gln Glu Pro Glu Glu Ala Ala Pro Lys Pro Asp
625 630 635 640
Asp Pro Cys Pro Glu Gly Trp His Thr Phe Pro Ser Ser Leu Ser Cys
645 650 655
Tyr Lys Val Phe His Ile Glu Arg Ile Val Arg Lys Arg Asn Trp Glu
660 665 670
Glu Ala Glu Arg Phe Cys Gln Ala Leu Gly Ala His Leu Pro Ser Phe
675 680 685
Ser Arg Arg Glu Glu Ile Lys Asp Phe Val His Leu Leu Lys Asp Gln
690 695 700
Phe Ser Gly Gln Arg Trp Leu Trp Ile Gly Leu Asn Lys Arg Ser Pro
705 710 715 720
Asp Leu Gln Gly Ser Trp Gln Trp Ser Asp Arg Thr Pro Val Ser Ala
725 730 735
Val Met Met Glu Pro Glu Phe Gln Gln Asp Phe Asp Ile Arg Asp Cys
740 745 750
Ala Ala Ile Lys Val Leu Asp Val Pro Trp Arg Arg Val Trp His Leu
755 760 765
Tyr Glu Asp Lys Asp Tyr Ala Tyr Trp Lys Pro Phe Ala Cys Asp Ala
770 775 780
Lys Leu Glu Trp Val Cys Gln Ile Pro Lys Gly Ser Thr Pro Gln Met
785 790 795 800
Pro Asp Trp Tyr Asn Pro Glu Arg Thr Gly Ile His Gly Pro Pro Val
805 810 815
Ile Ile Glu Gly Ser Glu Tyr Trp Phe Val Ala Asp Pro His Leu Asn
820 825 830
Tyr Glu Glu Ala Val Leu Tyr Cys Ala Ser Asn His Ser Phe Leu Ala
835 840 845
Thr Ile Thr Ser Phe Thr Gly Leu Lys Ala Ile Lys Asn Lys Leu Ala
850 855 860
Asn Ile Ser Gly Glu Glu Gln Lys Trp Trp Val Lys Thr Ser Glu Asn
865 870 875 880
Pro Ile Asp Arg Tyr Phe Leu Gly Ser Arg Arg Arg Leu Trp His His
885 890 895
Phe Pro Met Thr Phe Gly Asp Glu Cys Leu His Met Ser Ala Lys Thr
900 905 910
Trp Leu Val Asp Leu Ser Lys Arg Ala Asp Cys Asn Ala Lys Leu Pro
915 920 925
Phe Ile Cys Glu Arg Tyr Asn Val Ser Ser Leu Glu Lys Tyr Ser Pro
930 935 940
Asp Pro Ala Ala Lys Val Gln Cys Thr Glu Lys Trp Ile Pro Phe Gln
945 950 955 960
Asn Lys Cys Phe Leu Lys Val Asn Ser Gly Pro Val Thr Phe Ser Gln
965 970 975
Ala Ser Gly Ile Cys His Ser Tyr Gly Gly Thr Leu Pro Ser Val Leu
980 985 990
Ser Arg Gly Glu Gln Asp Phe Ile Ile Ser Leu Leu Pro Glu Met Glu
995 1000 1005
Ala Ser Leu Trp Ile Gly Leu Arg Trp Thr Ala Tyr Glu Arg Ile Asn
1010 1015 1020
Arg Trp Thr Asp Asn Arg Glu Leu Thr Tyr Ser Asn Phe His Pro Leu
1025 1030 1035 1040
Leu Val Gly Arg Arg Leu Ser Ile Pro Thr Asn Phe Phe Asp Asp Glu
1045 1050 1055
Ser His Phe His Cys Ala Leu Ile Leu Asn Leu Lys Lys Ser Pro Leu
1060 1065 1070
Thr Gly Thr Trp Asn Phe Thr Ser Cys Ser Glu Arg His Ser Leu Ser
1075 1080 1085
Leu Cys Gln Lys Tyr Ser Glu Thr Glu Asp Gly Gln Pro Trp Glu Asn
1090 1095 1100
Thr Ser Lys Thr Val Lys Tyr Leu Asn Asn Leu Tyr Lys Ile Ile Ser
1105 1110 1115 1120
Lys Pro Leu Thr Trp His Gly Ala Leu Lys Glu Cys Met Lys Glu Lys
1125 1130 1135
Met Arg Leu Val Ser Ile Thr Asp Pro Tyr Gln Gln Ala Phe Leu Ala
1140 1145 1150
Val Gln Ala Thr Leu Arg Asn Ser Ser Phe Trp Ile Gly Leu Ser Ser
1155 1160 1165
Gln Asp Asp Glu Leu Asn Phe Gly Trp Ser Asp Gly Lys Arg Leu Gln
1170 1175 1180
Phe Ser Asn Trp Ala Gly Ser Asn Glu Gln Leu Asp Asp Cys Val Ile
1185 1190 1195 1200
Leu Asp Thr Asp Gly Phe Trp Lys Thr Ala Asp Cys Asp Asp Asn Gln
1205 1210 1215
Pro Gly Ala Ile Cys Tyr Tyr Pro Gly Asn Glu Thr Glu Glu Glu Val
1220 1225 1230
Arg Ala Leu Asp Thr Ala Lys Cys Pro Ser Pro Val Gln Ser Thr Pro
1235 1240 1245
Trp Ile Pro Phe Gln Asn Ser Cys Tyr Phe Asn Met Ile Thr Asn Asn
1250 1255 1260
Arg His Lys Thr Val Thr Pro Glu Glu Val Gln Ser Thr Cys Glu Lys
1265 1270 1275 1280
Leu His Pro Lys Ala His Ser Leu Ser Ile Arg Asn Glu Glu Glu Asn
1285 1290 1295
Thr Phe Val Val Glu Gln Leu Leu Tyr Phe Asn Tyr Ile Ala Ser Trp
1300 1305 1310
Val Met Leu Gly Ile Thr Tyr Glu Asn Asn Ser Leu Met Trp Phe Asp
1315 1320 1325
Lys Thr Ala Leu Ser Tyr Thr His Trp Arg Thr Gly Arg Pro Thr Val
1330 1335 1340
Lys Asn Gly Lys Phe Leu Ala Gly Leu Ser Thr Asp Gly Phe Trp Asp
1345 1350 1355 1360
Ile Gln Ser Phe Asn Val Ile Glu Glu Thr Leu His Phe Tyr Gln His
1365 1370 1375
Ser Ile Ser Ala Cys Lys Ile Lys Met Val Asp Tyr Glu Asp Lys His
1380 1385 1390
Asn Gly Thr Leu Pro Gln Phe Ile Pro Tyr Lys Asp Gly Val Tyr Ser
1395 1400 1405
Val Ile Gln Lys Lys Val Thr Trp Tyr Glu Ala Leu Asn Ala Cys Ser
1410 1415 1420
Gln Ser Gly Gly Glu Leu Ala Ser Val His Asn Pro Asn Gly Lys Leu
1425 1430 1435 1440
Phe Leu Glu Asp Ile Val Asn Arg Asp Gly Phe Pro Leu Asn Val Gly
1445 1450 1455
Leu Ser Ser His Asp Gly Ser Glu Ser Ser Phe Glu Trp Ser Asp Gly
1460 1465 1470
Arg Ala Phe Asp Tyr Val Pro Trp Gln Ser Leu Gln Ser Pro Gly Asp
1475 1480 1485
Cys Val Val Leu Tyr Pro Lys Gly Ile Trp Arg Arg Glu Lys Cys Leu
1490 1495 1500
Ser Val Lys Asp Gly Ala Ile Cys Tyr Lys Pro Thr Lys Asp Lys Lys
1505 1510 1515 1520
Leu Ile Phe His Val Lys Ser Ser Lys Cys Pro Val Ala Lys Arg Asp
1525 1530 1535
Gly Pro Gln Trp Val Gln Tyr Gly Gly His Cys Tyr Ala Ser Asp Gln
1540 1545 1550
Val Leu His Ser Phe Ser Glu Ala Lys Gln Val Cys Gln Glu Leu Asp
1555 1560 1565
His Ser Ala Thr Val Val Thr Ile Ala Asp Glu Asn Glu Asn Lys Phe
1570 1575 1580
Val Ser Arg Leu Met Arg Glu Asn Tyr Asn Ile Thr Met Arg Val Trp
1585 1590 1595 1600
Leu Gly Leu Ser Gln His Ser Leu Asp Gln Ser Trp Ser Trp Leu Asp
1605 1610 1615
Gly Leu Asp Val Thr Phe Val Lys Trp Glu Asn Lys Thr Lys Asp Gly
1620 1625 1630
Asp Gly Lys Cys Ser Ile Leu Ile Ala Ser Asn Glu Thr Trp Arg Lys
1635 1640 1645
Val His Cys Ser Arg Gly Tyr Ala Arg Ala Val Cys Lys Ile Pro Leu
1650 1655 1660
Ser Pro Asp Tyr Thr Gly Ile Ala Ile Leu Phe Ala Val Leu Cys Leu
1665 1670 1675 1680
Leu Gly Leu Ile Ser Leu Ala Ile Trp Phe Leu Leu Gln Arg Ser His
1685 1690 1695
Ile Arg Trp Thr Gly Phe Ser Ser Val Arg Tyr Glu His Gly Thr Asn
1700 1705 1710
Glu Asp Glu Val Met Leu Pro Ser Phe His Asp
1715 1720
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An isolated human dendritic cell receptor comprising amino acid sequences selected from: TVDCNDNQPGAICYYSGNETEKEVKPVDSVKCPSPVLNTPWIPFQNCCYN FIITKNRHMATTQDEVQSTCEKLHPKSHILSIRDEKENNFVLEQLLYFNYMA SWVMLGITYRNNSL amino acid at position 1208-1323 of SEQ ID NO:1 and SQHRLFHLHSQKCLGLDITKSVNELRMFSCDSSAML amino acid at position 71-106 of SEQ ID NO:1.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process and apparatus for recovery of solvents.
2. Description of the Prior Art
In the known processes and apparatus, which are described, for example, in Ullmann's Encyclopedia of Technical Chemistry, Vol. 1 (1951), page 338, a carrier gas stream laden with solvent vapors in an evaporation space is cooled to condense out solvent vapors and to separate the solvent. After condensation and separation the carrier gas stream lean in solvent vapors is returned into the evaporation space after being reheated. The solvent vapors are not completely condensed out of the carrier gas stream since there remains in the carrier gas stream a certain residual amount of solvent vapor, corresponding to the vapor pressure of the solvent at the temperature of the coolant. In order to avoid losses of solvent, the carrier gas stream is conducted in a circuit. The ability of the carrier gas stream, which is lean in solvent vapors, to take up solvent vapors is hence in fact somewhat reduced; however, this is unimportant for the efficiency of the process.
The process is quite generally suitable for removal of volatile solvents from non-evaporable substrates.
A field of application is the removal of solvent residues from chemical substances which have been produced or purified with the use of solvents. Further fields of application lie in the paint and lacquering fields, the field of chemical cleaning of textiles, the film and foil field, the rubber processing field, and the adhesives and adhesive materials field.
In prior art apparatus, generally, separate cooling devices for condensing out the solvent vapors and devices for reheating the carrier gas stream lean in solvent vapors are provided. Deficiencies in these prior art apparatus include that considerable amounts of coolant are required and a high energy demand to reheat the carrier medium lean in solvent vapors. This reheating of the carrier gas stream is necessary so that the carrier gas stream can rapidly become re-laden in the evaporation space with a sufficient amount of solvent vapor, i.e., so that the substrate is rapidly dried.
It was possible to attempt to achieve a saving of energy by using the coolant which has been heated on passage through the cooling device for reheating the carrier gas stream lean in solvent vapors, i.e., to conduct the coolant countercurrent to the carrier gas stream. However, it is immediately obvious that only a small fraction of the heat taken from the carrier gas stream previously in the cooling device can be returned to the carrier gas stream. Because of the relatively low temperature difference between the carrier gas and the coolant, the cooling device and the device for reheating the carrier gas stream have to be provided with large heat exchange surfaces.
The process is thus disadvantageous not only because of its high energy and coolant consumption, but also because of its high cost in apparatus.
An apparatus for recovery of solvent from a hot carrier gas stream laden with solvent vapors is known from DE-PS No. 27 25 252, in which the carrier gas stream is compressed, cooled, and expanded with production of work, for condensing out the solvent vapors and separating the solvent. The carrier gas stream lean in solvent vapors is conducted back into the evaporation space after being reheated.
Return of this carrier gas stream takes place, however, in admixture with a carrier gas stream taken from the evaporation space and laden with solvent vapors. After being heated in indirect heat exchange with the compressed carrier gas stream, the admixture is conducted back into the evaporation space in a duct loop together with the carrier gas stream lean in solvent vapors. Better heat regulation is accomplished but having the disadvantage that the carrier gas stream conducted back into the evaporation space has a relatively high content of solvent vapors. The drying effect in the evaporation space is reduced in this manner. It is further disclosed in DE-PS No. 27 25 252 that the work liberated by the expansion in an expansion turbine can be recovered. However, details are lacking as to where this work can be usefully utilized.
An object of the present invention is to improve upon a process and an apparatus of the kind described above, with low cost in apparatus while utilizing the work produced from the expansion of the compressed carrier gas stream laden with solvent vapors and the carrier stream returned to the evaporation space is as lean as possible in solvent vapors.
BRIEF DESCRIPTION OF THE INVENTION
A process for recovery of solvents is provided. A carrier gas stream laden with solvent vapors in an evaporation space is compressed, cooled, and expanded with production of work in order to condense out the solvent vapors and separate the solvent. The carrier gas stream lean in solvent vapors is conducted back into the evaporation space after being reheated. The process is characterized in that the whole of the work produced on expansion is transferred in direct mechanical coupling to one of two or more compression stages for compressing the carrier gas stream laden with solvent vapors.
An apparatus for carrying out the process includes in a carrier gas circuit: an evaporation space in which the heated carrier gas stream is laden with solvent vapors, a compressor, a cooling device for condensing the solvent vapors out of a carrier gas stream, an expansion apparatus, a solvent separator, and a device for reheating the carrier gas stream lean in solvent vapors. The apparatus is characterized by the expansion apparatus being directly mechanically coupled to one of two or more compressors.
DETAILED DESCRIPTION OF THE INVENTION
In the apparatus according to the invention, the carrier gas stream, conducted in the circuit, takes up the evaporated solvent in high concentration in the evaporation space (usually a dryer), and the solvent is withdrawn from the carrier gas stream in the cooling device by cooling and condensing. While the carrier gas stream laden with solvent vapors is in fact compressed, and expanded with production of work after cooling, in the prior art, the work of expansion is not used as compression work in the system, which is contrary to the present invention. Thus, in accordance with the present invention, only the difference between the compression and expansion work is to be supplied to the one compression stage, i.e., by means of an additional external work machine which is directly mechanically coupled to the one compressor. This difference covers the amount of work needed for separation of the solvent vapor from the carrier gas stream and also to overcome thermodynamic losses (friction, taking up heat from the surroundings).
The density of the mixture of carrier gas stream and solvent vapors is increased by compression. Hence the efficiency of the heat exchanger is increased. Because of the reduced gas volume, the heat exchanger and the other parts of the apparatus which are under pressure can be kept compact. Finally, no chemical, in particular no oxidative influence on the solvent vapors takes place during the compression and expansion, in contrast to recovery processes in which adsorbents such as active carbon are utilized. Such adsorbents can often act on the solvent vapors with the formation of injurious decomposition products. Since the carrier gas stream is constantly circulated, these decomposition products would build up and react undesirably with the products to be dried or with the parts of the apparatus. A known case is the decomposition of chlorinated hydrocarbons in the presence of water vapor, with the formation of hydrogen chloride.
The second or the further compression stages are preferably driven separately by work supplied from outside, i.e. the second or further compressors are mechanically coupled to external work machines. This arrangement ensures a better control of the compression process and among other things a better regulation of the desired final pressure. Further, the dimensions of the gearing required between the work machine and the compressor can be kept low.
An expansion turbine is preferably used as the expansion apparatus, because of its high efficiency. Additionally the expansion turbine is more easily coupled to a compressor than is, for example, a piston machine. The additional work machine is preferably an electric motor.
The process according to the invention can be applied, for example, in connection with the production of flat adhesive materials, in which an adhesive is applied to paper or textile lengths or tapes. Such tapes can, for example, be used as technical adhesive tapes or as tapes or lengths for medical purposes (e.g., adhesive plaster). In order to apply the adhesive to the length of paper or textile, the adhesive is brought to a fluid state by means of liquid solvents so that it can be applied in sufficiently thin and uniform layers. The solvent evaporates during drying. The coated substrate remains in an evaporation space in contact with the carrier gas, which takes up the solvent, for a time determined by the volatility and amount of solvent.
The examples of embodiments given below relate to apparatus for this special application. The invention is, however, applicable with success to the other fields of application mentioned hereinbefore.
Solvents for adhesives and also many other materials are usually solvents or solvent mixtures whose vapors are inflammable. According to the invention, for recovery of such solvent vapors there is used a carrier gas with an oxygen content lying below the ignition limit. Exemplary of such carrier gases are gases which are inert from the outset, such as nitrogen or carbon dioxide; however, the oxygen content of air can be reduced by admixture of an inert gas to an extent such that the ignition limit is no longer reached. In certain cases it is also possible to use combustion exhaust gases with a low oxygen content.
The inflammability of the solvent vapors is, however, not only a function of the oxygen content in the carrier gas, but also depends on the concentration and nature of the solvent vapor. Thus, for example, the danger of ignition is greater with low-boiling hydrocarbons and ethers than with halogenated hydrocarbons. The inflammability properties of various solvents are however known, and the permissible solvent vapor concentrations and oxygen contents can be taken from the literature or determined by simple tests.
The use of an inert or low-oxygen carrier gas stream affords the advantage that the carrier gas stream can take up a large amount of solvent vapors without the danger of an explosion arising. In this manner the amount of carrier gas to be circulated can be kept low, so that the amount of energy required for cooling or reheating the carrier gas can be reduced.
The process according to the invention is not restricted to the recovery of organic solvents; inorganic solvents, such as ammonia and sulfur dioxide, can also be used, and also solvents falling between inorganic and organic, such as carbon disulfide or carbon tetrachloride. Since these solvents (with the exception of carbon disulfide) are incombustible, the maintenance of a given concentration of oxygen in the carrier gas is not necessary in these cases, i.e., in the simplest case air can be used as carrier gas.
Control of the process according to the invention, among other things in relation to suiting the apparatus to different solvents or solvent mixtures, is possible in various ways. For example, the speed of the material to be dried and moving through the evaporation space can be varied. The most important effective means of process control is to vary the speed of the carrier gas or the pressure in the system by varying the rpm of the drive motor of the one or further compressors. Bypass regulation of one or more compressors can also be carried out for this purpose.
A particularly simple possibility of regulating the temperature of the carrier gas stream laden with solvent vapors consists of bringing it into indirect heat exchange with a coolant before, between, and/or after the individual compression stages. For this purpose, an indirect cooler can be inserted between the evaporation space and the first compressor, between the first and second or respective following compressors, and/or between the last compressor and the expansion apparatus. The entry temperature of the carrier gas stream, laden with solvent vapors, into the first or following compressor and/or into the expansion apparatus, or the entry temperature of the carrier gas stream lean in solvent vapors into the evaporation space, can be suited to requirements in a simple manner by control of the flow of coolant into the cooler or coolers.
By insertion of an additional indirect cooler between the last compressor and the expansion apparatus, the carrier gas stream lean in solvent vapors enters the evaporation space with a lower and more controllable initial temperature. The additional cooler usually precedes the heat exchanger through which flows the carrier gas stream lean in solvent vapors. Preferably this cooler can, however, be preceded by a heat exchanger ("hot" heat exchanger) and followed by a heat exchanger ("cold" heat exchanger). In this manner a carrier gas stream enters the evaporation space at a lower temperature.
When the carrier gas stream laden with solvent vapors is cooled in the cooling device after leaving the last compressor, a portion of the solvent vapors can condense, depending inter alia on the temperature of the carrier gas stream lean in solvent vapors which is used as coolant. There is, for example, the possibility that water separates, as its boiling point is higher than that of many organic solvents. Though water is not used in the solvent mixtures for usual self-adhesive adhesives, it is still introduced into the system, since it is adsorbed on the paper or textile lengths used as substrates for the adhesive. It can even occur in a few cases that the water freezes out in the cold part of the heat exchanger or in the expansion apparatus and thus blocks the flow cross sections or damages the moving parts of the expansion apparatus.
In order to counter this danger, a water soluble solvent in liquid form is injected into the cooled carrier gas stream before expansion. When the solvent is dissolved in water, there results a solution with a lower freezing point than that of water and remaining liquid.
When the cold solvent is not soluble in water, the water precipitates on the surface of the cold solvent droplets, and thus cannot deposit on the solid boundaries of the flow paths.
This measure is carried out, as regards apparatus, by providing devices for injection of the liquid solvent into the carrier gas stream between the heat exchanger and the expansion apparatus.
When it is not desired to inject a liquid solvent, or when the danger exists that the condensed liquid will damage the moving parts of the expansion apparatus, e.g., the blades of the expansion turbine, a portion of the solvent vapors can be condensed out and separated from the cooled carrier gas stream before expansion. A further solvent separator can be provided for this purpose between the heat exchanger and the expansion apparatus.
A further means of controlling the temperature of the carrier gas stream is expanding the carrier gas stream, without production of work, subsequent to a partial expansion with production of work. In this instance, an expansion valve can be provided before the evaporation space. This expansion valve can be provided either at the inlet or the outlet of the heat exchanger. By means of this expansion valve, control can also take place to prevent icing in the pipe ducts to the expansion apparatus or in the expansion apparatus itself.
On passage through the expansion valve a small further cooling of the carrier gas stream takes place, in this case without production of work. The thus expanded carrier gas stream can now be used, if necessary, after separation of the condensed-out solvent, in indirect heat exchange as cooling gas for the carrier gas stream expanded with production of work. For this purpose, a further heat exchanger, through which flows the carrier gas stream lean in solvent vapors, can be inserted between the expansion apparatus and the first solvent separator. The expansion valve is inserted immediately before this heat exchanger.
Two embodiments of the apparatus according to the invention are illustrated in the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an apparatus in accordance with the invention in which the expansion apparatus is directly coupled to the second compressor, while the first compressor is coupled to an external work machine; and
FIG. 2 is an apparatus in accordance with the invention in which the expansion apparatus is directly coupled to the first compressor, while the second compressor is coupled to an external work machine.
DETAILED DESCRIPTION OF THE DRAWINGS
In the embodiment according to FIG. 1, a paper or textile length, 10, is provided with a coating of adhesive dissolved in a solvent. This length, 10, is moved (by drive means which are not shown) in the direction of the arrow A through the evaporation space, 12, which is shown schematically. The evaporation space, 12, is completely enclosed, so that no solvent vapors can reach the atmosphere.
A hot carrier gas stream, 14, e.g. a stream of nitrogen, lean in solvent vapors, is introduced into the evaporation space, 12, countercurrent (in the direction designated by arrow B) to the paper or textile length. Heating of this carrier gas stream takes place as described below.
The hot carrier gas stream, 14, flows through the evaporation space, 12, countercurrent to the paper or textile length, 10, and heats the paper or textile length, 10, to the extent that the solvent contained in the adhesive solution evaporates (illustrated by LM v in the drawing). The carrier gas stream thus becomes laden with solvent vapors and is cooled because of the heat of evaporation of the solvent. For example, when n-hexane is used as the solvent, the entry temperature of the gas stream into the evaporation space, 12, is, for example, 140° C., and the exit temperature is about 100° C. The carrier gas stream, 16, laden with solvent vapors leaving the evaporation space, 12, now enters a cooler, 18, through which a coolant, 20, flows in indirect heat exchange, with the stream, 16. The flow rate of the coolant and hence the temperature of the carrier gas stream, 16, laden with solvent vapors can be regulated by means of a throttle valve, 22. In the example shown in FIG. 1, the throttle valve, 22, is set so that the carrier gas stream leaving the cooler, 18, has a temperature of about 34° C., while the coolant, 20, is heated from about 12° to about 65° C.
The cooled carrier gas stream now enters the first compressor, 23, which is indirectly mechanically coupled via a coupling to an electric motor, 36, which acts as external work machine. The rpm of the electric motor, 36, can be controlled according to the low temperature required for condensation or the required volume for circulation. After compressor, 23, the carrier gas stream, 16, enters the second compressor, 24, which is directly mechanically coupled, as shown by the through shaft labeled 31, to the expansion apparatus, 30, further described below (an expansion turbine). The compressed carrier gas stream, 16, now enters heat exchanger, 26a ("hot" heat exchanger), in which it is cooled in indirect heat exchange with the carrier gas stream, 14, lean in solvent vapors. Heat exchanger, 26a, is bridged by a bypass valve, 27. An indirect cooler, 25, follows the heat exchanger, 26a, to regulate the temperature of the carrier gas stream. Without the cooler, 25, the carrier gas stream, 16, would have to be cooled so much in cooler, 18, that its temperature before entry into compressor, 23, would be only about 10° to 20° C. For this purpose cooler, 18, would have to be made very large. Insertion of cooler, 25, furthermore enables the temperature of the carrier gas stream to be regulated over a wide range, specifically, by corresponding actuation of coolant valve, 29.
Following cooler, 25, is a heat exchanger, 26b, ("cold" heat exchanger), in which the carrier gas stream is again cooled in indirect heat exchange with the carrier gas stream, 14, lean in solvent vapors (in this example, to about 0° C.). Regulation of the carrier gas stream, 14, lean in solvent vapors is possible by means of bypass valve, 27.
Since the temperature of the carrier gas stream laden with solvent vapors remains constant in the "cold" heat exchanger, 26b, (in the case of n-hexane about 0° C.), when the valve, 27, is open the mass flow of coolant through the additional cooler, 25, must be increased.
A portion of the solvent vapors condenses out in heat exchanger, 26b. This portion is removed in solvent separator, 50. However, this is only necessary when the carrier gas stream contains a high concentration of solvent vapors and the amount of solvent separated after heat exchanger, 26b, is so large that precautions have to be taken against damage to the expansion apparatus, 30, by solvent droplets.
The mixture, 28, of carrier gas stream partially laden with solvent vapors and possibly still having liquid solvent particles therein flows into the expansion apparatus, 30, constructed as an expansion turbine (modified turbosupercharger). As already described, the turbine, 30, is connected directly, via shaft, 31, mechanically to the compressor, 24. The work produced in expansion turbine, 30, can thus be utilized practically without losses for compression of the carrier gas stream, 16, laden with solvent vapors in compressor, 24, since no gearing losses arise. Motor, 36, which drives the first compressor, 23, is the single external energy source for the system, and the supply of energy can be flexible according to the demands of the system.
Because of the work produced, a further cooling of the carrier gas stream takes place in the expansion turbine, 30, and the mixture, 32, of carrier gas stream lean in solvent vapors and possibly still having present liquid solvent particles (a fraction higher than in 28) reaches solvent separator, 34, in which the mixture, 32, is separated. The carrier gas stream, 14, lean in solvent vapors leaving the solvent separator, 34, has a temperature, in the example used, of about -40° C., and flows successively through heat exchangers, 26b and 26a, in indirect heat exchange with the carrier gas stream, 16, laden with solvent vapors. The former is thereby heated to about 140° C., i.e., to a temperature required for evaporation of the solvent in the evaporation space, 12.
An expansion valve, 38, can be provided for further control of the temperature of this carrier gas stream. When the carrier gas stream passes through this valve there occurs a further cooling, without the production of work. The temperature of the system can thus be regulated not only by means of throttle valve, 22, but also by means of expansion valve, 38, in a simple manner. Without insertion of further regulating devices, the system can be adjusted for the most diverse solvent combinations with these two valves. The cooling of the carrier gas stream occurring at expansion valve, 38, can be used for cooling the carrier gas stream after the expansion turbine, 30, (not shown in the drawing), and a solvent separator can, if necessary, be inserted after expansion valve, 38.
Separation of the mixture into a carrier gas stream, 14, lean in solvent vapors, and liquid solvent (possibly mixed with solid ice particles), takes place in solvent separator, 34, as previously mentioned. Liquid solvent is drawn off via duct, 40. As a rule, the liquid solvent is immediately used for production of the solvent solution. For this purpose it may be necessary to separate out any water which may be present from the solvent, or to adjust the proportions of the individual solvent components. In general, however, the proportions of solvent components remain constant after a stable operating state has been attained, since the evaporation space, 12, is enclosed so that no solvent vapors escape during operation. Return of the recovered solvent is indicated by the dashed line, 42.
If necessary, a smaller portion of the recovered solvent can be conducted via duct, 44, to a pump, 46, and injected by means of the pump into the heat exchanger, 26b, and/or into the mixture, 28, before expansion turbine, 30. As already mentioned above, icing of the heat exchanger, 26b, the expansion apparatus, 30, and the connecting duct, 28, is to be prevented by means of this water-soluble solvent fraction, in that the solvent forms a low-melting mixture with the water to prevent deposition of ice on the cold solvent droplets. The solvent inlet ducts are labeled, 48a or 48b. Icing of the expansion turbine, 30, and also the danger of damage to the vanes of the expansion turbine by solvent droplets or ice particles are also reduced by means of solvent separator, 50.
In the embodiment shown in FIG. 2, the elements which are identical or equivalent to those of FIG. 1 are given the same reference numerals. The most important difference is that the expansion apparatus, 30, is directly mechanically coupled to the first compressor, 23, (via shaft, 31), while the second compressor, 24, is coupled to the electric motor, 36. This arrangement has the advantage over that of FIG. 1 in that the pressure or temperature of the gas stream laden with solvent vapors before entry into the "hot" heat exchanger, 26a, can be regulated even better, since a deviation from the set values at this point can be countered directly by means of motor, 36, and the opposing control becomes immediately effective.
Furthermore, in this embodiment the expansion apparatus, 30, is constructed as an expansion turbine with guide vane adjustment, giving a further possibility of control and enabling the efficiency of the expansion turbine to be optimized in correspondence with the pressure and flow conditions in the system at any given time. Finally, a further valve, 21, is provided before compressor, 23, as a control element.
The invention is not limited to the examples of embodiments shown, but can be varied in manifold ways without departing from the scope of the invention which is defined by the following claims.
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A process for the recovery of solvents is disclosed. A hot carrier gas stream laden with solvent vapors from an evaporation space is compressed, cooled, and expanded with production of work for condensing and separating the solvent. The carrier gas stream lean in solvent vapors is conducted back into the evaporation space after being reheated. The whole of the work arising on expansion is transferred in direct mechanical coupling to one of two or more compression stages for compression of the carrier gas stream laden with solvent vapors. An apparatus for practicing the process is also disclosed.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 10/196,330 filed Jul. 15, 2002 now U.S. Pat. No. 6,601,712 which application is a divisional application of U.S. patent application Ser. No. 09/910,649 filed Jul. 20, 2001 now U.S. Pat. No. 6,460,708 titled “Bicycle Carrier” which application is a divisional application of U.S. patent application Ser. No. 09/447,908 filed Nov. 23, 1999 now U.S. Pat. No. 6,283,310 titled “Bicycle Carrier” and are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to bicycle carriers and more particularly to a fork block and wheel tray used to secure a bicycle on a roof rack.
BACKGROUND OF THE INVENTION
With the growing popularity of bicycling as a recreational activity, vehicles are often equipped with racks to transport bicycles. Such racks come in many different styles and configurations. One common configuration is a roof rack in which one or more bicycles are mounted to a pair of crossbars that extend across the top of the vehicle.
Various systems have been developed to secure and stabilize bicycles on vehicle-mounted cross arms. One such system utilizes a fork block mounted to one of the bars with a skewer extending therethrough to receive and grip the front forks of a bicycle. Typically, a wheel tray extends from the fork block to the other crossbar to receive the rear tire of the bicycle. In a slight variation, a short wheel tray is attached to only one crossbar to receive the rear wheel. One limitation of this variation is that the rear wheel must be substantially centered over the crossbar to avoid creating excess torque on the short wheel tray and/or crossbar. This limitation can be a problem where the crossbars cannot be positioned on the vehicle to accommodate the wheel base of a particular bicycle, or where it is desirable to carry bicycles with different wheel bases.
In addition to meeting the basic physical requirements of mounting a bicycle on a vehicle, it is also important for a rack to permit the bicycle to be locked on to prevent unauthorized removal. In systems utilizing fork blocks, this is usually accomplished by providing a lock associated with the skewer to prevent the skewer from being opened. Existing lock designs are either unnecessarily complex or not sufficiently secure.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of a bicycle roof rack according to the present invention.
FIG. 2 is an exploded perspective view of a fork block according to the present invention.
FIG. 3 is a sectional view through the fork block of FIG. 2 .
FIG. 4 is a perspective view of a lower surface of a cap forming part of the fork block of FIG. 2 .
FIG. 5 is a sectional view through the fork block of FIG. 2 .
FIG. 6 is a cam follower forming part of the fork block of FIG. 2 .
FIG. 7 is a view of a lock portion of the fork block of FIG. 2 .
FIG. 8 is a graph of displacement as a function of rotation for various cam profiles.
FIG. 9 is an exploded perspective view of a wheel mount according to the present invention.
FIG. 10 is a sectional view of the wheel mount of FIG. 9 .
FIG. 11 is a perspective view of a clip according to the present invention.
FIGS. 12 and 13 illustrate various mounting positions for the wheel mount of FIG. 9 on a round crossbar.
FIGS. 14 and 15 illustrate various mounting positions for the wheel mount of FIG. 9 on a rectangular crossbar.
FIG. 16 is a perspective view of an alternative wheel mount according to the present invention.
FIG. 17 is a side-sectional view of the wheel mount of FIG. 16 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A bicycle mounting system according to the present invention is shown generally at 10 in FIG. 1 . System 10 includes a roof-mounted rack 12 that attaches to factory installed tracks 14 on a roof 16 of a vehicle 18 . Rack 12 includes towers 20 that interconnect the tracks to crossbars 22 . A bicycle 24 is secured to the crossbars by a fork block 26 and a wheel mount 28 .
The construction of fork block 26 is shown in FIGS. 2-7 . As shown in FIG. 2 , fork block 26 includes a molded plastic body 30 with an upper section 32 and a lower section 34 . The facing perimeters of each section are formed with stepped edges 36 that interlock with each other. The two sections are secured together by three bolts 38 that engage three corresponding nuts 40 . The bolts pass through holes 42 molded in each section. A socket 44 is formed at the bottom of each hole on the lower section to receive a nut. See FIG. 3 . The inside end of the socket is hexagonally shaped in cross-section to prevent the nut from rotating once placed in the socket.
Each section includes a channel 48 adapted to fit over a crossbar. The channel is shaped, as shown in FIG. 3 , to allow installation on either round or rectangular bars, which are the two most common shapes. The channels are sized so that as the sections just come together, the channels grip the bar with sufficient pressure to prevent slippage along the length of the bar. A plurality of reinforcing ribs 50 run across the channels and are provided with teeth 52 . The teeth bite into a pliable coating that is typically applied to the surface of round crossbars to stabilize the fork block against rotation about the bars. The teeth are generally unnecessary in the case of rectangular crossbars where the non-symmetric cross-section prevents rotation.
The upper section includes wheel tray receiver in the form of a protrusion 58 configured to receive the front end of an elongate wheel tray 60 . A corresponding recess 62 is formed in the lower section. The wheel tray is secured to the protrusion by a screw that fits down through a hole 64 in the protrusion, through a hole 66 in the tray and into a flat nut 68 which rides in a track 70 formed in the bottom of the wheel tray. As will be described below, and as depicted in FIG. 1 , the fork block can also be used with a short wheel tray rather than tray 60 .
A ridge 74 runs across the top of the upper section with a bore 76 formed therethrough to receive a skewer 78 . The ridge is formed with a gap 80 at the center and extensions 82 at each end. Metal bearing sleeves 84 are pressed over the extensions to provide a hard surface for the forks to press against. A security cover or cap 86 fits into a recess 88 formed in the top of the upper section. The cap includes a retainer 90 that fits into the gap in the ridge around the skewer to hold the cap on the upper section. See FIG. 4 .
It should be noted that the cap blocks access to the heads of the bolts that secure the upper and lower sections together. As a result, the sections cannot be removed from the crossbar without removing the cap. Since the cap cannot be removed without removing the skewer, as long as the skewer cannot be removed, the fork block and bicycle carried thereon cannot be removed from the vehicle.
The skewer is part of a skewer assembly 94 , shown in FIGS. 2 and 5 , that also includes a cam lever 96 , a cam follower 98 and an adjustment nut 100 . The skewer includes a flattened section 102 with a hole 104 near the end to receive a pivot pin 106 which pivotally connects the cam lever to the skewer. The cam lever includes a slot 108 that fits over the flattened section and allows the cam lever to rotate thereon. The pin is preferably press fit through a hole 110 formed in the sides of the cam lever on either side of the slot and through the skewer.
The cam lever includes a handle portion 112 to allow a user to pivot the lever. As the lever pivots, a cam surface 114 that rides against the cam follower. The cam surface is shaped so that as the cam lever is pivoted, it pushes the cam follower toward the fork block. More particularly, the cam surface is shaped so that, as the lever is rotated from the open position to the closed, the cam follower is moved rapidly over the first two-thirds of rotation and then slower and with greater leverage as the closed position is approached. The shape of this profile is depicted at 115 in FIG. 8 . The adjustment nut is positioned on the skewer to adjust as necessary for different fork thickness.
The described cam surface profile provides rapid throw with low force during the first part of closing where the forks have not been contacted and high force at the end to clamp the forks. As a result, it is not necessary to loosen the nut to allow the forks to be removed, even when the forks are equipped with knobs to prevent accidental wheel loss. This is in contrast to the standard eccentric circle cams utilized on prior skewers. An eccentric circle has a throw rate as a function of rotation that starts small, reaches a maximum rate of change at 90-degrees, and decreases again until the closed position is reached. See the curve indicated at 116 in FIG. 8 . It can be seen that curve 115 has the same slope, and therefore clamping force as a function of rotation during the final section of operation, but has a much higher slope where no pressure is required. With an offset circular cam, the overall throw cannot be increased without increasing the slope in the clamping region and thus decreasing the available clamping leverage. By way of comparison, the skewer clamp of the present invention provides more than three-eighths of an inch of throw versus the five-sixteenths or less typically found in circular cam devices. This increased throw comes without a corresponding reduction in holding force because of the shape of the cam surface. Although the size of a circular cam can be increased to achieve a desired throw, the resultant device would have less clamping force for a given torque on the cam than the system of the present invention. This reduced force may prevent adequate grip on the bicycle forks or may make the force required to close the cam unacceptably high.
The cam follower has an elongate hollow cylindrical body 118 that fits over the skewer. The body includes a serrated end 120 disposed toward the fork block to improve the grip on the bicycle fork. See FIG. 6. A spring 122 is disposed inside the cylindrical body to bias the cam follower against the cam lever. A smooth cam bearing plate 124 is formed on the opposite end of the plate for the cam surface to slide against. The bearing plate includes a lateral extension 126 with a slot 128 formed therein. The flattened end of the skewer passes through a correspondingly-shaped hole 130 in the bearing plate to prevent the follower from rotating on the skewer.
The cam lever further includes a lock-receiving bore 132 that is configured to receive a lock cylinder 134 . The lock cylinder snaps into the lock-receiving bore and includes a T-shaped catch 136 that projects out of the cam lever to selectively engage slot 128 in the cam follower. In particular, with the catch oriented parallel to the slot, the cam lever can be moved freely between the open and closed positions. The open position is depicted by the dashed lines in FIG. 5 . However, if the catch is rotated 90-degrees in the slot, as shown by the dashed lines in FIG. 7 , the lever can no longer be rotated to release the skewer assembly. A key 138 is inserted into the lock cylinder to rotate the catch.
As depicted in FIG. 1 and described above, the rear tire can be held to the crossbar by a long wheel tray or wheel mount 28 . Wheel mount 28 is shown in detail in FIGS. 9-10 and includes a wheel tray portion 140 . The wheel tray portion is cupped along the elongate axis to support a standard sized wheel at two circumferentially spaced points around the perimeter of the wheel. This arrangement eliminates the problem of the wheel tray “rocking” on a single tangent point on the surface of the wheel, as occurs with straight wheel trays.
The wheel tray portion is also cupped in the direction transverse to the elongate axis to stabilize the wheel against lateral movement. The wheel is held in the tray portion by a ratchet strap 142 . Ratchet strap 142 is molded as a single piece and includes a central bridge portion 144 , two toothed regions 146 and grip holes 148 at each end. The ends of the ratchet strap are inserted through receivers 150 formed on each side of the wheel tray portion. A spring-biased pawl 152 is associated with each receiver and includes a circular pad 154 to allow a user to pivot the pawl. Teeth 156 formed on the pawl allow the strap to be inserted, but prevent withdrawal unless the pawl is pivoted to disengage the teeth by pressing on the circular pad. When the ends of the strap are inserted and pulled tight, the bridge portion pushes down on the bicycle wheel to hold it against the wheel tray portion.
The wheel tray portion is held to a round crossbar by a clip 160 , such as shown in FIG. 11 . Clip 160 includes a recess 162 sized and shaped to closely fit over a round crossbar. A split 164 allows the ends of the clip to be spread apart to install the clip on the crossbar. The top surface 166 of the clip fits against a flat mounting surface 168 formed on the bottom of the wheel tray portion. A bolt 170 fits down through the wheel tray portion and the clip and is engaged by a T-nut 172 . As the T-nut is tightened, the split is pressed together and the crossbar is firmly gripped.
As shown in FIGS. 12 and 13 , the wheel tray portion can be mounted to the crossbar with either the bolt in front or behind the bar. Furthermore, the mount can be rotated around the bar. The ability to rotate around the bar and position the mount slightly in front of or behind the crossbar allows the mount to accommodate bicycles with wide range of wheel bases. The longitudinal cupping of the wheel tray portion around the perimeter of the tire reduces the tendency of the wheel tray to rock on the perimeter of the wheel. This combination of rotational flexibility and stability on the tire transfers torque created when the center of the wheel is placed significantly in front of or behind the cross-arm to the frame of the bicycle instead of causing the mount to rotate around the crossbar.
The mount can also be used with a rectangular cross-section crossbar by utilizing a rectangular clip 176 , as shown in FIG. 9 . Clip 176 is constructed similarly to clip 160 , but includes a recess that is rectangular in cross-section rather than circular. Clip 176 includes a flat side 178 and a stepped side 180 . The flat side is mounted to the wheel tray portion as previously described for the round clip and can be mounted in front of or behind the crossbar to accommodate variations in wheel base. See FIGS. 14 and 15 . However, because of the irregular cross-sectional profile, it is not possible to rotate the clip around the bar.
In order to provide increased range of wheel base accommodation on a rectangular bar, an angled mounting surface 182 is formed on the bottom of the wheel tray portion. The angled mounting surface inclines the wheel tray portion relative to the cross-arm. This simulates in a discrete fashion the effect of rotation in the case of a round bar. As before, the mount can be attached to the crossbar with the wheel tray facing forward or backward.
FIGS. 16 and 17 depict a wheel mount 186 having a monolithic construction. Mount 186 includes a wheel tray portion 188 with a construction similar to wheel tray portion 140 . The bicycle wheel is secured in the wheel tray portion by an elastic band 190 with a plurality of holes 192 that is stretched between mounting studs 194 formed on each side of the wheel tray portion. The mount is secured to the bar by a clip 196 formed integrally with the bottom of the wheel tray portion. A slot 198 is formed at one side of the clip to allow it to open up to be installed over a crossbar. A bolt 200 and T-nut 202 are used to tighten the clip on the bar. It should be noted that the cross section of the opening in the clip is sculpted to allow it to be installed on either a round bar or a rectangular bar. In addition, the sculpting allows the mount to be positioned on the rectangular bar at a number of different rotational positions.
The above-described arrangements for attaching the mount to the crossbar allows the mount to accommodate wheel base variations of plus or minus 9 inches on round bars and plus or minus 6 inches on square bars. Thus, a bicycle with a wheel base of 32 inches could be mounted together with a bicycle with a 50 inch wheel base on a rack with crossbars spaced at 41 inches. Alternatively, this arrangement allows the position of the crossbars to be adjusted over a wide range of positions when mounting a bicycle of a fixed wheel base. For instance, an average mountain bike has a wheel base of 40-42 inches and can be mounted on bars spaced from 32 to 50 inches. This flexibility allows the rack to be used on a wide range of vehicle styles. With prior systems, the mounting flexibility of the short wheel mount was not possible without using a long-style wheel tray.
While the invention has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. Applicants regard the subject matter of the invention to include all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. No single feature, function, element or property of the disclosed embodiments is essential to all embodiments of the invention. The following claims define certain combinations and subcombinations which are regarded as novel and non-obvious. Other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of the present claims or presentation of new claims in this or a related application. Such claims, whether they are different, broader, narrower or equal in scope to the original claims, are also regarded as included within the subject matter of applicants' invention.
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A rack for carrying a bicycle on a vehicle. The rack includes forward and rear crossbars extending across a top surface of the vehicle and a pair of tower bodies associated with each crossbar to secure the crossbars to the vehicle. A wheel mount is attached to a first one of the crossbars. The wheel mount is adapted to support a wheel of the bicycle with a lowest point on the wheel positioned over a range of positions relative to the crossbar including with the lowest point positioned off the wheel mount.
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INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS
[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.
[0002] This application is a continuation application of U.S. application Ser. No. 14/318,138 filed Jun. 27, 2014, now U.S. Pat. No. 9,144,420, which claims priority to Ecuadorean Patent Application No. SP2013-12745 filed on Jun. 28, 2013, the entire contents of which are hereby incorporated by reference and should be considered a part of this specification.
BACKGROUND
[0003] 1. Field
[0004] The present application is directed to a system for collecting an endometrial tissue sample, and more particularly to a non-invasive endometrial sample collector.
[0005] 2. Description of the Related Art
[0006] There are several existing procedures for obtaining samples of endometrial tissue. One such procedure involves the sampling of the endometrium with a small plastic device that is introduced in the uterine cavity and through the uterine cervix in order to obtain the tissue sample. This procedure is usually performed in a doctor's office, without anesthesia.
[0007] Another existing procedure for obtaining an endometrial tissue sample involves cervical dilation and curettage (D&C). The D&C procedure requires insertion of instruments (e.g., curette or sharp curettage, suction curettage, electric vacuum aspiration) in the uterine cavity and through the uterine cervix to remove endometrial tissue samples, such as by scraping and scooping the endometrial tissue sample. This procedure is performed in a hospital, under anesthesia. The procedure is often performed blindly by the doctor (e.g., without the use of any imaging technique such as ultrasound or hysteroscopy).
[0008] Still another existing procedure for obtaining an endometrial tissue sample involves a hysteroscopy. This procedure involves introducing an optical system (e.g., endoscope) within the uterine cavity and through the uterine cervix to directly observe the endometrium. The endoscope can have operative channels through which instruments (e.g., biopsy instruments, resectoscope) can be deployed to obtain a sample of the endometrial tissue under the visual guidance provided by the optical system. Such a procedure can be performed at a hospital or surgical centers, or a clinic, and can be performed under local anesthesia. Hysteroscopies are more expensive procedures (from the patient's and doctor's point of view) since they require expensive equipment and trained specialists.
[0009] All of the above described existing procedures for obtaining endometrial tissue samples have numerous disadvantages and potential risks to the patient, including: the risk of infection (e.g., due to the introduction of instruments into the vaginal cavity); the risk of perforating the endometrium and uterine wall (e.g., and possibly damage other organs, such as the intestines); severe bleeding (even in the absence of perforation of the endometrium); endometrial lesions by scarring, leading to infertility (i.e., Asherman's Syndrome); the risk of interrupting an existing but undiagnosed pregnancy; the risk of side effects from antibiotics or pain medication; the risks associated with anesthesia; pain and/or discomfort to the patient; interruption of sexual activity following the procedure; interruption of work and/or social activity for the patient following the procedure; and the risk of allergic reactions to drugs (e.g., antibiotics, analgesic, anesthesia, etc.), iodine (used for cleaning the uterine cervix and vagina during the procedure), latex (e.g., surgical gloves). Other drawbacks of existing procedures include the amount of time the procedures take, the elevated cost of the procedures and the complications they cause in the patient's lives (e.g., anxiety, interruption of work, family interactions and sexual activity).
SUMMARY
[0010] Accordingly, there is a need for an improved system and method for obtaining an endometrial tissue sample that does not suffer from the drawbacks associated with existing procedures, such as those described above.
[0011] In accordance with an aspect of the invention, an endometrial sample collector is provided. The collector comprises an outer body of absorbent material configured for insertion into a vaginal cavity of a patient such that a distal end of the body is positioned proximate a uterine cervix of the patient. The collector also comprises an internal collection assembly disposed within the outer body of absorbent material. The internal collection assembly comprises a funnel having an opening at the distal end of the outer body configured to face the uterine cervix when the outer body is positioned in the vaginal cavity, and a reservoir in fluid communication with the funnel. During a menstruation cycle of the patient when endometrial tissue cells are shed within menstrual fluid that passes through the uterine cervix, at least a portion of said menstrual fluid is directed to the reservoir via the funnel under the force of gravity.
[0012] In accordance with an aspect of the invention, an endometrial sample collector is provided. The collector comprises an outer body of absorbent material configured for insertion into a vaginal cavity of a patient such that a distal end of the body is positioned proximate a uterine cervix of the patient. The collector also comprises an internal collection assembly disposed within the outer body of absorbent material. The internal collection assembly comprises a funnel having an opening at the distal end of the outer body configured to face the uterine cervix when the outer body is positioned in the vaginal cavity, a conduit in fluid communication with the funnel, and a reservoir in fluid communication with the conduit. During a menstruation cycle of the patient when endometrial tissue cells are shed within menstrual fluid that passes through the uterine cervix, at least a portion of said menstrual fluid is directed to the reservoir via the funnel and the conduit under the force of gravity.
[0013] In accordance with an aspect of the invention, a method for passively collecting an endometrial tissue sample is provided. The method comprises inserting a sample collector into a vaginal cavity of a patient so that a distal end of the collector is positioned proximate a uterine cervix of the patient. The method also comprises collecting an endometrial sample in the sample collector during a menstrual cycle of the patient or during any type of normal or abnormal bleeding solely under the force of gravity. The method also comprises sending the sample collector with the collected sample to a laboratory for evaluation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic perspective top view of an endometrial sample collector.
[0015] FIG. 2 is a schematic perspective top view of the endometrial sample collector of FIG. 1 , showing internal components of the collector in phantom.
[0016] FIG. 3 is a schematic bottom view of the endometrial sample collector of FIG. 1 .
[0017] FIG. 4 is a schematic front view of the endometrial sample collector.
[0018] FIG. 5 is a schematic perspective top view of one embodiment of a collection assembly of the endometrial sample collector.
[0019] FIG. 6A is a schematic perspective top view of one embodiment of a collection assembly of the endometrial sample collector.
[0020] FIG. 6B is a schematic perspective top view of one embodiment of a collection assembly of the endometrial sample collector.
[0021] FIG. 6C is a schematic perspective top view of one embodiment of a collection assembly of the endometrial sample collector.
[0022] FIG. 6D is a schematic perspective top view of one embodiment of a collection assembly of the endometrial sample collector.
[0023] FIG. 7A is a schematic top view of the collection assembly of FIG. 6A .
[0024] FIG. 7B is a schematic top view of the collection assembly of FIGS. 6B, 6C and 6D .
[0025] FIG. 8 is a block diagram illustrating a method of collecting an endometrial tissue sample.
DETAILED DESCRIPTION
[0026] FIGS. 1-4 show and endometrial sample collector 100 that extends between a proximal end 2 and a distal end 3 and includes and outer body 10 and an internal collection assembly 50 . The outer body 10 is of an absorbent material (e.g., cotton, rayon, sponge material, absorbent polymer), such as the material used in typical tampons, and has absorption channels 11 through which fluid passes toward the internal collection assembly 50 . The outer body 10 of absorbent material advantageously facilitates patient comfort during collection of an endometrial sample in the manner discussed further below. The sample collector 100 can have a thread or cord 20 attached to it to aid in the removal of the collector 100 . As shown in FIG. 1 , the thread or cord 20 is in the form of a loop. However, the thread or cord 20 can optionally be a single string that extends to a free end (e.g., not a loop).
[0027] The endometrial sample collector 100 has a length L between the proximal end 2 to the distal end 3 of between about 4 cm and about 6 cm, and has a width W of between about 1 cm and about 3 cm. However, the endometrial sample collector can have other suitable dimensions.
[0028] The inner collection assembly 50 can be wrapped by the outer body 10 . The collection assembly has a cup or funnel 52 with an open end at the distal end 3 of the collector 100 that receives the sample therein. The funnel 52 is in fluid communication with a conduit 54 , which is itself in communication with a reservoir 56 , such that the conduit 54 is interposed between the funnel 52 and the reservoir 56 . The reservoir 56 can be at least partially filled with a fluid 4 that preserves the endometrial sample once received. The funnel 52 , conduit 54 and reservoir 56 can be separate components that are coupled together to form the collection assembly 50 . Optionally, the funnel 52 , conduit 54 and reservoir 56 can be made as a single monolithic piece (e.g., via an injection molding process). In other variations, the funnel can be augmented to have, or can be replaced with, a mesh or screen or permeable layer (e.g., foam layer) through which the sample fluid can pass to the reservoir 56 . The funnel 52 , conduit 54 and reservoir 56 can be made of a bio-compatible material, such as a plastic material, or other suitable material. The conduit 54 can optionally be excluded and the funnel 52 be in fluid communication with the reservoir 56 .
[0029] As discussed above, the fluid 4 in the reservoir 56 facilitates preservation of the collected endometrial sample. In one embodiment, the fluid 4 can be sterile saline. In another embodiment, the fluid 4 can be a solution made from a 1 L amount of distilled water in combination with the following composition: 0.9 gm/L Sodium Thioglycollate, 10.0 gm/L Sodium Glycerophosphate, 0.1 gm/L Calcium Chloride, and 3.0 gm/L Agar. The solution has a pH of 7.4±0.2. In some embodiments, the composition can optionally include 0.002 gm/L of methylene blue.
[0030] As shown in FIG. 5 , the collection assembly 50 can have a length L 2 that is substantially equal to the length L of the collector 100 . In one embodiment, the length L 2 is about 6 cm. The funnel 52 has a width W 1 (e.g., a diameter), and the reservoir 56 has a width W 2 , with the conduit 54 having a width smaller than the widths W 1 , W 2 of the funnel 52 and reservoir 56 . Optionally, the width of the conduit 54 can be generally equal to the widths W 1 , W 2 of the funnel 52 and reservoir 56 . The width W 1 of the funnel 52 can optionally be substantially equal to the width W 2 of the reservoir 56 . Optionally, the widths W 1 , W 2 (e.g., diameters) of the funnel 52 and reservoir 56 can be about 2 cm. As shown in FIG. 5 , the reservoir 56 has a generally spherical shape. However, the reservoir 56 can have other suitable shapes (e.g., oval).
[0031] FIGS. 6A-6D show various embodiments of the collection assembly 50 , in which the funnel 52 and reservoir 56 are the same, but where the conduit 54 is different for each embodiment.
[0032] In FIG. 6A , the conduit 54 A has a cross-shaped cross-section (see FIG. 7A ) that defines channels 54 A 2 between adjacent fins 54 A 2 of the conduit 54 A. The channels 54 A 2 can extend along the length of the conduit 54 A and can receive fluid axially from the funnel 52 as well as radially through the outer body 10 of absorbent material. The channels 54 A 2 can direct the sample fluid to the reservoir 56 .
[0033] In FIG. 6B , the conduit 54 B has a plurality of openings 54 B 1 distributed on a surface of the conduit 54 B (e.g., in spiral form) that are in fluid communication with an inner flow channel 54 B 2 of the conduit 54 B. Fluid can pass axially through the flow channel 54 B 2 from the funnel 52 to the reservoir 56 (see FIG. 7B ). Fluid can also pass transversely from the outer body 10 of absorbent material, through the openings 54 B 1 and into the flow channel 54 B 2 , which then directs the fluid to the reservoir 56 .
[0034] In FIG. 6C , the conduit 54 C has a plurality of openings 54 C 1 distributed on a surface of the conduit 54 C (e.g., in linear form) that are in fluid communication with an inner flow channel 54 C 2 of the conduit 54 C. Fluid can pass axially through the flow channel 54 C 2 from the funnel 52 to the reservoir 56 (see FIG. 7B ). Fluid can also pass transversely from the outer body 10 of absorbent material, through the openings 54 C 1 and into the flow channel 54 C 2 , which then directs the fluid to the reservoir 56 .
[0035] In FIG. 6D , the conduit 54 D is a tube that without any openings on its outer surface and has an internal flow channel 54 D 2 that directs fluid from the funnel 52 to the reservoir 56 , as shown in FIG. 7B .
[0036] FIG. 8 is a block diagram illustrating a method 200 of collecting an endometrial tissue sample using the sample collector 100 . The sample collector 200 is first inserted 210 (e.g., by the patient) into the vaginal cavity, in a similar manner as a tampon, so that the distal end 3 of the collector is proximate the uterine cervix and so that the funnel 52 faces the uterine cervix. Optionally, the distal end 3 is placed in contact with the uterine cervix. During menstruation, menstrual fluid, which will include endometrial tissue that is shed during the menstrual cycle and passes through the uterine cervix, is collected 220 by the collector 100 in the manner discussed above. For example, menstrual fluid can be collected in the funnel 52 and directed via the conduit 54 A, 54 B, 54 C, 54 D to the reservoir 56 , where the endometrial cells in the sample can be preserved in the preservation liquid 4 . Additionally, menstrual fluid absorbed by the outer body 10 of absorbent material can be directed transversely through channels (e.g., 54 A 1 ) or openings (e.g., 54 B 1 , 54 C 1 ) in a surface of the conduit 54 A, 54 B, 54 C, which can then also be directed to the reservoir 56 . Advantageously, the endometrial sample collector 100 passively collects the endometrial tissue sample using gravity and without the use of an external actuation force (e.g., without an aspiration or vacuum force, without a mechanical force such as scraping, etc.). Once the sample has been collected, the collector 100 can be can packaged in a container (e.g., plastic receptacle) and be sent 230 to a laboratory for evaluation. For example, the sample collector 100 can include user instructions directing the user on how to collect the sample, and how to package the sample for shipping to the laboratory, and optionally instructions on where to ship the collected sample.
[0037] Advantageously, the endometrial sample collector 100 and its use allows the patient to collect the sample without having to visit a doctor's office, clinic or hospital, and therefore without disruption to their normal daily activities. Additionally, the use of the collector 100 is non-invasive and does note expose the patient to the potential risks noted above with existing procedures (e.g., risk of infection, risk of perforation of the endometrium, pain and discomfort, bleeding, allergic reaction to medication, risks associated with anesthesia). Further, the sample collector 100 is as easy to use for patients as existing tampons. Additionally, the sample collector 100 can be used in patients with intact hymens (e.g., virgin women), patients that refuse gynecological exams or who live in remote areas far away from healthcare facilities, or patients who have problems adopting the correct gynecological position due to problems in their pelvic articulations, which is often the case following menopause. Further, the sample collector 100 allows the collection of endometrial tissue samples at much lower cost than existing procedures because, for example, doctor's fees (e.g., gynecologist, anesthesiologist), hospital fees, and disposable instruments and devices are avoided.
[0038] While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure. Accordingly, the scope of the present inventions is defined only by reference to the appended claims.
[0039] Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
[0040] Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.
[0041] Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and/or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.
[0042] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.
[0043] Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment.
[0044] Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.
[0045] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” refer to a value, amount, or characteristic that departs from exactly parallel by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.
[0046] The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.
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A non-invasive endometrial sample collector has an outer body of absorbent material configured for insertion into a vaginal cavity of a patient such that a distal end of the body is positioned proximate a uterine cervix of the patient. The collector has an internal collection assembly disposed within the outer body of absorbent material. The internal collection assembly includes a funnel having an opening at the distal end of the outer body configured to face the uterine cervix when the outer body is positioned in the vaginal cavity, and a reservoir in fluid communication with the funnel. During a menstruation cycle of the patient when endometrial tissue cells are shed within menstrual fluid that passes through the uterine cervix, or during any type of normal or abnormal bleeding episode, at least a portion of said fluid is directed to the reservoir via the funnel under the force of gravity.
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CROSS-REFERENCE TO RELATED PATENTS
The present invention relates to a punch and die unitary tool set for operation by a powder compacting press as disclosed in U.S. Pat. Nos. 3,328,840, 3,561,054, 3,561,056, 3,574,892, 3,645,658, 3,715,796, 3,730,659, 3,741,697 and 3,826,599, all assigned to the same assignee as the present application. The present application is an improvement of the telescopic punch assembly or tool set disclosed in U.S. Pat. Nos. 3,593,366 and 3,671,157, also assigned to the same assignee as the present application.
BACKGROUND OF THE INVENTION
The present invention relates to an improved unitary tool capsule or tool and die assembly for powder compacting presses. More particularly, the present invention relates to a tool and die set provided with a plurality of telescopic concentric punches for a single die cavity which are actuatable by a single-action powder compacting mechanical press having a cam-actuated ram.
In U.S. Pat. Nos. 3,593,366 and 3,671,157, there are disclosed powder compacting tool sets comprising dual, telescopic punches axially movable relative to and independently of each other in a precisely adjusted relationship, for forming against the surface of an anvil overlapping the opening of the die cavity, complex shaped articles such as cups, flanged buttons and the like.
The present invention represents a further advance in the technology of compacting relatively complex articles by means of at least three telescopic coaxial punches independently reciprocable by means of a single cam-actuated ram and by means of fluid pressure such as hydraulic or pneumatic fluid pressure, combined with means for the independent adjustment of each punch member such as to establish the desired characteristics for density, thickness and acurate dimensional consistency of the finished articles.
SUMMARY OF THE INVENTION
The principal object of the present invention therefore is to provide a novel unitary punch and die set for a powder compacting press adapted to compact, from powder material, an article of complex shape, through a single stroke of the ram of a press, by means of a multi-punch assembly, each of the several punches, which are disposed concentric to each other, being independently actuated and adjusted relative to the others. For forming articles provided with an aperture, a stationary adjustable core rod is also provided.
The many objects and advantages of the present invention will be apparent to those skilled in the art when the following detailed description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawing wherein like reference numerals refer to like parts and in which:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of an example of article made of compacted powder material by means of the punch and die assembly of the present invention;
FIG. 2 is a perspective view of another example of part;
FIG. 3 is a schematic sectional view of a telescopic punch and die assembly according to the present invention, shown in the die cavity fill position;
FIG. 4 is a view similar to FIG. 3 but showing the respective positions of the punches in the press position;
FIG. 5 is a view similar to FIG. 4, but showing the respective positions of the punches during ejection of the part from the die cavity;
FIG. 6 is a view similar to FIG. 5, and showing the end of the part ejection step;
FIG. 7 is a sectional view of a multi-punch and die assembly according to the present invention, taken substantially along lines 7--7 of FIGS. 9-11;
FIG. 8 is a partial sectional view thereof, taken along lines 8--8 of FIGS. 9 and 10;
FIG. 9 is a view from line 9--9 of FIG. 7;
FIG. 10 is a view from line 10--10 of FIG. 7;
FIG. 11 is a view from line 11--11 of FIG. 7;
FIG. 12 is a partial view similar to FIG. 7, but showing a modification of the invention; and
FIG. 13 is a diagram of the cam contour for actuating the punches of the punch and die assembly of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing and more particularly to FIGS. 1 and 2, the invention is particularly well adapted for compacting from powder material articles such as the cup-shaped article 10 of FIG. 1 or 11 of FIG. 2, each provided with, for example, a centrally disposed aperture 12 and an annular recess 13. Such articles, compacted from powder metal, ceramic, glass or the like, are obtained by means of a triple-punch tool set 14, schematically illustrated through consecutive steps of operation at FIGS. 3-6.
As schematically illustrated at FIGS. 3-6, a punch and die set 14 according to the present invention comprises an outer punch 16 reciprocable in a bore 18 formed in a die plate 20. The outer punch 16 has a longitudinal bore 22 in which is reciprocably disposed an intermediary punch 24. The intermediary punch 24 is in turn provided with a longitudinal bore 26 in which is reciprocably disposed an inner punch 28. The tool set 14 further comprises a core rod 30 disposed in a longitudinal bore 32 formed in the inner punch 28. As will be explained hereinafter in further detail, the outer punch 16, the intermediary punch 24 and the inner punch 28, which are disposed telescopically and concentric to each other in the example illustrated, are reciprocable independently of each other by the press mechanism, not shown, while the core rod 30 is generally held in a fixed position with its end face 34 flush with the upper surface 36 of the die plate 20.
The outer punch 16 has an annular end face 38 which is concentric to the annular end face 40 of the intermediary punch and also concentric to the annular end face 42 of the inner punch 28. In the position illustrated at FIG. 3, the annular end face 40 of the intermediary punch 24 is disposed at a level which is at a predetermined distance below the upper surface 36 of the die plate 20, and the annular end faces 42 and 38 of the inner punch 28 and outer punch 16, respectively, are disposed coplanar and a predetermined distance below the surface of the end face 40 of the intermediary punch 24. The space above the end faces of the three punches is filled with powder material 41, by way of a powder dispenser, not shown, which forms part of the work station positioner of the press, in the same manner as explained in the aforesaid U.S. patents. The space above the punch end faces, which defines a die cavity 44, is filled with powder material 41 to a level even with the upper surface 36 of the die plate 20 as a result of the wiping action of the edge of the powder dispenser.
After filling of the die cavity 44 with powder material 41, the anvil 46, FIG. 4, which also forms part of the work station positioner, is placed overlapping the die cavity 44 and clamped in position, the overlapping portion of the anvil 46 being firmly engaged with the upper surface 36 of the die plate 20. The intermediary punch 24 is advanced a predetermined distance while the outer punch 16 and the inner punch 28 are advanced a greater distance, such as to compact the powder material 41 in the die cavity 44 against the face of the anvil 46 to an appropriate shape and to appropriate dimensions. The outer punch 16 and the inner punch 28 are advanced simultaneously and in unison the same relative distance toward the face of the anvil 46 such as to remain constantly coplanar.
At FIG. 5, the three punches 16, 24 and 28 have been moved in unison, after removal of the anvil 46 from above the die cavity, to a position whereby the annular end face 38 of the outer punch 16 and the annular end face 42 of the inner punch 28 are flush with the upper surface 36 of the die plate 20, the annular end face 40 of the intermediate punch 24 remaining relative to the annular end faces 28 and 42 of the other punches in the position which it occupied during pressing (FIG. 4). The compacted article 10 is therefore ejected and projects above the die plate 20, and the end face 34 of the core rod 30 is about flush with the end of the aperture 12 in the part 10.
The next step, which is illustrated at FIG. 6, consists in maintaining the intermediary punch 24 stationary, while the outer punch 16 and the inner punch 28 are further advanced in unison, so as to disengage completely from the annular groove 13 of the part 10. The part 10 is therefore completely ejected and freed from the punches and can be picked up and carried away by any appropriate means such as mechanical means or vacuum suction means. It will be readily apparent that alternatively, in order to free the part 10, the inner and outer punches 28 and 16, respectively, may be maintained in the position that they occupied at FIG. 5, while the intermediate punch 24 is retracted to a position whereby its annular end face 40 is flush with the annular end faces 28 and 42 of the outer punch 16 and the inner punch 28, respectively.
The punches 16, 24 and 28 are subsequently differentially retracted within the die bore 18 to the position illustrated at FIG. 3, at which time the die cavity 44 is again filled with powder material 41, and the diverse steps of pressing and ejecting the part 10 are repeated.
Referring now to FIGS. 7-11, there is illustrated in detail a punch and die assembly 14 according to the present invention which comprises an outer punch 16 made preferably of an ultra-hard material, such as tungsten carbide and the like, which is slidably disposed in the bore 18 of a die bushing 50, also made of ultra-hard material such as tungsten carbide or the like. The die bushing 50 is press-fitted, cemented, or otherwise fastened in the shouldered bore 52 of a die button 54 removably fitted in a bore 56 formed in the die plate 20. The die plate 20 is in turn mounted on the top of a spacer plate 58 by any appropriate means such as screws, bolts or the like, not shown. The bore 56 in the die plate 20 has an annular shoulder 60 engaging an annular shoulder 62 in the periphery of the die button 54, and the die button 54 and, consequently, the die bushing 50 are held removably in position by means of an annular retainer 64 having a peripheral thread engaging an internally threaded bore 66 formed in the spacer plate 58, substantially according to the arrangement disclosed and claimed in co-pending application Ser. No. 734,970, filed Oct. 22, 1976, issued Oct. 11, 1977 as U.S. Pat. No. 4,053,267 and assigned to the assignee of the present application.
The punch and die assembly 14 is mounted in an appropriate aperture 68 formed in the table 70 of a press, not shown, by any appropriate means such as bolts or clamps.
The outer punch 16 has a longitudinal bore 22 through which is slidably disposed the intermediary punch 24, having in turn a longitudinal bore 26 through which is slidably disposed the inner punch 28. The inner punch 28 is also tubular and has a longitudinal bore 32 accepting therethrough the core rod 30. The three concentric punches and the core rod 30 are shown at FIG. 7 in the position corresponding to the full ejection of the compacted article, not shown, as illustrated at FIG. 6, the annular face 38 of the outer punch 16 being coplanar with the annular face 40 of the intermediary punch 24 and the annular face 42 of the inner punch 28. The end face 34 of the core rod 30 is maintained fixedly flush with the surface 36 of the die plate 20 and the die bushing 50.
The core rod 30 is supported by a core rod holder 72 which is in the form of a plate having a pair of bores 74 through each of which is passed a column 76, see also FIGS. 9-11, which projects below the die spacer plate 58. The core rod holder 72 is affixed to the columns 76 by convenient means such as set screws, not shown, such that the end face 34 of the core rod 30 may be adjusted to any appropriate longitudinal position. If so desired, the core rod holder 72 may be made reciprocable relative to the support columns 76 and reciprocated in unison with one of the punches, or independently, by means alike those described hereinafter for reciprocating the punches.
The core rod 30 is held in its holder 72 by being provided with an enlarged disk-like foot portion 78 formed integral at the end of the core rod 30, the body of the core rod 30 passing through a longitudinal bore 80 formed in the holder 72. The core rod foot portion 78 is held in position in the holder 72 by a retainer plate 82 fastened to the bottom of the holder 72 by means such as screws 84.
The outer punch 16 is held by a punch holder in the form of a plate 86 which is provided with a pair of bushed bores 88 slidably accepting the support columns 76 therethrough. The outer punch 16 is provided with an enlarged foot portion 89 inserted in a recess 90 formed on the top of the plate 86 and is held in position by means of fasteners such as screws 92. The plate 86 is provided with a substantially centrally disposed bore 94 allowing the periphery of the intermediary punch 24 to project therethrough.
The intermediary punch 24 is supported by a punch holder plate 96 also reciprocably supported by the columns 76 passing through a pair of bearing-provided bores 98, FIGS. 7 and 10. The plate 96 has a circular recess 100 at the center of its upper surface which accepts the enlarged foot portion 102 of the intermediate punch 24, appropriate bolts or screws 104 holding the punch securely in position on the holder plate 96.
The inner punch 28 is similarly held by a punch holder plate 106 slidably supported by the support columns 76, each passed through one of a pair of bearing-provided bores 108. The bottom of the inner punch 28, which freely passes through a central bore 110 in the intermediary punch support plate 96, is provided with an enlarged foot portion 112 disposed in a recess 114 formed in the upper surface of its support plate 106, and is fastened therein by means of fasteners such as bolts 115. The inner punch holder plate 106 has a central aperture 116 affording passage to the core rod 30.
A punch actuating member 120 is coupled to the ram 122 of the press by means of a threaded collar coupling 124. The actuating member 120 has a reduced diameter upper end 126 provided with a peripheral thread 128 accepting an internally threaded adjusting ring 130 affixed in an appropriate position by way of radial set screws 131. A pair of actuating bars 132 passed through appropriate aligned apertures 134 and 136 respectively in the core rod support plate 72 and in the inner punch support plate 106 have each a lower end face 138 abutting the upper surface 140 of the adjusting ring 130 and an upper end face 142 capable of abutting against the lower surface 146 of the intermediary punch holder plate 96. Therefore, upward motion of the actuating member 120 results in upward motion of the intermediary punch holder plate 96 and consequently of the intermediary punch 24, through the connection provided by the actuating bars 132. The adjustment of the ring 130 along the threaded end portion 128 of the actuating member 120 determines the maximum advance of the annular end face 40 of the intermediary punch 24. A plurality of compressed coil springs 148, disposed between the top of the intermediary punch holder plate 96 and the bottom of the outer punch holder 86, constantly urge the two punch holder plates away from each other.
The amount of reciprocation of the intermediary punch holder plate 96 towards the stationary core rod holder plate 72 is adjustably determined by means of a pair of adjustment rods 149 passed through apertures 150 in the inner punch holder plate 106 and having an upper end 152 engageable with the lower surface 146 of the intermediary punch holder plate 96. The lower end 154 of each rod 148 abuts against the upper face 156 of an internally threaded adjusting ring 158 threading around the threaded periphery of an adjusting plug 160 having an internally threaded bore 162 threading around the threaded periphery 164 of an upward projecting prong portion 166 integrally formed on the top of the core rod holder plate 72. Radially disposed set screws, such as set screw 159, immobilize the ring 158 relative to the plug 160 which, in turn, may also be provided with radial set screws, not shown, for immobilizing relative to the threaded prong 166. The upper end face 168 of the plug 160 acts as an adjustable abutment limiting the downward stroke of the inner punch holder plate 106, while the adjustment of the threaded ring 158 relative to the plug 160 in turn determines the limit of the downward stroke of the intermediary punch holder plate 96, by way of the abutment means formed by the rods 149, as previously explained.
The actuating member 120 has an enlarged radially extending annular portion defining a piston member 170 for a reciprocable cylinder designated generally at 172. The reciprocable cylinder 172 comprises an upper end plate 174 having a reduced diameter bore 176 through which projects a smooth surface projecting portion 178 of the actuating member 120 disposed between the threaded end portion 126 thereof and the enlarged diameter piston portion 170 thereof. A groove 180, provided with a seal 182, is disposed about the periphery of the portion 178, to prevent leakage to the ambient of fluid introduced into a chamber 184 thus formed between the upper face of the piston member 170 and the inner surface of the cylinder end plate 174. A passageway 186 places the chamber 184, through a fitting 188, in communication with a source of hydraulic or pneumatic fluid, not shown. The lower end of the reciprocable cylinder 172 is closed by an end plate 190 fastened to the upper end plate 174 by means of appropriate fasteners such as bolts 192. An undercut annular groove on the lower face of the piston member 170 forms a fluid chamber 194 into which fluid may be introduced by way of a passageway 196. The piston member 170 has a peripheral groove 198 provided with an annular ring or seal 200 which prevents fluid transfer from one side of the piston member 170 to the other side. An annular groove 202 provided with a seal 204 is disposed on the inner bore 206 of the end plate 190 and prevents leakage of fluid from the chamber 194 to the ambient.
The reciprocable cylinder 172 is guided during its stroke relative to the actuating member 120 by way of a pair of diametrically opposed bearing-provided bores 208 through each of which is passed a support column 76. It can thus be seen that when pressurized fluid is introduced by way of passageway 186 into the chamber 184, the reciprocable cylinder 172 is displaced upwardly to the position shown at FIG. 7 relative to the actuating member 122, and when fluid is exhausted from the chamber 184 while at the same time fluid under pressure is introduced into the chamber 194, the reciprocable cylinder 172 is displaced downwardly, relative to the actuating member 120, until an annular abutment 209 formed on the inner face of the end plate 174 engages the upper face of the piston member 170.
Each of a pair of push-pull bars 210 has an end fastened to the top of the reciprocating cylinder 172 by means of a bolt 212. The other end of each push-pull bar 210 is fastened to the bottom of the outer punch holder plate 86 by way of a bolt 214. Each push-pull bar 210 passes freely through appropriate cut-out portions or notches 211 disposed at the edge of the inner punch holder plate 106 and of the intermediary punch holder plate 96. In this manner, the outer punch holder plate 86 and, consequently, the outer punch 16 are reciprocated by the reciprocable cylinder 172. The reciprocable cylinder 172 is in turn reciprocable both in unison with the actuating member 120 and relative to the reciprocating member 120, the latter when pressurized fluid is introduced in one of the chambers 184 or 194 while pressurized fluid is exhausted from the other chamber. The reciprocable cylinder 172 is also arranged to displace, as best shown at FIG. 8, the inner punch holder plate 106 by means of a push bar 216 disposed between the upper surface of the cylinder end plate 174 and the lower surface of the punch holder plate 106. The upper end of the push bar 216 is attached to the inner punch holder plate 106 by way of a bolt 218, while its lower end 220 only abuts against the upper face of the cylinder end plate 174 and may therefore separate therefrom under certain conditions of operation. As also shown at FIG. 8, a plurality of compressed coil springs 222 are disposed between the bottom of the outer punch holder plate 86 and the top of the inner punch holder plate 106, the coil springs 222 passing freely through appropriate bores 224 disposed through the intermediary punch holder plate 96, such that the outer punch holder plate 86 and the inner punch holder plate 106 are normally biased away from each other.
During operation of the tool capsule 14 mounted in the table of a powder compacting press, the ram 122 of the press is reciprocated by a cam, not shown, which in turn reciprocates the actuating member 120. The same cam, or another cam dependent from the press drive mechanism, operates in timed relationship with the operation of the ram 122 a two-way valve which permits to introduce pressurized fluid into the appropriate chamber 184 or 194, while exhausting fluid from the other chamber, such as to reciprocate the reciprocable cylinder 172 relative to the actuating member 120.
FIG. 7 illustrates the relative position of the elements causing full ejection of the compacted part, not shown at FIG. 7, from the die cavity. Such step is illustrated schematically at FIG. 6, and corresponds to the maximum extension outside of the die bore 18 of the outer punch 16, the intermediary punch 24 and the inner punch 28. FIG. 13 represents schematically a planar projection of an example of a press operating cam profile for actuating the ram 122 of the press which in turn actuates the actuating member 120. Full line curve A represents the profile of the cam, as a function of the rotation of the cam during a complete revolution. Ejection of the compacted part occurs at about 270° of rotation of the cam which corresponds to the top of the upward stroke of the actuating member 120 directly displacing through the threaded ring 130 and the bars 132 the intermediary punch holder plate 96 to the position illustrated at FIG. 7, which in turn displaces the intermediary punch 24 and its annular end face 40 to the top of its stroke to the position shown at FIG. 7 and also at FIGS. 5 and 6. Simultaneously therewith, pressurized fluid is introduced into the chamber 184 while fluid is exhausted from the chamber 194, such that the reciprocable cylinder 172, FIG. 7, is displaced upwardly relative to the piston member 170 of the actuating member 120. Through the push-pull bars 210, the outer punch holder plate 86 is therefore displaced upwardly in unison with the inner punch holder plate 106 being displaced upwardly by the push bars 216 engaging the top of the reciprocable cylinder 172. Consequently, the annular end face 38 of the outer punch 16 and the annular end face 42 of the inner punch 28 are displaced to the top of their stroke to the position illustrated at FIG. 7 and also at FIG. 6, flush with the annular end face 40 of the intermediary punch 24. The part 10 is therefore freed from the end of the intermediary punch 24 and can be removed from above the punches. The portion a of the cam contour A of FIG. 13 causes the upward stroke of the actuating member 120 and consequently of the intermediary punch 24, while the dashed line B at FIG. 12 represents the simultaneous travel of the outer punch 16 and the inner punch 28 due to the operation of the reciprocating fluid actuated cylinder 172.
Subsequently thereto, during the rotation of the cam from 270° to 360°, FIG. 13, pressurized fluid is exhausted from the chamber 184 while pressurized fluid is introduced into the chamber 194, therefore pulling downwardly the outer punch holder plate 86 and retracting the outer punch 16, while simultaneously allowing the outer punch holder plate 106 to move downwardly, under the pressure of the springs 222, thus also retracting the inner punch 28. However, simultaneously therewith, the ram 122 of the press is allowed by the cam to move downwardly such that all three punches are displaced downwardly to the feed position illustrated at FIG. 3 and corresponding to the flat portion b of the cam contour of FIG. 13 corresponding to the 90° angular rotation position of the cam. It is to be noted that in such position, the feed position, the annular faces 38 and 42 of respectively the outer punch 16 and the inner punch 28 are coplanar and at a given distance from the level of the annular end face 40 of the intermediary punch 24. In the feed position illustrated schematically at FIG. 3, the bottom surface 146 of the intermediary punch holder plate 96 engages the end face 152 of each stationary rod 148, and is prevented from moving downwardly any further than allowed by the adjustment of the threaded ring 158 around the threaded plug 160. However, the actuating member 120 is free to be displaced downwardly any amount permitted by the contour of the cam, as the bars 132 are free to separate at either end 138 or 142 from the top surface 140 of the collar 130 and from the bottom surface 146 of the intermediary punch holder plate 96.
After the die cavity 44 has been filled with powder material 41, as shown at FIG. 3, the anvil 46 is placed over the die cavity opening and the cam having rotated as shown at FIG. 13 to the press position c, corresponding to 180° of rotation of the cam, the actuating member 120 has been displaced upwardly, therefore displacing in turn the cylinder 172 until eventually the upper surface 140 of the ring 130 abuts against the end face 138 of the bars 132, causing the upper end face 132 of the bars to engage the lower surface 146 of the intermediary punch holder plate 96. Consequently, the intermediary punch 24 is displaced upwardly, but of a distance less than the outer punch 16 and the inner punch 28, with the result that in the press position of FIG. 4, the distance separating the plane of the annular end face 38 of the outer punch 16, coplanar with the annular end face 42 of the inner punch 28, from the plane of the annular end face 40 of the intermediary punch 24 is smaller than the distance corresponding to the feed position of FIG 3. Such a differential action is necessary to provide uniform density of the finished part, in view of its geometry.
After the part has been compacted, the contour of the cam is such as to slightly relieve the pressure on the ram and consequently on the actuating member 120, as shown by the relatively lower flat portion d of the cam contour A of FIG. 13. The anvil is removed from above the die cavity and the part is ejected to the position shown at FIG. 5 as a result of the ram and consquently the actuating member 120 being displaced upwardly by the contour a of the cam corresponding to 270° of rotation of the cam. At this time, as previously explained, fluid is removed from the chamber 194 while fluid is introduced into the chamber 184 thus displacing further upwardly the reciprocating cylinder 172 for displacing the part 10 to the full eject position of FIG. 6.
The assembly or tool set illustrated at FIG. 12 is in principle and structure alike the structure of FIGS. 7-11 with, however, an additional adjustment limiting the travel of the inner punch holder plate 106 towards the reciprocable cylinder 172. This adjustment is provided by a peripheral thread 230 formed on the outside surface of the cylinder housing 174 around which is threaded an adjusting ring 232 having an upper annular abutment surface 234 engaged with the end 236 of a pair of abutment bars 238 having their upper end 240 bolted to the bottom surface of the inner punch holder plate 106 by appropriate fasteners such as bolts 242. The bars 238 accomplish the same function as the bars 216 of FIG. 8, that is that of limiting the downward stroke of the inner punch holder plate 106 relative to the cylinder 172, but the structure of the adjusting ring 232 provides an adjustment of the limit of the downward motion of the inner punch plate holder 106, and consequently of the inner punch.
It can thus be seen that the present invention provides a multiple-action punch and die assembly with appropriate adjustment of the extreme positions of the punches during reciprocation, a further adjustment of the punch actuating member being provided in the press ram mechanism itself, and by combining the mechanical actuation of the punches by means of the press ram with auxilliary actuation by fluid means, a great flexibility of adjustment and stroke motion of the individual punches are obtained with a single-action cam driven press, in the course of a single revolution of the actuating cam.
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A punch and die set for operation by the ram of a powder compacting press, comprising at least three concentrically disposed telescopic punches independently reciprocable within a single die cavity. Each punch is separately supported by a punch holder plate, one of which is directly reciprocable from the press ram, another of which is reciprocable by way of appropriate abutments dependent from the first punch holder and the third of which is independently reciprocable relative to the first one by way of fluid pressure.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to an amphibious vehicle.
[0002] The amphibious vehicle contemplated by the present invention is lightweight in nature. Nevertheless, it requires a power plant with a certain amount of power output in order that the vehicle on water can get up on to the plane and travel as a planing vehicle. Such power levels may however be capable of imparting undesirably high speed and acceleration potential to the vehicle when used on land. Moreover, legislative requirements in certain parts of the world actually restrict power and/or road speed for certain types of vehicles. For example, a Low Speed Vehicle in the USA must not be capable of exceeding 25 mph on the road while in Europe a road legal All Terrain Vehicle must be restricted to an engine power output of less than 15 kW/20 brake horsepower.
SUMMARY OF THE INVENTION
[0003] In a first aspect the present invention provides an amphibious vehicle comprising at least three wheels; handlebars operable to steer at least a front pair of the wheels; a sit-astride seat; a power plant driving at least one of the wheels when the vehicle is operating in a land mode; a jet drive or propeller driven by the power-plant when the vehicle is operating in a water mode; wherein power control means is provided to control in amount power delivered to drive the driven wheel(s), the power control means operating to limit power transmitted to the driven wheel(s) in land mode operation while allowing greater power to be transmitted to the jet drive or propeller.
[0004] In a second aspect the present invention provides an amphibious vehicle comprising: at least three wheels; handlebars operable to steer at least a front pair of the wheels; a sit-astride seat; a power plant driving at least one of the wheels when the vehicle is operating in a land mode; a jet drive or propeller driven by the power plant when the vehicle is operating in a water mode; wherein speed control means is provided to offer resistance to motion of the vehicle on land whilst not limiting speed of the vehicle over water.
[0005] In third aspect the present invention provides an amphibious vehicle comprising: at least three wheels; handlebars operable to steer at least a front pair of the wheels; a sit-astride seat; a power plant driving at least one of the wheels when the vehicle is operating in a land mode; a jet drive or propeller driven by the power plant when the vehicle is operating in a water mode; wherein the power plant outputs power via a rotating output shaft; and speed control means is provided to limit the rotational speed of the driven wheel(s) when the vehicle is operating in the land mode.
[0006] These and other features and advantages of the present invention will become apparent from the following detailed description of preferred embodiments which, taken in conjunction with the accompanying drawings, illustrate by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of an amphibious vehicle according to the present invention;
[0008] FIG. 2 is a view of the vehicle of FIG. 1 in which the top surface of the vehicle has been made transparent; and
[0009] FIG. 3 corresponds to the view in FIG. 2 , save that the FIG. 2 shows the vehicle in water mode and the FIG. 3 shows the vehicle in land mode.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] Turning firstly to FIG. 1 there can be seen in the Figure an amphibious vehicle 10 having four wheels 11 , 12 , 13 and 14 , handlebars 15 for steering the front wheels 11 and 14 and a sit-astride seat 16 . As can be seen in FIG. 2 , there is located inside the vehicle a gasoline reciprocating piston multi-cylinder internal combustion engine 17 which when the vehicle is in land mode drives the two rear wheels 13 and 12 to rotate. The vehicle also has a jet drive 18 at the rear of the vehicle which is driven by the engine 17 to propel the vehicle 10 when operating in water mode.
[0011] The hull 19 of the vehicle has on its lower surface a planing surface (not shown) to enable the vehicle to plane across the water when in its water mode. To facilitate this the road wheels 11 , 12 , 13 and 14 are connected to the remainder of the vehicle by a suspension system which allows them to be moved between an extended position (as shown in FIG. 3 ) for land use and a retracted position (as shown in FIGS. 1 and 2 ) for use on water.
[0012] In order that the vehicle 10 operates as a planing vehicle on water, even when transporting 2 or 3 passengers, the engine 17 must have a certain power output. However, since the vehicle 10 will be very light, this power output if fully available on land would make the vehicle difficult to drive because it would be capable on land of excessive speed and excessive acceleration.
[0013] The present invention provides for the restriction of the power available to the road wheels and/or restriction of the speed of rotation of the road wheels by a power or speed control system which limits the power available to drive the wheels in road use or the rotational speed of the wheels, whilst allowing greater power to be available to the jet drive or propeller in marine use and/or allowing the jet drive/propeller to rotate at greater rotational speed than the road wheels. The power control system can take many forms, including:
[0014] 1. Provision of a fuelling system for the engine 17 which operates to restrict the flow of fuel to the engine when the vehicle is operating in road mode. For an engine with a carburettor this would be done by metering the fuel supplied from a fuel pump and for a fuel injection engine the fuel supply pressure could be varied. For a diesel engine the mechanical governor could be restricted in land mode.
[0015] 2. Provision of an exhaust throttle or brake which restricts flow of combusted gases from the combustion chambers of the engine 17 during road mode operation.
[0016] 3. The use of an intake throttle whose limit of opening can be controlled so that in marine mode the intake throttle will be capable of opening to wide open throttle, but in land mode the movement of the throttle will be restricted to an extreme position which is still partly closed. This can be done by deploying a mechanical throttle stop to limit throttle movement in land mode and retracting the stop for marine use. Alternatively the throttle could be an electrically operated throttle controlled by an electronic control system which receives a signal indicative of position of a manually operable throttle control and controls position of the throttle accordingly; in land mode operation the system will limit throttle motion to restrict engine output power and thereby vehicle speed. A mechanical throttle damper could also be employed operable only in land mode to damp throttle movement (or with different characteristics in land and marine modes, with a greater degree of damping applied in land mode).
[0017] 4. If the engine 17 is a multi-cylinder engine then it is envisaged that the engine could be provided with a cylinder deactivation system so that all of the cylinders would be active when the vehicle is operating in water mode and then some of the cylinders deactivated for land mode. If the engine is a spark ignition engine which uses port fuel injectors, one for each cylinder, then this could be achieved by deactivating the ignition system for the relevant cylinders and deactivating the port fuel injectors for the relevant cylinders.
[0018] 5. The engine 17 could be provided with an electronic ignition system (assuming it is a spark ignition engine), and the timing of the spark could be varied to alter the power output of the engine between marine mode operation and land mode operation.
[0019] 6. The engine 17 could be connected to the wheels 12 via a gearbox which is deliberately chosen to be a low ratio gear box so that the rotational speed of the wheels 12 and 13 is limited by the maximum speed of revolution of the engine 17 . The transmission could comprise a simple manual gearbox, an automatic gearbox or a continuously variable gearbox, all suitably configured to ensure that a gear ratio is never employed which at maximum engine speed would result in excessive land speed of the vehicle.
[0020] 7. The engine 17 could be adapted to be a “dual fuel” engine, for instance operating using gasoline on water and using compressed natural gas (which has a lower calorific value) in land mode.
[0021] 8. The engine 17 could be a supercharged engine with an engine driven compressor. The supercharger could be driven by a clutch and the clutch closed during marine mode (so that the engine is supercharged) and opened during land mode so that the engine loses its supercharging and therefore loses power.
[0022] 9. The engine 17 could be a turbocharged engine. If so, a bypass passage could be included to bypass the turbocharger so that the engine is turbocharged only during marine operation and not during land use. Additionally, or alternatively the vanes in the turbocharger could be made to have a variable pitch, in which case the pitch would be varied to decrease boost in land mode and increase boost in marine mode. Additionally, or alternatively the engine could be provided with a pair of turbochargers, high pressure and low pressure, and the low pressure turbocharger used on its own in land mode could then be replaced by the high pressure turbocharger in water mode (or both turbochargers operated simultaneously in water mode).
[0023] 10. The engine 17 could be provided with multiple poppet valves per cylinder, including at least two inlet poppet valves per cylinder. A poppet valve deactivation system could then be operated to deactivate e.g. one or each pair of inlet poppet valves, in order to decrease the flow of air through the engine in land mode.
[0024] 11. The air inlet manifold for the engine 17 could be made of variable length and could be “tuned” to give good performance during marine mode operation (by ensuring that a standing wave is set up in the inlet manifold which gives rise to high pressure just behind the inlet poppet valves). The inlet manifold could then be “detuned” for land use to reduce the engine performance and output.
[0025] 12. By suitable programming of an engine control unit it will be possible to give an engine characteristics for water mode operation which are different to the characteristics for land mode operation. For instance, the engine control unit can vary the fuelling (as described above) and the spark ignition timing (also described above).The engine control unit could be provide with a pair of different throttle maps, one for land use and the other for marine use.
[0026] 13. Certain internal combustion engines have been proposed which achieve variable compression ratios in the cylinders of the engine. SAAB has an engine with a tilting cylinder block which enables compression ratio to be varied. Others have proposed variable length pistons or movable cylinder heads. Crank mechanisms have also been proposed in the past which vary the piston travel. Any of these mechanisms could be used to alter the power output from the engine so that the power output is greater in marine mode than in land mode.
[0027] 14. It is known in several engines available today to vary in timing the opening and closing of inlet and exhaust valves of the engine. This can be achieved, for instance, using cam phasing mechanisms. Varying the valve timing can lead to a change in the characteristics of the engine and a power output in land mode which is less than the power output in marine mode.
[0028] 15. For a simpler and somewhat cruder approach, the power control mechanism could act on the clutch which connects the engine to the driven road wheels. The clutch mechanism could be controlled to deliberately allow clutch slippage and therefore limit the power transmitted to the road wheels, even though the engine itself outputs the same amount of power both in land and water modes.
[0029] 16. Another simple approach to limiting power output would be to warm the intake air prior to combustion, which could be done, for instance, by running hot coolant around the air intake with the flow of hot coolant switched on and off depending upon operating mode.
[0030] 17. The body of the vehicle could be provided with moving flaps which are retracted during marine mode operation to make the vehicle more streamlined and then extended during land mode operation to give greater air resistance and restrict thereby the speed of the vehicle. The movable body parts of the vehicle could be a front screen of the vehicle, which could be tilted into a more upright position in land mode, or a spoiler. Also the air intake apertures in the vehicle body (which provide a flow of cooling air to the radiator(s) of the vehicle) could be provided in deployable scoops which are extended in land mode operation of the vehicle to increase air flow and to increase drag. The vehicle suspension could also be provided with a tilting mechanism which would tilt the vehicle with increasing speed in order that the vehicle presents a greater effective frontal area to increase drag.
[0031] 18. It would be possible to fit the vehicle with a sophisticated braking system which would apply brakes to the road wheels to limit the top speed of the vehicle. This could be a function of a traction control system of the vehicle.
[0032] 19. The engine could be provided with an alternator or other electrical charger which is switched in to be driven by the engine during land mode, but which is decoupled from the engine during marine mode so that the net power of the engine is reduced in land mode because of the power needed to power the electrical charger.
[0033] 20. A very basic way of restricting the performance of the vehicle on land is to provide it with tyres which have high rolling resistance and high friction.
[0034] 21. It is also possible to configure the vehicle with a first throttle control for road use and a second throttle control for marine use, with each throttle control being made automatically inactive depending upon the mode of operation. The road use throttle control would only allow the throttle to be opened part way and not a wide open throttle thereby restricting the power output during land operation. On the other hand, the marine mode operation would allow the vehicle to operate with wide open throttle and would not restrict the power output of the engine.
[0035] 22. Many internal combustion engines are now provided with exhaust gas recirculation in order to improve the overall emissions of the engine. It would be possible to adapt an exhaust gas recirculation system to feed back sufficient exhaust gas into the combustion chambers that the overall power output of the engine was reduced. This would be done for land operation, whereas the exhaust gas recirculation would be reduced or stopped completely for water use.
[0036] 23. Whilst in the drawings and as described above, the vehicle has a single internal combustion engine as its power plant, the vehicle could be provided with, for instance, two internal combustion engines. The transmission connecting the internal combustion engines to the jet drive/propeller and to the driven road wheels would operate under the control of the power control system in order to either power the jet drive/propeller using both engines, with the driven road wheels driven by only one engine, or alternatively to drive the jet drive/propeller with a first engine and the driven road wheels with a second, different engine. The second engine would have a reduced power output as compared with the first engine.
[0037] In the modes of operation described above, in which an absolute limit is placed on vehicle speed it may be desired to provide a warning light in the instrument cluster to warn the driver when the speed limit is reached.
[0038] For all of the embodiments described above there will be an electronic control system which senses whether the vehicle is in road mode operation or marine mode operation and then controls the power output of the engine accordingly. The simplest way of providing for this would be to sense whether the wheels are in their retracted or extended positions. The wheels will typically be extended or retracted under manual control and a sensor can easily be provided to detect which location they are in. The switch-over of engine power output or the switch of power available to the vehicle wheels will occur automatically on the sensing of a change of mode from water mode to land mode. The driver will not be allowed to override the action of the power control system.
[0039] Whilst sensing the position of the wheels will give the easiest way of detecting whether the vehicle is in land mode or water mode, other ways of detecting this are possible: for instances, sensors to detect the immersion of the hull in water, e.g. hull-mounted pressure sensors, or sensors detecting the presence of water in the intake pipe leading to a jet drive.
[0040] While a particular form of the present invention has been illustrated and described, it will also be apparent to those skilled in the art that various modifications can be made without departing from the spirit and the scope of the present invention. Accordingly, it is not intended that the invention be limited except by the appended claims.
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Amphibious vehicle needs less power on land than on water. A control system is provided to limit power and/or speed on land, using: restriction of flow of fuel, air, or exhaust gases; heated intake air; exhaust gas recirculation; declutching of a supercharger; bypassing of a turbocharger; a variable throttle stop, dual throttles, or a switchable throttle damper; cylinder or intake valve deactivation; a dual length intake manifold; dual mode ignition or engine mapping; dual fuel—gasoline on water, compressed natural gas on road; variable compression ratios or valve timing; a clutch designed to slip; automatic brake application; or aerodynamic brakes. The suspension may tilt the vehicle to increase aerodynamic resistance. The road transmission may be geared to limit maximum speed. High rolling resistance tyres or twin engines may be used. A sensor on retractable suspension may indicate whether the vehicle is on land or on water.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to methods and apparatus for circulating and dispensing fluids; more particularly, to methods and apparatus for circulating and dispensing fluids having magnetorheological properties; and most particularly, to methods and apparatus for managing and metering magnetorheological fluids being used in a magnetorheological finishing apparatus.
2. Discussion of the Related Art
It is well known in the art of finishing and polishing surfaces to use, as a finishing agent, particulate fluid suspensions having magnetorheological properties. Such fluids, known as magnetorheological fluids (MR fluids), comprise magnetically soft particles which can become oriented and magnetically linked into fibrils in the presence of a superimposed magnetic field, thereby increasing the apparent viscosity of the fluid by many orders of magnitude. Such increase is known as magnetic “stiffening” of the MR fluid. It is further known to incorporate finely-divided abrasives into MR fluids used in finishing and polishing to increase the rate of removal of material. Non-stiffened, or magnetically relaxed, MR fluid can be stored and pumped as a low-viscosity fluid, having a viscosity typically of about 50 cp or less, then stiffened to a semi-rigid paste of 10 5 cp or more in a magnetic work zone for finishing or polishing, then relaxed again outside the work zone for collection, reconditioning, and reuse. Apparatus and methods for magnetorheological finishing and for delivery of MR fluids are disclosed in, for example, U.S. Pat. No. 5,951,369 issued Sep. 14, 1999 and U.S. Pat. No. 5,971,835 issued Oct. 26, 1999, both to Kordonski et al., the relevant disclosures of which are herein incorporated by reference.
MR fluid finishing apparatus typically includes a fluid delivery system (FDS) for dispensing MR fluid onto a rotating carrier surface, whereon the fluid is carried into and out of the work zone. MR fluid is a relatively unstable suspension because the magnetic particles tend readily to agglomerate and to settle out of suspension and thereby stagnate. Thus, a primary concern in configuring an FDS for MR fluid is keeping the fluid relatively homogeneous in the system, and very highly homogeneous at the point of dispensing into the work zone. An FDS must receive spent fluid from the work zone, recondition the fluid for reuse as by adjusting the temperature and viscosity, homogenize the adjusted fluid, and redispense the fluid into the work zone at a controlled flow rate. A suitable prior art FDS is disclosed in U.S. Pat. No. 5,951,369 incorporated above.
Because of these various requirements, the prior art FDS is relatively complex and includes a first peristaltic pump for removing spent fluid from a scraper at the work zone and returning the fluid to a reservoir; a mixer in the reservoir for rehomogenizing the fluid; a tempering subsystem at the reservoir for cooling the fluid, which tends to become heated in the work zone; a second peristaltic pump and cylindrical nozzle having a fixed restriction for redispensing the fluid; a pulse-dampener for removing pulses generated by the pumps; and a viscosity measuring and correcting subsystem. Flow may be controlled by manually setting the speed of the second pump, and preferably is monitored via a magnetic induction flowmeter.
Several problems are presented by the prior art FDS.
First, the system is cumbersome, as it is essentially an assemblage of discrete components, each intended to perform a single task. Thus, the system is wasteful of space.
Second, the flow control system requires a positive-displacement (PD) pump. Some known PD pumps such as gear pumps are unsuited to the task of pumping MR fluids. A peristaltic pump can meet the positive-displacement need over a short period of time; however, the pulsating output mandates the pulse-dampening apparatus already noted, and the delivery lines within the pump are subject to fatigue and must be replaced frequently.
Third, correct composition of the MR fluid being redispensed is inferred from an inline viscometer which incorporates a cylindrical nozzle that, for flow reasons, must be relatively long and thus is cumbersome. In the flow and composition control strategy employed, a constant input pressure at the entrance to the nozzle and a constant flowrate at the flowmeter indicate a constant viscosity and hence constant composition of the fluid being dispensed.
What is needed is an improved fluid delivery system for managing MR fluid in an MR finishing apparatus wherein flow is inherently smooth, pulsations are not generated, and pulsation dampening is unnecessary; wherein the dispensing flow is maintained at a desired flowrate by a closed-loop flow control subsystem; wherein the composition of the MR fluid is automatically corrected to aim during a reconditioning step; wherein the sizes of components such as a dispensing nozzle are minimized; and wherein mixing, tempering, and pressurizing of MR fluid is performed in a single vessel.
It is a primary objective of the invention to provide a simple, compact fluid delivery system for managing and dispensing magnetorheological fluid for use by a magnetorheological finishing apparatus.
SUMMARY OF THE INVENTION
Briefly described, a magnetorheological fluid delivery system in accordance with the invention comprises various elements connected by conduit means, including a mixing and tempering vessel. Fluid being returned from use in a work zone is admitted to the vessel via a plurality of tangential ports near the bottom of the vessel, creating a mixing of the fluid in the vessel and thus promoting homogeneity. Fluid may be reconstituted in the vessel by metered addition of carrier fluid to compensate for carrier fluid lost in the work zone. A centrifugal pump, preferably operating at a fixed speed, collects the fluid from the vessel and pressurizes the system. Preferably, the pump is disposed in the vessel. Fluid is fed through a magnetic-induction flowmeter and a magnetic valve having solenoid windings whereby fluid may be controllably stiffened and thus flow restricted by the associated viscous drag created in the bore of the valve. A closed-loop feedback control system connects the output of the flowmeter to performance of the valve. A nozzle having a slot-shaped bore dispenses MR fluid for re-use in the work zone. A flush diaphragm pressure transducer at the entrance to the nozzle inferentially measures relaxed viscosity and provides signals to a computer for dispensing metered amounts of carrier fluid into the mixing vessel to assure correct composition of the reconstituted fluid as it is dispensed.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features, and advantages of the invention, as well as presently preferred embodiments thereof, will become more apparent from a reading of the following description in connection with the accompanying drawings in which;
FIG. 1 is a schematic view of a prior art fluid delivery system for magnetorheological fluids, substantially as disclosed as FIG. 10 in U.S. Pat. No. 5,951,369;
FIG. 1 a is a cross-sectional view of a prior art nozzle useful in the delivery system shown in FIG. 1 ;
FIG. 2 is a schematic view of an improved fluid delivery system in accordance with the invention;
FIG. 3 is an isometric view, partially in cutaway, of a mixing/tempering vessel and a pressurizing pump;
FIG. 4 is a plan view of a magnetic valve;
FIG. 5 is a cross-sectional view taken along line 5 — 5 in FIG. 4 ;
FIG. 6 is a schematic cross-sectional view of the valve shown in FIGS. 4 and 5 , showing the direction and intensity of magnetic flux within the valve; and
FIG. 7 is an isometric view, partially in cutaway, of an improved viscometric nozzle in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
The benefits and advantages of a magnetorheological fluid delivery system in accordance with the invention may be better appreciated by first considering a prior art system.
Referring to FIG. 1 , a prior art fluid delivery system 10 (FDS) is shown for providing MR fluid 11 to a carrier surface 12 of a magnetorheological finishing apparatus (not otherwise shown) at a constant aim flow rate and viscosity; for recovering MR fluid from the carrier surface; and for conditioning recovered MR fluid for re-use. MR fluid 11 is scraped from the carrier surface 12 by scraper 14 and returned via line 16 to an inline mixing and tempering vessel 18 wherein agglomerates are broken up, carrier fluid is replenished as described below, and the reconstituted MR fluid is re-tempered to an aim temperature. A prior art system typically includes a supplementary peristaltic pump 20 to acquire the spent MR fluid from scraper 14 and deliver it to vessel 18 . Retempered MR fluid is withdrawn from vessel 18 by a primary peristaltic delivery pump 22 and is delivered through an inline magnetic-induction flowmeter 24 . The output of peristaltic pumps is cyclic and therefore a pulse dampener 26 is required in the fluid delivery system downstream of pump 22 . Flowmeter 24 and the drive for pump 22 are connected to a computer 28 which sets a flow aim and the rotational speed of the pump. From the flowmeter, MRF passes through nozzle 30 and is discharged for work onto carrier surface 12 .
Referring to FIG. 1 a , prior art nozzle 30 is an inline capillary rheometer or viscometer at the discharge end of the fluid delivery system and comprises a capillary tube 32 formed of a non-magnetic material, for example, stainless steel or ceramic, having a length to diameter ratio preferably greater than about 100:1. Tube 32 is surrounded by a magnetic shield 34 formed preferably of a magnetically soft material, for example, low-carbon cold rolled steel. Tube 32 and shield 34 are spaced apart by one or more non-magnetic centering spacers 36 and by a non-magnetic transition piece 38 for smoothly narrowing the MR fluid flow from the diameter of the supply line 40 to the diameter of tube 32 . Disposed between supply line 40 and transition piece 38 is a pressure transducer 42 having a diaphragm 44 for sensing line pressure at the entrance to the capillary tube and sending a signal thereof to computer 28 . Since nozzle 30 is disposed at the end of the delivery line, the pressure drop through the nozzle may be measured relative to ambient pressure, and thus only one pressure sensor is required. Computer 28 is programmed with an algorithm for calculating MR fluid viscosity as a function of pressure and flowrate through nozzle 30 . When a predetermined upper viscosity control limit is exceeded, computer 28 signals metering pump 46 to inject a computer-calculated replenishing amount of carrier fluid into mixing/tempering chamber 18 where the fluid is mixed into the recirculating MRF.
Referring to FIGS. 2 through 7 , an improved and compact fluid delivery system 50 (FDS) in accordance with the invention is shown for providing MR fluid to a carrier surface 12 of a magnetorheological finishing apparatus (not otherwise shown) at a constant aim flow rate and viscosity; for recovering MR fluid from the carrier surface; and for conditioning recovered MR fluid for re-use. System 50 includes significant improvements in mixing, pumping, metering, and dispensing over prior art system 10 , and is significantly less complex and more compact. Several components of system 10 are eliminated, including supplementary pump 20 and pulsation dampener 26 .
As shown in FIG. 2 , MR fluid 11 is scraped from the carrier surface 12 by scraper 14 and returned via line 16 to an improved inline mixing and tempering vessel 52 wherein agglomerates are broken up, carrier fluid is replenished, and the reconstituted MR fluid is re-tempered to an aim temperature and prepared to be re-dispensed onto carrier surface 12 .
As shown in FIG. 3 , improved vessel 52 includes an insulating jacket 54 surrounding a mixing chamber 56 . Spent MR fluid being returned from scraper 14 is drawn into chamber 56 via at least one passage 58 , and preferably a plurality of such passages, extending from a splitting block 60 on the underside of vessel 52 and entering into chamber 56 through jacket 54 at ports 55 near the bottom 62 of the chamber and substantially tangential to the inner wall 64 of the chamber. This configuration causes a high level of swirling agitation of MR fluid within chamber 56 without resort to a separate mechanical mixer as is required in prior art mixing chambers. MR fluid is drawn into splitting block 60 from return line 16 , wherein the fluid flow is split into a plurality of streams following passages 58 . As in the prior art system, replenishing carrier fluid is injected from a source (not shown) via replenishment pump 46 and line 66 in response to commands from computer 28 , either into return line 16 as shown in FIG. 2 or directly into vessel 52 .
Disposed within chamber 56 is a centrifugal pump 66 having a vertical drive shaft 68 supporting a conventional vaned impeller 70 near the bottom 62 of the chamber. Preferably, impeller 70 is vaned on both the upper and lower surfaces thereof to balance the pumping load and to increase the output volume. Pump housing 72 surrounds the shaft and impeller and is closed at its lower end by an end plate 74 having a central aperture 76 for receiving the outer end of shaft 68 and impeller 70 and for admitting MR fluid from the lower part of chamber 56 to impeller 70 . Housing 72 is provided with an inlet passage 78 for admitting MR fluid from the upper part of chamber 56 to impeller 70 . An outlet passage 80 extends within housing 72 from the periphery of impeller 70 through jacket 54 to the exterior of vessel 52 . Housing 72 is further surrounded by tempering coils 82 of a conventional liquid heat exchanger tempering system (not shown) for adjusting the temperature of MR fluid within chamber 56 to a predetermined aim in known fashion.
Pump drive 84 is disposed outside and above vessel 52 and is coupled to shaft 68 via a central bore in housing 72 , which housing also functions as the closing cover for vessel 52 . Drive 84 is operationally connected via conventional interface conversion elements to control computer 28 which may, via connection 85 , set and maintain the rotational speed of pump 66 , preferably at a predetermined fixed speed selected to optimize the output of the pump, for example, 3200 rpm. Alternatively, the speed of the pump may be set manually by conventional electromechanical means.
Referring to FIGS. 3 through 6 , a novel magnetic flow control valve 86 and a conventional magnetic induction flowmeter 24 are disposed inline downstream of pump 66 . Flowmeter 24 senses the flow volume of material passing therethrough and communicates with computer 28 which then sends a controlling signal to valve 86 to adjust the flow sensed by flowmeter 24 to some predetermined aim. The flowmeter, valve, and computer thus form a conventional closed-loop feedback control system. Because pump 66 is a centrifugal pump and therefore non-positive-displacement, unlike prior art peristaltic pump 22 , hydraulic slip can occur within the pump, permitting valve 86 simply to throttle the pump output.
Magnetic flow control valve 86 comprises a solenoid without an armature, the MR fluid replacing the armature, and having first and second end caps 87 , 89 having first and second nipples 91 , 93 , respectively for connection of the valve into the FDS. The end caps are magnetically linked by a cylindrical housing 95 which also functions as a magnetic shunt. Hollow first and second magnet polepieces 88 , 90 , respectively extend axially towards each other from end caps 87 , 89 , respectively, within windings 92 which may be, for example, 1000 ampere-turns. Polepieces 88 , 90 are separated by a non-magnetic spacer 94 also within the windings and preferably having an axial bore of the same diameter as the bores in the polepieces, such that the axial passageway 96 extending through valve 86 is of a single non-restricted diameter. Spacer 94 forms and fills a magnetic gap between the polepieces. Each of polepieces 88 , 90 is tapered toward the other, preferably conically, on an outer surface thereof as shown in FIGS. 5 and 6 , such that magnetic flux is directed and concentrated towards the gap, creating a magnetic field 98 within passageway 96 in which the flux lines are substantially parallel to the axis of the passageway, as shown in FIG. 6 . In operation, when the windings are de-energized, passageway 96 exerts low viscous drag on MR fluid flowing through the valve. Flow through the valve is limited only by the diameter of passageway 96 , the output pressure of pump 66 , and the mechanical restrictions in the FDS downstream of the valve. When the windings are controllably energized in response to signals from computer 28 , MR fluid in the magnetic field is magnetically stiffened within the valve to a higher apparent viscosity, thus creating increased flow resistance due to viscous drag on the walls of passageway 96 . Flow is thus controllably decreased from the non-energized level. The MR fluid becomes again relaxed, of course, upon passing out of the valve. By controllably varying the intensity of the magnetic field by varying the current through windings 92 , computer 28 is able to control the flow through the FDS in response to a predetermined flow aim and to the actual flow as measured by flowmeter 24 .
Referring to FIG. 7 , an improved dispensing nozzle 30 a is an inline capillary rheometer or viscometer at the discharge end of fluid delivery system 50 and comprises a barrel 32 a formed of a non-magnetic material, for example, stainless steel or ceramic. Barrel 32 a is surrounded by a magnetic shield 34 a formed preferably of a magnetically soft material, for example, low-carbon cold rolled steel. A non-magnetic transition piece 38 a smoothly narrows the MR fluid flow from the diameter of the supply line 40 into barrel 32 a . Extending through shield 34 a and barrel 32 a and exposed to the material flowpath is a pressure transducer 42 a for sensing line pressure at the entrance to the capillary tube and sending a signal thereof to computer 28 . Since nozzle 30 a is disposed at the end of the delivery line, the pressure drop through the nozzle may be measured relative to ambient pressure, and thus only one pressure transducer is required. Computer 28 is programmed with an algorithm for calculating MR fluid viscosity as a function of pressure and flowrate through nozzle 30 a . When a predetermined upper viscosity control limit is exceeded, computer 28 signals replenishment pump 46 to inject a computer-calculated replenishing amount of carrier fluid into either return line 16 or mixing/tempering vessel 52 wherein the fluid is mixed into the recirculating MR fluid.
A particular feature and advantage of nozzle 30 a over prior art nozzle 30 is the incorporation of a non-cylindrical slot-shaped flow passage 100 through barrel 32 a rather than the conventional cylindrical flow passage in nozzle 30 . Passage 100 has first and second opposed parallel planar walls 102 having a longer transverse length than third and fourth opposed walls 104 . A first advantage is that passage 100 dispenses MR fluid onto carrier surface 12 as a pre-formed ribbon. A second advantage is that pressure transducer 42 a may be mounted in a planar wall 102 of passage 100 , permitting the use of an inexpensive flush diaphragm 44 a in replacement of the prior art diaphragm 44 . A third advantage is that a slot-shaped passage exhibits increased viscous drag of the MR fluid because of greater surface area per unit length; therefore, a significantly shorter nozzle can yield a back pressure at transducer 42 a equal to the back pressure present at prior art transducer 42 .
Pressure drop along a slot-like channel and a round pipe are presented as follows:
Δ P slot = 2 μ L slot Q b 3 w ( Eq . 1 ) Δ P pipe = 8 μ L pipe Q π R pipe 4 ( Eq . 2 )
where μ is fluid viscosity, L slot is slot length, b is slot half-height, w is the width of the channel, L pipe is pipe length, R is pipe radius and Q is flow rate. When the pressure drop, flow rate, and viscosity in both channels are the same, then
2 L slot b 3 w = 8 L pipe π R 4
or ( Eq . 3 ) L slot = L pipe 4 b 3 w π R 4 ( Eq . 4 )
To provide the same fluid velocity in both channels, the channels' cross sectional areas must be the same
2 b w= 3.14 R 2 and L slot =L pipe (2 b 2 /R 2 ) (Eq. 5)
The cross-sectional area of a cylindrical tube having a radius of 1.5 mm is about the same as the cross-sectional area of a slot-shaped passage having a slot height of 1.5 mm and slot width of 5 mm. Thus, for example, a prior art cylindrical nozzle 30 having a tube length of 200 mm can be replaced with an improved nozzle 30 a having a barrel 32 a with a slot length of about 100 mm. Such a shortening of the nozzle greatly enhances the desirable compactness of an MR fluid delivery system.
From the foregoing description it will be apparent that there has been provided an improved delivery system for magnetorheological fluid. Variations and modifications of the herein described fluid delivery system will undoubtedly suggest themselves to those skilled in this art. Accordingly, the foregoing description should be taken as illustrative and not in a limiting sense.
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A magnetorheological fluid delivery system includes a mixing and tempering vessel. Fluid is admitted to the vessel via a plurality of tangential ports, creating a mixing of the fluid in the vessel and promoting homogeneity. Fluid may be reconstituted in the vessel by metered addition of carrier fluid. A fixed-speed centrifugal pump disposed in the vessel pressurizes the system. Fluid is pumped through a magnetic-induction flowmeter and a magnetic flow control valve having solenoid windings whereby MR fluid is magnetically stiffened to restrict flow. A closed-loop feedback control system connects the output of the flowmeter to performance of the valve. A nozzle having a slot-shaped bore dispenses MR fluid for re-use in the work zone. A planar-diaphragm flush-mounted pressure transducer at the entrance to the nozzle and flowmeter inferentially measure relaxed viscosity and provide signals to a computer for dispensing metered amounts of carrier fluid into the mixing vessel to assure correct composition of the reconstituted fluid as it is dispensed.
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FIELD OF THE INVENTION
This invention relates to archery and more particularly to apparatus for stabilizing a drawn bow string against inadvertent lateral deflection by the archer's hand.
BACKGROUND OF THE INVENTION
When an archer draws a bow string with a notched arrow he tries to anchor the string drawing hand on a part of his head, say, his cheek or chin, but there is tendency for the hand holding the bow to wobble slightly relative to the anchored hand so that the arrow upon release of the bow string is projected along a path which is to one side or the other of the intended flight path to the target.
A principal object of the invention is to provide a stabilizer bar which extends from the bow to the limit of a drawn bow string and has sufficient rigidity to prevent the bow or notched arrow end from moving relative to each other as the arrow is aimed at a target.
Another object of the invention is to provide adjustable means for limiting the maximum drawn extent of the bow string to suit an individual archer.
Still another object of the invention is to provide a stabilizer bar which is extensible and retractable in length between a bow string in its unflexed condition and the string in its fully flexed condition thus minimizing structure extending beyond the bow which could impede an archer's travel through undergrowth or over rough terrain.
The foregoing and other objects will become apparent as the following detailed description is read in conjunction with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a bow and drawn bow string showing a stabilizer bar of the present invention;
FIG. 2 is a horizontal cross sectional view of the stabilizer bar of the invention, with parts omitted for clarity, taken substantially on the line 2--2 of FIG. 1;
FIG. 3 is a top plan view partly broken away showing the manner of use of the present invention;
FIG. 4 is a side elevational view partly broken away showing an arrow notched in a drawn bow string;
FIG. 5 is an enlarged broken perspective view of a typical bow string clamp which may be used in conjunction with the present invention; and
FIG. 6 is a schematic top plan view of dual stabilizing bars constructed in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and particularly FIG. 1, the numeral 10 designates a bow to whose mid point 11 is attached a bracket 12 which includes a platform 14 normal to the vertical axis 15 of the bow when in its position of FIG. 1. The platform 14 carries a housing member 16 having an open ended bore 18 therethrough whose longitudinal axis 20 (FIG. 3) is perpendicular to the vertical axis 15 of the bow 10, when in the position of FIG. 1, and laterally spaced from but parallel to the plane 22 defined by a drawn bow string 24 as should be clear in FIG. 3.
A tube 25 is fixed, as by a set screw 26, within the through bore 18 and has front and rear parts 28, 30. An extensible and retractable stabilizer bar, generally indicated by the numeral 32, is telescopically connected to the rear part 30 of the tube 25. The bar 32 comprises as many sections 32a, 32b, 32c, as convenient, with each section having a limiting collar 34 as is conventional with telescoping tubular members.
A linearly adjustable member 36 is carried by the front part 28 of the fixed tube 25. The member 36 desirably comprises a tube which is telescopically received within the outer open end of the front part 28 of the fixed tube 25 and is provided with a locking collar 38 which cooperates with a collar 39 on the front end 28 of the fixed tube 25. The locking collar 38 is of conventional construction and may be of the type which, when turned in one direction releases camming surfaces (not shown) from radially movable internal clamp members (not shown) to permit the adjusting tube 36 to be moved linearly in or out of the front tube part 28 and, when correctly positioned as further explained below, to be locked in its adjusted position by turning the collar in the opposite direction.
In accordance with the invention a flexible element 40 is connected at one end 41, as by a cross pin 42 best seen in FIG. 2, to the adjustable tubular element 36 and at its opposite end 44 to that end 45 of the stabilizer bar 32 which is remote from the bow 10.
A releasable bow string clamp 46, including a handle 48 graspable by an archer to retract the bow string 24 and flex the bow in readiness for shooting an arrow 50, is connected to the remote end 45 of the stabilizer bar 32 as best seen in FIG. 3. The handle 48 and clamp 46 are entirely conventional and in current use by archers to relieve the stress on fingers normally used to retract a bow string. Such clamps and handles are provided with a depressible button 52 or similar release device readily accessible to the archer's thumb, or to a finger, should the device 52 be a trigger, which, when depressed, causes the jaws of the clamp 46 to open and release the bow string 24 which in turn projects the arrow 50. As seen in FIG. 3 the handle and clamp assembly 46, 48 is connected to the remote end 32 of the stabilizer bar by a suitable linkage 54 which resists movement in any direction of the drawn bow string relative to the stabilizer bar 32.
In use, the archer initially fastens the bracket 12 to the mid point 11 of the bow 10, with the platform 14 serving to support an arrow 50 in shooting position between a side of the bow and the confronting side face of the housing member 16 as shown in FIG. 1. He then releases the locking collar 38 for the adjustable tube 36 and connects the bow string to the clamp 46, but without an arrow notched to the string. He draws the bow string to the maximum extent which is comfortable for him and, while holding the bow string in this position, an assistant may be requested to pull the adjustable tube 36 forwardly until the flexible element 42 is taut whereupon the assistant rotates the collar 38 to lock the adjustable tube 36 in its adjusted position. Thereafter, the flexible element will limit the maximum pull on the bow string to the same extent which is suitable for that particular archer.
It will be apparent, particularly in FIG. 5, that when the jaws of the clamp 46 engage the bow string 24 the inner end 50a of the arrow 50 is notched to the string 24 between upper and lower jaw parts 46a and 46b as is conventional. Further, it will be noted in FIG. 3 that the clamp 46 is off-set from the axis of the stabilizer bar so as to be in alignment with the arrow supporting portion of the platform 14. After the archer has aimed at the target with the arrow 50 being stabilized along its entire length relative to the bow through the steadying action of the stabilizer bar, and the string has been released by the jaws in response to depression of the button 52, the archer telescopically retracts the stabilizer bar by pushing the sections together until the bar is almost entirely within the fixed tube 28 except for the collars 34, and the jaw/handle assembly 46, 48. Thus when the archer is traveling over terrain covered with thick vegetation, the stabilizing tube presents only slight structure which can be hung up on the vegetation to impede the archer's progress. Normally, the bow string would be re-engaged with the clamp following each shot of an arrow. Also, when hunting, an arrow would likely be notched onto the string while it and the bow are unstressed. Should game suddenly appear, the archer would pull back on the handle 48 to extend the telescoping stabilizer bar 32 until the flexible element 42 is taut, aim the arrow at the game, and depress the release button to project the arrow with reasonable assurance that it would strike the target since the string, bow and arrow are essentially bound together by the stabilizer bar against relative lateral movement between these parts which otherwise could cause the arrow to be projected in a path leading to one side or the other of the target.
With reference to FIG. 6 there is schematically shown there dual stabilizer bars 60, 62 each of which is identical to the single stabilizer bar 32 described above. In FIG. 6, a bow (not shown) would be received in a central opening 64 of the bracket platform with any means, such as vertical flanges (not shown) being provided for fastening the assembly to the sides of a bow. The remote ends of the bars are interconnected by a handle 66 carrying a clamp 68 which is off-set to one side so as to align with the platform part on that side of the bow on which an arrow is supported while being shot. Only a single flexible member to limit the extent of bar extensions need be supplied though the use of two flexible members, one for each bar, is not precluded.
It should be apparent that the invention is susceptible of changes and modifications without, however, departing from the scope and spirit of the appended claims.
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A bow string stabilizer bar is telescopically carried by a bracket attached to a bow. The bar carries at its end remote from the bow a bow string clamp and handle assembly and a flexible element, whose length is adjustable, limits the extent to suit an individual archer to which the bar can be telescopically extended and hence the extent to which the bow string can be retracted preparatory to shooting an arrow. The stabilizer bar restrains the bow and bow string to move in a relatively fixed plane each time the string is retracted for shooting an arrow, thereby vastly increasing the accuracy of the archer.
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FIELD OF THE INVENTION
[0001] One exemplary aspect of the present invention is directed toward non-verbal communications. More specifically, one exemplary aspect is directed toward providing information about visually presented information in audio form to either a speaker or a listener such that they can benefit from awareness of the visually presented information.
BACKGROUND
[0002] Audio teleconferences may be supplemented with a visual channel that permits applications to be shared. Examples of products that support this capability include Webex® and Avaya Meeting Exchange®. Examples of applications that are commonly shared include MS Word®, MS PowerPoint® and whiteboards. In a similar manner, during a video conference, there may be various things presented such as exhibits, pictures, charts, graphs, drawings on a whiteboard or sketchpad, a physical object, or in general anything.
SUMMARY
[0003] One problem with this presented information is that some of the teleconference participants may be unable to see the shared visual information. Similarly, if a video conference participant has only audio conference capabilities, they may also not be able to see the shared visual information. For example, they may not have access to a PC or a video conference-enabled endpoint. They may also not have reliable Internet access. Or, they may have reliable Internet access, but may be unable to tunnel through firewalls or, the problem may be that they are blind.
[0004] There are certain automatic technologies that can provide verbal descriptions and summaries of at least some of the information that is shared visually during Webex® and meeting exchange-supplemented audio teleconferences. For example, simple text-to-speech engines can read the documents that are shared. Optical character recognition techniques can read text that is being written on whiteboards. When OCR is supplemented by image processors of greater sophistication, the shapes of objects and the structures of diagrams may be described. One exemplary aspect of the present invention utilizes these technologies to provide descriptions of shared visual information to the conference participants who are not video-enabled.
[0005] The U.S. Government's “Section 508” procurement regulations require video-intensive presentations, such as training films, to include a separate audio track that provides specialized narration for people who are visually impaired or blind. However, this audio track does not include information about visually presented information. Moreover, real-time communications do not currently convey any of the “marker or chalkboard” information unless one can see the board the communicator is using.
[0006] Accordingly, exemplary aspects of the present invention are directed toward providing descriptions of presented material to one or more conference participants. This presented material could be any one or more of a document, PowerPoint® presentation, spreadsheet, Webex® presentation, whiteboard, chalkboard, interactive whiteboard, description of a flowchart, picture, or in general any information visually presented at a conference.
[0007] Another exemplary aspect of the invention is directed toward assembling and forwarding descriptions of presented information via one or more of a message, SMS message, whisper channel, text information, non-video channel, MSRP, or the like, to one or more conference participant endpoints.
[0008] Yet another aspect of the present invention relates to providing descriptions of visually presented information, such as a document, spreadsheet, spreadsheet presentation, multi-media presentation, or the like, after one or more of OCR recognition and text-to-speech conversion, to a conference participant endpoint(s).
[0009] One exemplary method of supplying this summary of visually presented information would be a so called whisper announcement to either the listener or speaker. Another exemplary method would be to supply an audible indication when visually presented information is presented. For example, it could be, for example, a sound bite, such as “picture,” a tone, or in general any audible indicator that is correlatable to a specific visually presented piece of information or combination of pieces of information.
[0010] Each of these exemplary methods has advantages in certain situations and disadvantages in others. One aspect of the system allows customization such as that the system is capable of providing whichever form is most suitable to the target device and/or the user.
[0011] The choice of the methodology used to present the descriptions of the visually presented information could similarly be done with consideration of the target device and/or the user. Examples could include using a certain indicator when the user has the ability to view their device but does not have the ability via a headset to hear a whisper announcement.
[0012] Associated with one exemplary embodiment of the present invention could be a preference file that indicates in what form a user desires to receive the visually presented information as a function of time, place, device, equipment or personal capabilities, or the like. Similarly, a speaker or presenter who desires feedback about the visually presented information they are presenting could also have a preference about how much information is provided to them. For example, if a poster presented by a speaker is not in the field of view of the camera, a whisper announcement could be relayed back to the presenter indicating that, for example, the poster needs to be moved “to the right.”
[0013] Another exemplary aspect of the present invention is directed toward the detection, monitoring and analysis of one or more visually presented pieces of information in a remote location, such as a classroom. For example, if someone were to begin writing on a whiteboard, interactive whiteboard, retrieving a document, or introducing a picture or exhibit into the field of view of a video-conference camera, an indicator thereof could be provided to one or more conference participants. Additionally, the introduction of the visually presented information could dynamically trigger the appropriate analysis tool, such as OCR, text-to-speech, an image analysis module, or the like, to provide the description of the visually presented information. In accordance with yet another exemplary embodiment, there can be a plurality of participants who are not video-enabled who desire to receive an indicator of visually presented information. Thus, one or more of the participants who are not video-enabled, can have an associated profile that allows for one or more of the selection and filtering of what types of visually presented information the user will receive. In addition, the profile can specify how information relating to the descriptions of the visually presented information should be presented to the user. As discussed, this information could be presented via a text channel, via a whisper, such as in whisper channel A, while the conference continues on channel B, and a non-video channel associated with the conference and/or in an SMS message. This profile could be user-centric, endpoint-centric or associated with a conferencing system. For example, if the user is associated with either a bandwidth or processor limited-endpoint, it may be more efficient to have the profile associated with the conference system. Alternatively, or in addition, and for example, at the endpoint associated with a user is a laptop and associated webcam, one or more aspects of the profile (and functionality associated therewith) could be housed on the laptop.
[0014] Accordingly, one exemplary aspect of the invention is directed toward providing descriptions of visually presented information to non-video enabled participants.
[0015] Still another aspect of the invention is directed toward providing descriptions of visually presented information to video telephone participants who are not video-enabled.
[0016] Even further aspects of the invention are directed toward the detection and monitoring of visually presented information in a video conferencing environment.
[0017] Still further aspects of the invention are directed toward the detection of selection of an appropriate visually presented information analysis tool.
[0018] Even further aspects of the invention are directed toward a user profile that specifies one or more of the types of information to be received and the communication modality for that information.
[0019] Aspects of the invention also relate to generation and production of a transcript associated with a video conference that includes one or more of descriptions and indicators of the visually-presented information.
[0020] Yet another aspect of the present invention provides a video conference participant, such as the moderator or speaker, feedback as to the effectiveness and visibility of their visually presented information, e.g., field of view, zoom, focus, brightness, or the like.
[0021] Even further aspects of the invention relate to assessing the capabilities of one or more of the conference participants and, for each participant that is not video-enabled, associating therewith messaging preferences based on, for example, their capabilities and/or preferences.
[0022] Even further aspects of the invention relate to providing a conference transcript and the ability to adjust the granularity of a conference transcript to thereby govern what type of descriptions of visually presented information should be included therein. For example, some visually presented information, such as lengthy documents, or items that are difficult to describe, such as a multi-page complex spreadsheet, could be selected to be ignored, while on the other hand, information drawn on a whiteboard or a presented object may be desired to be captured. The documents that are not captured, if in electronic format, could be associated with the conference transcript and retrieved in their native format, for example, at a later time, via, for example, the selection of a hyperlink.
[0023] Aspects of the invention may also provide useful during interrogations, interviews, depositions, court hearings, or in general any environment in which it may be desirable to include descriptions of one or more pieces of visually presented information.
[0024] As discussed, one exemplary aspect of the invention provides audible and/or text input to conference participants who are unable to see visually presented information that one or more other conference participants may be showing. Examples of how this information could be provided include:
1. For conference participants who have a single monaural audio-only endpoint, audio descriptions of the visually presented information could be presented via a “whisper” announcement. 2. For conference participants who have more than one monaural audio-only endpoint, they could use one of the endpoints for listening to the conference discussion then utilize the other to receive audio descriptions of the visually presented information. 3. Conference participants who have a binaural audio-only endpoint could use one of the channels for listening to the conference discussions, and utilize the other to receive audio descriptions of one or more visually presented pieces of information. 4. Conference participants who have an audio endpoint that is email capable, SMS capable, or IM capable could receive descriptions of the visually presented information via these respective interfaces. 5. Conference participants who have an audio endpoint that is capable of receiving and displaying streaming text (illustratively, a SIP endpoint that supports IETF recommendation RFC-4103, “RTP payload for text conversation”) can have the description scroll across the endpoint's display, such that the text presentation is synchronized with the spoken information on the conference bridge.
[0030] The present invention can provide a number of advantages depending on the particular configuration. These and other advantages will be apparent from the disclosure of the invention(s) contained herein.
[0031] The phrases “at least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
[0032] The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.
[0033] The term “automatic” and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic even if performance of the process or operation uses human input, whether material or immaterial, received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material.”
[0034] The term “computer-readable medium” as used herein refers to any tangible storage and/or transmission medium that participate in providing instructions to a processor for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, NVRAM, or magnetic or optical disks. Volatile media includes dynamic memory, such as main memory. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, magneto-optical medium, a CD-ROM, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read. A digital file attachment to e-mail or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. When the computer-readable media is configured as a database, it is to be understood that the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like.
[0035] While circuit or packet-switched types of communications can be used with the present invention, the concepts and techniques disclosed herein are applicable to other protocols.
[0036] Accordingly, the invention is considered to include a tangible storage medium or distribution medium and prior art-recognized equivalents and successor media, in which the software implementations of the present invention are stored.
[0037] The terms “determine,” “calculate” and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.
[0038] The term “module” as used herein refers to any known or later developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and software that is capable of performing the functionality associated with that element. Also, while the invention is described in terms of exemplary embodiments, it should be appreciated that individual aspects of the invention can be separately claimed.
[0039] The preceding is a simplified summary of the invention to provide an understanding of some aspects of the invention. This summary is neither an extensive nor exhaustive overview of the invention and its various embodiments. It is intended neither to identify key or critical elements of the invention nor to delineate the scope of the invention but to present selected concepts of the invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] FIG. 1 illustrates an exemplary communications environment according to this invention; and
[0041] FIG. 2 illustrates an exemplary method for providing descriptions of visually presented communications to conference participants who are not video-enabled according to this invention.
DETAILED DESCRIPTION
[0042] The invention will be described below in relation to a communications environment, such as a video conferencing environment. Although well suited for use with circuit-switched or packet-switched networks, the invention is not limited to use with any particular type of communications system or configuration of system elements and those skilled in the art will recognize that the disclosed techniques may be used in any application in which it is desirable to provide secure feature access. For example, the systems and methods disclosed herein will also work well with SIP-based communications systems and endpoints. Moreover, the various endpoints described herein can be any communications device such as a telephone, speakerphone, cellular phone, SIP-enabled endpoint, softphone, PDA, conference system, video conference system, wired or wireless communication device, or in general any communications device that is capable of sending and/or receiving voice and/or data communications.
[0043] The exemplary systems and methods of this invention will also be described in relation to software, modules, and associated hardware and network(s). In order to avoid unnecessarily obscuring the present invention, the following description admits well-known structures, components and devices that may be shown in block diagram form, are well known, or are otherwise summarized.
[0044] For purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the present invention. It should be appreciated however, that the present invention may be practiced in a variety of ways beyond the specific details set forth herein.
[0045] FIG. 1 illustrates an exemplary communications environment 100 according to this invention. In accordance with this exemplary embodiment, the communications environment 100 enables video conferencing between a plurality of endpoints ( 25 , 35 , 45 ). More specifically, communications environment 100 includes a conferencing module 110 , and one or more networks 10 , and associated links 5 , connected to a video camera 15 viewing one or more visually presented pieces of information such as from the whiteboard 1 , picture 3 , exhibit 4 and interactive whiteboard 2 . It should further be appreciated that the interactive whiteboard 2 may have the capability for electronic capturing of information drawn thereon that could optionally or additionally be provided via network 10 and one or more links 5 , to the conferencing module 110 . In a similar manner, information such as documents, spreadsheets, spreadsheets, multimedia presentation, PDF presentations, and the like could be provided directly via a network 10 and one or more links 5 to the conference module 110 and/or captured by the video camera 15 and provided to the conference module 110 . Exemplary communications environment 100 could also include a webcam 12 , associated with conference participant at a conference participant endpoint 35 , and one or more non-video enabled conference participant endpoints 45 , connected via one or more networks 10 and links 5 to the conference module 110 . The non-video enabled conference participant endpoints 45 may be non-video enabled for any number of reasons. For example, they may not be able to receive video due to hardware limitations, a firewall(s) or some other limitation. They may also be non-video enabled not because of hardware or other limitations, but rather because the user elected not to receive video of this particular conference.
[0046] The conference module 110 includes a messaging module 120 , a visually presented information recognition module 130 , an OCR recognition module 140 , a text-to-speech module 150 , an image module 160 , a processor 170 and storage 180 . The conferencing module 110 can also include other standard conference bridge componentry which will not be illustrated for sake of clarity.
[0047] In operation, a video conference is established with the cooperation of the conference module 110 . For example, video camera 15 , which may have an associated audio input and presentation equipment, such as a display and loudspeaker, could be associated with conference participant 25 . Webcam 12 is provided for a conference participant at conference participant endpoint 35 with audio and video therefrom being distributed to the other conference endpoints. Similarly, the webcam 12 could be enabled to capture visually presented information which could then be processed in a similar manner to the visually presented information provided to video camera 15 . The non-video enabled conference participants at non-video enabled conference participant endpoints 45 , either because of endpoint capabilities or user impairment(s), are not able to receive or view video content from the other participants. The capabilities of these various endpoints can be registered with the conference module 110 , and in particular the messaging module 120 , upon initiation of a video conference. Alternatively, the messaging module 120 can interrogate one or more of the endpoints and determine the endpoint's capabilities, and/or the capabilities of the user based on, for example, a users profile associated with the endpoint. In addition, one or more of each endpoint and/or user associated with each endpoint may have a profile that not only specifies the capabilities of the endpoint, but also messaging preferences. As discussed, these messaging preferences can include the types of information to be received as well as how that information should be presented. As discussed hereinafter in greater detail, the messaging module 120 forwards this information via one or more of the requested modalities to one or more of the conference endpoints. It should be appreciated that while the messaging module 120 will in general only send the description information to non-video enabled conference participants, this messaging could in general be sent to any conference participant, such as the example discussed above when providing feedback to a presenter.
[0048] Even though not illustrated, the communications environment, and in particular the conference module 110 , could include a transcript module, that cooperates with one or more of the processor 170 and storage 180 that could be enacted upon the commencement of a video conference to create a conference transcript that includes one or more of the following pieces of information: participant information, description of visually presented information, timing information, and in general any information associated with the video conference and/or one of the described modules. The conference transcript can be conference-participant centric or, a “master” conference transcript that is capable of capturing and memorializing any one or more of the aspects of the video conference. Furthermore, associated with the conference transcript can be one or more electronic versions of visually presented information, such as a document, spreadsheet, PowerPoint®, multimedia presentation, image file, or the like, that could be opened for viewing and/or analysis at a later time.
[0049] Upon commencement of an exemplary video conference, the conferencing module 110 in cooperation with the messaging module 120 , can assess the capabilities of meeting participants via one or more of interrogation and/or greeting and the getting of a profile associated with that endpoint and/or user. Then, for each meeting participant that is not video enabled, the messaging preferences, capabilities and preferences can be determined. The conference then starts, taking into account these preferences and messaging capabilities.
[0050] Upon commencement of an exemplary video conference, one or more of the video-enabled participants are monitored and one or more of visually presented information and electronic documents is recognized. As the conference proceeds, one or more of video camera 15 and web camera 12 are monitored, to determine whether visually presented information is being presented. In a similar manner, the messaging module 120 monitors whether electronic information, such as a document, spreadsheet, or the like, is presented. Upon the determination that the visually presented information has been presented, the visually presented information is analyzed in cooperation with the visually presented information recognition module 130 . Upon the visually presented information recognition module determining the type of visually presented information, such as a document, writing on a whiteboard, picture, exhibit, or the like, visually presented information recognition module 130 cooperates with one or more of the OCR recognition module 140 , text-to-speech module 150 and image module 160 , along with the processor 170 and storage 180 as appropriate. Thus, for example, if the visually presented information is writing on a whiteboard 1 , the visually presented information recognition module 130 can cooperate with the OCR recognition module 140 to determine what has been written. Similarly, if the visually presented information is a picture 3 , the visually presented information recognition module 130 can cooperate with the image module 160 to provide a description thereof. For example, the picture 3 could be compared to known pictures having a similar content for which a description is available, and that description provided to the user. Similarly, the image module 160 could cooperate with the OCR recognition module 140 to assist with determining the content of the picture.
[0051] For example, a user could be drawing something on a white board and simultaneously describing what they are drawing. For example, as a user draws, the user draws a “stick figure” that is supposed to look like a person using a phone, the user could be saying something like, “and here is a person who is using the phone.” The image module 140 could track what the user is saying while they are drawing. This could then in turn be used in a couple of different ways. For example:
[0052] “The picture that had been identified as ‘a person who is using the phone’ has been erased.”
[0053] “A picture similar to one that had been described earlier as ‘a person who is using the phone’ has been added, along with some additional information.”
[0054] In general any technology used for image recognition could be used with the image module and the systems and methods of this invention.
[0055] Should the presented information be information such as a document 6 , the text-to-speech module 150 can translate this information to speech. Regardless of the type of description assembled by the visually presented information recognition module 130 , this description can be provided via the messaging module 120 to one or more of the conference participant endpoints as described. In addition, the descriptions of these various types of visually presented information can be logged and recorded in one or more conference transcripts.
[0056] FIG. 2 outlines an exemplary methodology for providing descriptions of visually presented information according to this invention. In particular, control begins in step S 200 and continues to step S 210 . In step S 210 , the capabilities of one or more of the meeting participants and/or endpoints are determined. Next, in step S 220 , for each meeting participant that is not video-enabled, the messaging capabilities/preferences for that endpoint/user are determined. Then, in step S 230 , the video conference is started in conjunction with optionally creating a transcript thereof. Control then continues to step S 240 .
[0057] In step S 240 , a determination is made whether visually presented information has been presented. If visually presented information has been presented, control continues to step S 250 with control otherwise jumping to step S 280 . For example, this can be based on one or more of a scene change, the accessing of a file(s), recognition of a presenter pointing at an object, or the like.
[0058] In step S 250 , the visually presented information is analyzed. For example, a first determination can be what type of visually presented information has been presented, e.g., picture, exhibit, document or the like. Next, in step S 260 , and optionally based on the analysis step, the appropriate action is dynamically chosen for providing a description of the visually presented information. As discussed, this can be based on one or more of OCR, text-to-speech, human-based input, image analysis, or in general any analysis as appropriate for visually presented information.
[0059] For example, for electronically presented information, information such as the filename extension can be analyzed. The analysis of the filename extension can be correlated to a table of known file name extensions and the type of information determined, e.g., “.doc” is a document, “.ppt” a spreadsheet, “.jpg” and image, and the like. This can then be used to assist with describing the presented information and optionally used to assist with determining what is the appropriate analysis tool for the presented information. For pictures and exhibits, a screen capture of the presented information could be performed, then in cooperation with, for example, human-based input, a description of the visually presented information assembled.
[0060] Then, in step S 270 , the description of the visually presented information is forwarded to one or more of the non-video enabled participants in accordance with their profile, and in general to any conference participant as discussed. Furthermore, if the conferencing system is maintaining a transcript of the conference, this information can be recorded in the transcript along with other information, such as the actual audio and video of the conference, and in general any information associated with a conference. Control then continues to step S 280 where a determination is made whether the conference has ended. If the conference has not ended, control jumps back to step S 240 . Otherwise, control continues to step S 290 where the control sequence ends.
[0061] A number of variations and modifications of the invention can be used. It would be possible to provide or claims for some features of the invention without providing or claiming others.
[0062] The exemplary systems and methods of this invention have been described in relation to enhancing video conferencing. However, to avoid unnecessarily obscuring the present invention, the description omits a number of known structures and devices. This omission is not to be construed as a limitation of the scope of the claimed invention. Specific details are set forth to provide an understanding of the present invention. It should however be appreciated that the present invention may be practiced in a variety of ways beyond the specific detail set forth herein.
[0063] Furthermore, while the exemplary embodiments illustrated herein show various components of the system collocated, certain components of the system can be located remotely, at distant portions of a distributed network, such as a LAN, cable network, and/or the Internet, or within a dedicated system. Thus, it should be appreciated, that the components of the system can be combined in to one or more devices, such as a gateway, or collocated on a particular node of a distributed network, such as an analog and/or digital communications network, a packet-switch network, a circuit-switched network or a cable network.
[0064] It will be appreciated from the preceding description, and for reasons of computational efficiency, that the components of the system can be arranged at any location within a distributed network of components without affecting the operation of the system. For example, the various components can be located in a switch such as a PBX and media server, gateway, a cable provider, enterprise system, in one or more communications devices, at one or more users' premises, or some combination thereof. Similarly, one or more functional portions of the system could be distributed between a communications device(s) and an associated computing device.
[0065] Furthermore, it should be appreciated that the various links, such as link 5 , connecting the elements can be wired or wireless links, or any combination thereof, or any other known or later developed element(s) that is capable of supplying and/or communicating data to and from the connected elements. These wired or wireless links can also be secure links and may be capable of communicating encrypted information. Transmission media used as links, for example, can be any suitable carrier for electrical signals, including coaxial cables, copper wire and fiber optics, and may take the form of acoustic or light waves, such as those generated during radio-wave and infra-red data communications.
[0066] Also, while the flowcharts have been discussed and illustrated in relation to a particular sequence of events, it should be appreciated that changes, additions, and omissions to this sequence can occur without materially affecting the operation of the invention.
[0067] In yet another embodiment, the systems and methods of this invention can be implemented in conjunction with a special purpose computer, a programmed microprocessor or microcontroller and peripheral integrated circuit element(s), an ASIC or other integrated circuit, a digital signal processor, a hard-wired electronic or logic circuit such as discrete element circuit, a programmable logic device or gate array such as PLD, PLA, FPGA, PAL, special purpose computer, any comparable means, or the like. In general, any device(s) or means capable of implementing the methodology illustrated herein can be used to implement the various aspects of this invention.
[0068] Exemplary hardware that can be used for the present invention includes computers, handheld devices, telephones (e.g., cellular, Internet enabled, digital, analog, hybrids, and others), and other hardware known in the art. Some of these devices include processors (e.g., a single or multiple microprocessors), memory, nonvolatile storage, input devices, and output devices. Furthermore, alternative software implementations including, but not limited to, distributed processing or component/object distributed processing, parallel processing, or virtual machine processing can also be constructed to implement the methods described herein.
[0069] In yet another embodiment, the disclosed methods may be readily implemented in conjunction with software using object or object-oriented software development environments that provide portable source code that can be used on a variety of computer or workstation platforms. Alternatively, the disclosed system may be implemented partially or fully in hardware using standard logic circuits or VLSI design. Whether software or hardware is used to implement the systems in accordance with this invention is dependent on the speed and/or efficiency requirements of the system, the particular function, and the particular software or hardware systems or microprocessor or microcomputer systems being utilized.
[0070] In yet another embodiment, the disclosed methods may be partially implemented in software that can be stored on a storage medium, executed on programmed general-purpose computer with the cooperation of a controller and memory, a special purpose computer, a microprocessor, or the like. In these instances, the systems and methods of this invention can be implemented as a program embedded on personal computer such as an applet, JAVA® or CGI script, as a resource residing on a server or computer workstation, as a routine embedded in a dedicated measurement system, system component, or the like. The system can also be implemented by physically incorporating the system and/or method into a software and/or hardware system.
[0071] Although the present invention describes components and functions implemented in the embodiments with reference to particular standards and protocols, the invention is not limited to such standards and protocols. Other similar standards and protocols not mentioned herein are in existence and are considered to be included in the present invention. Moreover, the standards and protocols mentioned herein and other similar standards and protocols not mentioned herein are periodically superseded by faster or more effective equivalents having essentially the same functions. Such replacement standards and protocols having the same functions are considered equivalents included in the present invention.
[0072] The present invention, in various embodiments, configurations, and aspects, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various embodiments, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the present invention after understanding the present disclosure. The present invention, in various embodiments, configurations, and aspects, includes providing devices and processes in the absence of items not depicted and/or described herein or in various embodiments, configurations, or aspects hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation.
[0073] The foregoing discussion of the invention has been presented for purposes of illustration and description. The foregoing is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the invention are grouped together in one or more embodiments, configurations, or aspects for the purpose of streamlining the disclosure. The features of the embodiments, configurations, or aspects of the invention may be combined in alternate embodiments, configurations, or aspects other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention.
[0074] Moreover, though the description of the invention has included description of one or more embodiments, configurations, or aspects and certain variations and modifications, other variations, combinations, and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments, configurations, or aspects to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.
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Descriptions of visually presented material are provided to one or more conference participants that do not have video capabilities. This presented material could be any one or more of a document, PowerPoint® presentation, spreadsheet, Webex® presentation, whiteboard, chalkboard, interactive whiteboard, description of a flowchart, picture, or in general, any information visually presented at a conference. For this visually presented information, descriptions thereof are assembled and forwarded via one or more of a message, SMS message, whisper channel, text information, non-video channel, MSRP, or the like, to one or more conference participant endpoints. These descriptions of visually presented information, such as a document, spreadsheet, spreadsheet presentation, multi-media presentation, or the like, can be assembled in cooperation with one or more of OCR recognition and text-to-speech conversion, human input, or the like.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 12/221,516, filed Aug. 4, 2008 and scheduled to issue as U.S. Pat. No. 8,215,251, on Jul. 10, 2012, which is a continuation of U.S. application Ser. No. 11/799,849, filed May 3, 2007, now U.S. Pat. No. 8,176,864, which is a continuation of U.S. application Ser. No. 10/826,195, filed Apr. 15, 2004, now U.S. Pat. No. 7,228,809, the disclosures of which are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to manufacturing garments and particularly relates to methods for making garments having finished edges.
Most garments are made by cutting fabric into pattern pieces and then sewing the cut pattern pieces together to make the garment. Typically, each cut pattern piece has one or more edges that are sewn to the edges of one or more adjacent cut pattern pieces, which forms a seam between the cut pattern pieces. The outer edges of the garment, however, are not sewn to the edges of other cut pattern pieces. As a result, the outer edges are exposed to forces that may fray or tear the fabric. In response to the tearing and fraying problem, the clothing industry has developed methods for finishing the edges of garments, including using narrow elastic, lace, trim and/or a folded over edge. The clothing industry also uses fabric having a knitted-in edge. Although this particular type of fabric provides garments having smoother edges, its use results in relatively low material yields.
The most common method for finishing the edge of a cut pattern piece involves using narrow elastic. Referring to FIG. 1A , a cut pattern piece 20 is made of cotton, nylon, polyester, or spandex fibers or any other natural or synthetic fibers commonly used to make garments. As shown in FIGS. 1A and 1B , the cut pattern piece 20 has an outer edge 22 and includes a plurality of fibers 26 having free ends 28 that terminate at the edge 22 . As is well known to those skilled in the art, the free ends 28 of the fibers 26 form a rough, outer edge that tends to fray and/or tear as the fabric is used.
In order to overcome the above-mentioned fraying problems in clothing such as activewear, shapewear and/or compression garments, most cut pattern pieces have a narrow elastic that is sewn onto the outer edge 22 . Referring to FIGS. 2A-2C and 3 A- 3 C, a cut pattern piece 20 has a rough, outer edge 22 with fibers having ends (not shown) that terminate at the edge. Referring to FIGS. 2A and 3A , a narrow elastic 23 is aligned over a top surface 30 of the cut pattern piece 20 . Referring to FIGS. 2B-1 , 2 B- 2 and 3 B, a flap 25 of fabric adjacent outer edge 22 is folded over the top surface 30 and the narrow elastic is positioned over the flap 25 . Referring to FIGS. 2B-2 , 2 C and 3 C, the flap 25 and the narrow elastic 23 are held in place by stitching 32 for forming a finished edge 34 on the cut pattern piece. The finished edge including the flap 25 and the narrow elastic 23 has a thickness H 1 that is substantially greater than the thickness H 2 of the original cut pattern piece 20 . As a result, the finished edge is bulky and is likely to be visible through outerwear.
As noted above, in most garments, the finished edge is made using a narrow elastic. In some garments, however, the finished edge is made using lace, a fold-over edge, or trim, with and without using a narrow elastic. The presence of the bulky edge ( FIG. 2C ) is not desirable, particularly when the fabric is used for producing garments such as activewear, shapewear, garments having one or more support panels and garments using compression fabric. The presence of a bulky finished edge is particularly undesirable when the fabric is to be used in undergarments and bathing suits. This is because the finished edge, as shown in FIG. 2C , adds unwanted bulkiness to the garment. For example, a bulky finished edge on an undergarment is undesirable because it may, inter alia, be seen through clothing worn over the undergarment. The bulky finished edge is also less stretchable, so that it will not readily adjust to a wearer's body. This will cause the garment to ride-up and bind to a wearer, causing discomfort.
The clothing industry has also developed fabrics having knitted-in edges, whereby relatively complex stitching is used at the edges to avoid the fraying and tearing problems described above. Although garments having knitted-in edges are smoother than garments that use narrow elastic, lace and/or trim, making the fabric for the garments is more expensive. This is because a knitted-in edge requires complex knitting that adds to the cost of making the fabric. In addition, the knitted-in edge provides limitations that adversely affect material yield.
Referring to FIG. 4 , a spread 20 has a knitted-in finished edge 34 formed along a lower edge thereof. The knitted-in finished edge may also have rubber fibers that are knitted into the fabric to provide gripping to increase the hold of the garment to the body. The spread 20 has a length designated L and a width designated W. In the particular example shown in FIG. 4 , the spread has a length L of 252 inches and a width W of 26 inches. A pattern is then used to define a series of pattern pieces 38 A- 38 F. An automatic cutting machine or hand-cutting tool may then be used to cut the pattern pieces 38 A- 38 F. Due to the requirement that each cut pattern piece have a portion of the knitted-in finished edge 34 incorporated therein, only one pattern piece may be cut from each of the respective panels 40 A- 40 F of spread 20 . As a result, the fabric in each panel section 40 A- 40 F that is not part of one of the cut pattern pieces 38 A- 38 F is waste material. As is well known to those skilled in the art, wasting material from a spread having a finished edge is undesirable and costly. In the particular spread 20 shown in FIG. 4 , the material yield of the spread is 57.13% because the cut pattern pieces 38 A- 38 F utilize 57.13% of the spread, with 42.87% of the spread being unusable waste material. This level of waste is undesirable in the highly competitive and cost-conscious garment industry.
In view of the above-described problems, there is clearly a need for garments having finished edges that are not bulky. There is also a need for garments having finished edges that can grip and that do not ride-up over a wearer's body to cause binding. There is also a need for garments having finished edges that are smooth and that do not show through outer garments. Furthermore, there is a need for methods of making garments that improve material yield and reduce waste.
SUMMARY OF THE INVENTION
In certain preferred embodiments of the present invention, a method of making a fabric having a finished edge includes providing a fabric having a plurality of fibers with free ends of the fibers at an edge of the fabric and disposing a curable polymer over the edge of the fabric so that the curable polymer engages the free ends of the fibers at the edge of the fabric. The method desirably includes, after the disposing step, curing the polymer for binding the free ends of the fibers at the edge of the fabric to the cured polymer. In preferred embodiments, the fabric may be made of cotton, nylon, polyester and spandex fibers or any other natural or synthetic fibers used to make fabric. In certain preferred embodiments, the fabric is cut into pattern pieces before the curable polymer material is disposed on the fabric. Each cut pattern piece may be sewn to one or more other pieces of fabric for making a garment. Although the present invention is not limited by any particular theory of operation, it is believed that cutting the pattern pieces before forming the finished edge will dramatically improve the material yield from a spread, particularly in comparison to techniques using fabric having knitted-in edges. This particular feature will be described and shown in more detail below in FIG. 5 of the present application.
Prior to disposing the polymer material, an edge of the cut pattern piece is desirably positioned over an absorbent material, such as a sheet of absorbent paper. In one preferred embodiment, the absorbent paper is a roll of elongated paper that is unrolled onto a conveyor system, with the paper provided on a top surface of the conveyor, between the cut pattern piece and the conveyor. In certain preferred embodiments, at least the edge of the cut pattern piece is in contact with the absorbent material as the polymer is deposited onto the cut pattern piece. Although not limited by any particular theory of operation, it is believed that the absorbent material acts as a shield that prevents the polymer material from coming in direct contact with the conveyor. This shielding action avoids the need to clean or remove polymer from the conveyor. The absorbent material may also assist in the formation of a clean edge of cured polymer material at the edge of the pattern piece.
In certain preferred embodiments, the polymer includes silicone. As is well known to those skilled in the art, a silicone is defined as any one of a large group of siloxanes that are stable over a wide range of temperatures. More specifically, silicones are any of a group of semi-inorganic polymers based on the structural unit R 2 SiO, where R is an organic group, characterized by wide-ranging thermal stability, high lubricity, extreme water repellence and physiological inertness. Silicones are typically used in lubricants, adhesives, coatings, paints, synthetic rubber, electrical insulation and prosthetic replacements for body parts. In one particularly preferred embodiment, the silicone is a compound made up of, by weight, approximately 10-30% silica and 60-90% vinylpolydimethylsiloxane.
The method also desirably includes aligning the edge of the cut pattern piece with a dispenser for the curable polymer and dispensing the curable polymer from the dispenser onto the edge of the cut pattern piece. In certain preferred embodiments, the dispenser includes at least one opening for dispensing the curable polymer. In other preferred embodiments, the dispenser includes a series of openings for dispensing the curable polymer, at least one of the openings having a different size than at least another one of the openings.
After the polymer has been deposited on the cut pattern piece, the polymer is desirably cured using heat. In one preferred embodiment, one or more heating stations are provided for heating the polymer material previously applied to the cut pattern piece. The cut pattern piece may be placed in thermal communication with the one or more heating elements. In one preferred embodiment, the cut pattern piece may be moved on a conveyor element, such as a conveyor belt, with the absorbent material positioned atop the conveyor and the fabric positioned at least partially on the absorbent material. Each heating station may have one or more heating elements for generating heat. The temperature of the polymer and/or the temperature of the cut pattern pieces may be monitored to insure that the polymer is heated to an adequate temperature to properly cure the polymer. In certain preferred embodiments, the polymer is heated to approximately 260-280 degrees Fahrenheit. In more preferred embodiments, the polymer is heated to approximately 265-275 degrees Fahrenheit. The time limit for heating the polymer may vary. In one preferred embodiment, heating for about one minute cures the polymer on the cut pattern piece.
The conveyor element may have a top surface for supporting the cut pattern pieces. In one preferred embodiment, the conveyor element may include a conveyor belt having a top surface for supporting the cut pattern pieces as the pieces move between various stations, i.e. alignment station, disposing polymer station, curing station, etc. In one particular preferred embodiment, the top surface of the conveyor belt may include a material having a low coefficient of friction or a non-stick material such as the material sold under the trademark TEFLON. As a result, there may be no need to provide an absorbent material between the pattern pieces and the conveyor because any polymer deposited on the conveyor may be easily removed from the top surface such as by using a scrapper.
The step of disposing a curable polymer on the cut pattern piece may include disposing a first polymer bead over the edge of the pattern piece and disposing at least one second polymer bead adjacent the first polymer bead. The at least one second polymer bead may be narrower than the first polymer bead. In more preferred embodiments, the at least one second polymer bead includes a plurality of second polymer beads. The at least one second polymer bead may include a plurality of second polymer beads spaced from one another, with the fabric of the pattern piece exposed between the plurality of second polymer beads. The one or more second polymer beads may extend in a direction parallel to the edge of the fabric or may extend along a path that mirrors the edge of the fabric.
In other preferred embodiments, the polymer may be provided on the pattern piece away from the edge of the pattern piece. In these embodiments, the polymer may provide gripping to prevent the fabric from riding or slipping over the body of a garment wearer. The polymer may be one or more beads that follow an S-shaped or curved pattern. The one or more polymer beads may be continuous or non-continuous, e.g. intermittent deposits of polymer on a fabric. The polymer may also be provided as polymer dots on the fabric. The intermittent polymer deposits may form a matrix of polymer on a fabric. In certain preferred embodiments, the spacing between the polymer beads may be increased for increasing the stretchability of the fabric. In other preferred embodiments, the spacing between the polymer beads may be decreased for increasing the gripping of the fabric. The polymer beads may also be applied over a central region of a fabric to provide gripping at the central region for holding the fabric in place over a body.
Another preferred embodiment of the present invention involves cutting a spread. As is well known to those skilled in the art, cutting a spread involves laying down fabric having a desired length in multiple layers. Typically, a spread may include 100 or more layers of fabric. Before cutting the spread into pattern pieces, a particular pattern is selected and applied to the spread. The pattern may be applied through a computer system that analyzes the length of the fabric and determines how to maximize the number of pattern pieces that may be cut from the fabric. The computer system may also control an automatic cutting machine for cutting the fabric into cut pattern pieces. The spread may also be cut by placing a pattern over the spread and cutting the pattern pieces by hand using a cutting tool. In one particular preferred embodiment, a method of making a cut pattern piece for a garment includes providing a spread, and cutting the spread to provide cut pattern pieces, each cut pattern piece including a plurality of fibers having free ends that terminate at an edge of the pattern piece. The method desirably includes after the cutting step, disposing a curable polymer over the edges of the cut pattern pieces so that the curable polymer engages the free ends of the fibers at the edges of the pattern pieces. After the curable polymer is disposed, the polymer is desirably cured for binding the free ends of the fibers at the edges of the pattern pieces to the cured polymer. Each pattern piece having the cured polymer edge may be sewn to at least one other piece of fabric for making the garment. The curable polymer material may be placed on the cut pattern piece by disposing a first polymer bead over the edge of the pattern piece and disposing at least one second polymer bead over the pattern piece adjacent the first polymer bead, whereby the at least one second polymer bead is narrower than the first polymer bead. The at least one second polymer bead may include a plurality of second polymer beads spaced from one another on the pattern piece with a face of the pattern piece being exposed between the plurality of second polymer beads.
In another preferred embodiment of the present invention, a section of a garment includes a cut pattern piece having a plurality of fibers with free ends that terminate at an edge of the pattern piece, and a bead of cured polymer material provided over the edge of the pattern piece, the bead of cured polymer material encapsulating at least some of the free ends of the fibers that terminate at the edge of the pattern piece. The pattern piece desirably includes a plurality of second beads of cured polymer material disposed on the pattern piece adjacent the first bead of cured polymer material, whereby the plurality of second beads are spaced from one another on the pattern piece with a face of the pattern piece being exposed between the second beads. The second beads preferably provide gripping which holds the fabric in place over a wearer's body.
The present invention provides tremendous benefits over prior art methods of making garments. Specifically, the present invention dramatically increases the material yield from fabric spreads. Prior art methods that use fabric having knitted-in edges require that the finished edge be formed on a spread before the spread is cut to make cut pattern pieces. Because the pattern pieces must be cut from the knitted-in finished edge, a large area of the spread away from the finished edge cannot be used. In contrast to these prior art methods, the present invention enables pattern pieces to be cut from any region of a spread. Thus, the cut pattern pieces do not have to incorporate a knitted-in finished edge, inter alia, because the finished edge of the present invention is preferably formed only after the pattern pieces have been cut.
The present invention also enables a spread to have more layers of fabric. When laying a spread of fabric having knitted-in edges, the knitted-in edges are thicker than the rest of the fabric. This limits the number of layers that can be stacked atop one another. Typically, a spread of fabric having knitted-in edges can only be stacked 24 or 48 layers high. In addition, fabric having knitted-in edges is also harder to handle. All of these factors slow down the process of producing pattern pieces having knitted-in edges, which adds to the cost and time needed to manufacture garments.
The present invention also provides finished edges that are sleeker and thinner than prior art products having a relatively thick finished edge. As described herein, a silicone bead that finishes an edge is much thinner than the prior art finished edges that use folded-over edges, narrow elastic, trim and/or lace. The silicone beads also provide a garment that grips for preventing the garment from riding over a wearer's body. As a result, the garment will not ride and bind (e.g. constrain). The present invention also provides a garment having stability due to the gripping from the polymer. This stability minimizes the likelihood that the fabric will roll over upon itself, which may result in bunching or binding of the garment. The present invention also provides a finished edge that has more stretch because it does not have a thick finished edge that is formed when using narrow elastic, trim, lace and/or a folded-over edge.
In another preferred embodiment of the present invention, a garment includes a cut pattern piece made of a fabric having edges and an interior region of the fabric being spaced from the edges. The fabric may include natural fibers such as cotton fibers or synthetic fibers such as nylon, polyester and spandex fibers. The garment preferably includes at least one bead of silicone deposited in the interior region of the fabric, whereby the silicone is in contact with the fabric and provides gripping for holding the cut pattern piece in place on a wearer's body. The garment may be an undergarment, activewear, shapewear, a bathing suit, a garment having one or more support panels or a garment that uses compression fabric.
In another preferred embodiment, a method of increasing material yield when cutting pattern pieces from fabric includes laying a spread of fabric having a bottom edge, cutting a plurality of pattern pieces from the spread of fabric, wherein at least some of the cut pattern pieces do not include the bottom edge of the spread of fabric, and disposing a curable polymer material such as silicone over one or more edges of the cut pattern pieces including the at least some of the cut pattern pieces that do not include the bottom edge of the spread of fabric. In this particular embodiment, the cut pattern pieces may include fibers having free ends that terminate at the one or more edges of the cut pattern pieces. The method also desirably includes curing the polymer material for finishing the one or more edges of the cut pattern pieces.
In still another preferred embodiment of the present invention, a garment includes a cut pattern piece made of a fabric with fibers having free ends terminating at an edge of the cut pattern piece, and a polymer material provided on the fabric in contact with the free ends of the fibers, whereby the polymer material provides a finished edge for the cut pattern piece. The fabric may include compression fabric or stretchable fabric such as fabric used in activewear or shapewear. The garment may be an undergarment, activewear, shapewear, a bathing suit, a garment having support panels and a garment using compression fabric. In highly preferred embodiments, the finished edge of the cut pattern piece is devoid of narrow elastic, a folded-over edge, trim and/or lace. As a result, the finished edge of the present invention is not bulky and is able to more easily stretch to adjust to various body dimensions and body movements. As a result, the garment will be less likely to bind to and ride over a wearer's body. In certain preferred embodiments, the polymer material provided on the stretchable fabric includes a first polymer bead provided in contact with the free ends of the fibers and at least one second polymer bead in contact with the fabric, the at least one second polymer bead being spaced from the first polymer bead. The at least one second polymer bead desirably provides gripping for holding the fabric in place over a wearer's body.
In yet another preferred embodiment of the present invention, a garment having a sleek finished edge includes a cut pattern piece made of fibers, at least some of the fibers having free ends that terminate at an edge of the cut pattern piece, and a cured polymer material such as silicone provided in contact with the free ends of the fibers at the edge of the cut pattern piece, the cured polymer material providing a sleek finished edge to the cut pattern piece, the finished edge being preferably devoid of a folded-over edge, narrow elastic, trim and/or lace. Due to the absence of the narrow elastic, trim or lace, the finished edge is much thinner than prior art finished edges, and is better suited for stretching, which prevents binding and ride-up.
In still another preferred embodiment of the present invention, a method of controlling a stretchable garment utilizing the stretch characteristics of stretchable fabric includes providing a spread of stretchable fabric that is more stretchable in a first axial direction and less stretchable in a second axial direction, and cutting a pattern piece from the spread, wherein the at least one cut pattern piece has unfinished edges with free ends of fibers at the unfinished edges. The method desirably includes disposing a curable polymer over one of the unfinished edges of the cut pattern piece so that the curable polymer engages the free ends of the fibers, wherein the one of the unfinished edges having the curable polymer disposed thereon extends along a third axial direction that crosses the first axial direction, and after the disposing step, curing the polymer for finishing the edge of the fabric.
The present invention provides garments that have smoother finished edges than garments that use folded-over edges, narrow elastic, trim and/or lace at the finished edge. As a result, the garments of the present invention will not have bulky finished edges. Moreover, the finished edges of the present invention are more stretchable than the finished edges of garments that use folded-over edges, narrow elastic, trim and/or lace. As a result, the finished edge of the present invention minimizes ride-up and binding. Furthermore, the smooth finished edges or the present invention are less likely to be visible through outer garments than are garments having bulky finished edges made of folded-over edges, narrow elastic, trim or lace.
The present invention also improves material yield over techniques that use fabric having knitted-in edges. This is due to the fact that the finished edge is formed after the pattern piece has been cut. As a result, the cut pattern pieces of the present invention do not need to incorporate a particular edge of a spread, such as a knitted-in edge. This enables an operator to cut pattern pieces in regions of a spread that are spaced from the edges of the spread, thereby maximizing material yield.
The present invention also improves material yield because an operator has more flexibility to cut a pattern piece from anywhere along a width of a spread. In contrast, methods using fabric with knitted-in edges must cut each pattern piece within the width of one of the panels of a spread. The smaller width of the panels versus an entire spread (20 inches v. 80-120 inches) reduces flexibility when marking patterns on fabric having a knitted-in edge, which further reduces material yield.
Moreover, the present invention saves money because it enables the production of garments having smooth finished edges without requiring the use of fabric having costly knitted-in edges. Thus, manufacturers will save money on fabric for making garments.
These and other preferred embodiments of the present invention will be described in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a panel having an edge.
FIG. 1B shows an expanded view of the edge of the panel shown in FIG. 1A .
FIGS. 2A , 2 B- 1 , 2 C and 3 A- 3 C show a conventional method of making a finished edge on a panel.
FIG. 2B-2 shows a perspective view of FIG. 2B-1 .
FIG. 4 shows a conventional spread having pattern pieces defined in the spread.
FIG. 5 shows a plan having pattern pieces defined therein, in accordance with certain preferred embodiments of the present invention.
FIG. 6 shows a plan view of a cut pattern piece having an unfinished edge, in accordance with certain preferred embodiments of the present invention.
FIGS. 7A-7C show a method of forming a finished edge on the cut pattern piece of FIG. 6 , in accordance with certain preferred embodiments of the present invention.
FIGS. 8A and 8B show a conventional undergarment having finished edges that are bulky so as to show through outerwear.
FIGS. 9A and 9B show an undergarment having finished edges including a polymer bead for binding ends of fibers, in accordance with certain preferred embodiments of the present invention.
FIG. 10 shows a cut pattern piece having an unfinished edge.
FIG. 11 shows the cut pattern piece of FIG. 10 having a first polymer edge forming a finished edge and second polymer beads forming a gripping surface, in accordance with further preferred embodiments of the present invention.
FIG. 12A shows an expanded plan view of the cut pattern piece shown in FIG. 11 .
FIG. 12B shows a cross-sectional view of the cut pattern piece of FIG. 12A taken along line 12 B- 12 B thereof.
FIG. 13 shows a process for forming a finished edge on a cut pattern piece, in accordance with certain preferred embodiments of the present invention.
FIG. 14 shows a system for forming a finished edge on cut pattern pieces, in accordance with certain preferred embodiments of the present invention.
FIG. 15A shows a plan view of first and second stations of the system shown in FIG. 14 .
FIG. 15B shows a plan view of third and fourth stations of the system of FIG. 14 .
FIG. 15C shows a plan view of fourth and fifth station of the system shown in FIG. 14 .
FIG. 16 shows a bottom view of an applicator device used for applying a curable polymer material to a cut pattern piece, in accordance with certain preferred embodiments of the present invention.
FIG. 17A shows a front elevation view of the applicator device of FIG. 16 .
FIG. 17B shows a side elevation view of the applicator device of FIG. 17A .
FIG. 18 shows a spread including a stretchable fabric having a first direction of stretch, in accordance with certain preferred embodiments of the present invention.
FIG. 19 shows a pattern piece cut from the spread of FIG. 18 .
DETAILED DESCRIPTION
Referring to FIG. 5 , in accordance with certain preferred embodiments of the present invention, a spread 120 has a length designated L and a width designated W. In the particular example shown in FIG. 4 , the spread has a length L of 117.56 inches and a width W of 73.50 inches. A pattern is used to define a series of pattern pieces 138 A- 138 L. An automatic cutting machine or hand-cutting tool may be used to cut the pattern pieces 138 A- 138 L. Because the spread 120 has no finished edge, such as a knitted-in edge, the cut pattern pieces may include those cut from the spread at a location away from an edge of the spread. As a result, a greater percentage of the spread may be used to make cut pattern pieces, which will improve the material yield of the spread. In the particular spread 120 shown in FIG. 5 , the material yield of the spread is 86.70% because the cut pattern pieces 138 A- 138 L utilize 86.70% of the spread 120 , with 13.3% of the spread being unusable waste material. The 86.70% material yield is a tremendous improvement over the 57.13% material yield described in conjunction with the FIG. 4 prior art embodiment that uses fabric having a knitted-in edge. Thus, the present invention saves money by increasing material yield. The present invention also saves money because it obviates the need to use fabric having knitted-in edges, thereby saving on the cost of materials. The present invention is also more economical because it allows more layers of fabric to be stacked in the spread (i.e. 100-200 layers) before cutting the spread, which results in more cut pattern pieces being produced at a faster rate. In contrast, a spread of knitted-in fabric can only be stacked about 24-48 layers high before cutting, because the knitted-in edge is thicker than the remaining portion of the fabric. The thicker edge makes one edge of the spread higher than the other edges of the spread.
Referring to FIGS. 6 and 7 A- 7 C, in certain preferred embodiments of the present invention, a cut pattern piece 120 is made of a plurality of fibers 126 having free ends 128 that terminate at an edge 122 of the pattern piece. In order to prevent the free ends 128 of the fibers 126 of the pattern piece from fraying or tearing, a silicone bead is deposited in contact with a top surface 130 of the cut pattern piece 120 , adjacent the edge 122 of the pattern piece.
As shown in FIGS. 7A and 7B , the silicone material 162 is deposited in contact with the first surface 130 and the edge 122 of the cut pattern piece. As shown in FIG. 7C , the silicone 162 engages and/or contacts the free ends 128 of the fibers 126 . Although the present invention is not limited by any particular theory of operation, it is believed that the silicone 162 at least partially encapsulates and/or contacts to the free ends 128 of the fibers 126 so as to bind the free ends of the fibers to the silicone, which prevents the edge 122 of the pattern piece 120 from fraying or tearing. As a result, the pattern piece does not require a finished edge that includes narrow elastic, trim, lace, folded-over edge or a knitted-in finished edge. Furthermore, a spread 120 is preferably cut into pattern pieces 138 A- 138 L ( FIG. 5 ) before applying the silicone material 162 at the edge 122 . The ability to cut the spread into cut pattern pieces before forming the silicone finished edge provides a tremendous cost savings over prior art methods because it improves material yield. Thus, one particular benefit of the present invention is that it provides an increased material yield from fabric spreads. In addition, providing a finished edge of silicone reduces the thickness of the pattern piece at the finished edge. In certain preferred embodiments, the thickness of the finished edge including the silicone bead is 1/16 inch, which is significantly thinner than the prior art finished edges using narrow elastic ( FIG. 2 c ), lace, trim or folded-over edges, which provides thicker finished edges of ⅛ inch or greater.
FIGS. 8A and 8B show a conventional undergarment 164 having bulky, finished edges 166 . Due to the thickness of the bulky edges 166 , the undergarment may be visible through outerwear.
FIGS. 9A and 9B show an undergarment 164 ′ having a silicone finished edge that is made using the inventive process described herein. As shown in FIG. 9A , after a pattern piece has been cut, a silicone material 162 is deposited at the edge 122 of the piece. The combined thickness of the silicone and the fabric is substantially thinner than the thickness of the finished edge 166 shown in the undergarment 164 of FIGS. 8A and 8B . As a result, the undergarment 164 ′ of the present invention does not have a bulky edge that is likely to be visible through outerwear. Thus, the finished edge formed using the present invention is more stretchable and less likely to bind.
FIG. 10 shows a cut pattern piece 220 having an edge 222 . Although not shown in FIG. 10 , the edge 222 includes a plurality of fibers having ends that terminate at the edge 222 . On a microscopic scale, the free ends of the fibers at the edge are loose, which makes the edge subject to fray or tear when wearing or washing the piece 220 . Referring to FIG. 11 , in order to bind the free ends of the fibers, a first bead of silicone material 262 is deposited at the edge 222 . The first bead of silicone material 262 preferably contacts and binds the free ends of the fibers at the edge 222 of the pattern piece 220 . The pattern piece also has a series of second silicone beads 268 deposited adjacent the first silicone bead 262 . The second beads 268 are preferably thinner than the first bead 262 of silicone material. The series of second beads 268 preferably extend parallel to the edge 222 of fabric 220 . In other preferred embodiments, the second beads may be remote from an edge and/or may follow a path that is curved, S-shaped, or discontinuous and/or a path that comprises a series of silicone dots.
FIG. 12A shows a magnified view of the pattern piece 220 shown in FIG. 11 . The pattern piece 220 includes edge 222 having a first silicone bead 262 deposited over the edge for finishing the edge. Although the present invention is not limited by any particular theory of operation, it is believed that the silicone at least partially encapsulates and/or binds the free ends of the fibers to prevent the fibers from fraying and tearing. In addition, a series of second silicone beads 268 extend in a direction generally parallel with the edge 222 of fabric 220 . The second silicone beads 268 are spaced apart from one another so that a face of the pattern piece 220 is exposed and/or accessible between the second beads 268 . As shown in FIG. 12A , a first one 268 A of the second silicone beads is spaced from the first silicone bead 262 so that first fabric section 220 A is exposed therebetween. In addition, a second one 268 B of the second silicone beads is spaced from the first one 268 A of the second silicone beads so that a second fabric section 220 B is exposed therebetween. The second silicone beads 268 continue in a similar fashion to provide a silicone web that extends a substantial distance inwardly from edge 222 of pattern piece 220 . The density of the silicone web may be modified depending upon the characteristics desired for the underlying pattern piece. If the spacing between the second silicone beads of the web is increased, the pattern piece will be more stretchable and will provide less gripping. If the spacing between the second silicone beads of the web is decreased, the pattern piece will be less stretchable and provide more gripping. The spacing may be modified depending upon the intended use of the garment.
FIG. 12B shows a magnified view of the pattern piece of FIG. 11 . The pattern piece 220 has top surface 230 and outer edge 222 . A first silicone bead 262 is deposited over the edge 222 of the pattern piece so as to finish the free ends of the fibers that terminate at the edge of the pattern piece. In addition, the web of second silicone beads 268 is deposited over the first surface 230 , adjacent the first silicone bead 262 . The second silicone beads 268 are preferably spaced from one another, with portions of the first surface 230 of pattern piece 220 being exposed and accessible through the web of second silicone beads 268 . Although the present invention is not limited by any particular theory of operation, it is believed that providing the web of second silicone beads 268 atop the pattern piece 220 ( FIGS. 12A and 12B ) produces a pattern piece that is less likely to slip or ride-up over a wearer's body. Ride-up may cause an undergarment to bind around a body part, e.g. a leg, which may cause a constricted feeling. Ride-up may also cause bunching of the fabric, which may be visible through outerwear. It is believed that the web of second silicone beads provides the fabric with a gripping feature that prevents the fabric from sliding and riding-up over a wearer's body.
FIG. 13 shows a process for providing a finished edge on a cut pattern piece, in accordance with certain preferred embodiments of the present invention. During a first stage 280 , a spread of fabric is cut to provide one or more pattern pieces. The pattern piece may be cut by hand or using a computer-assisted cutting instrument. During a second stage 282 , an edge of the cut pattern piece is aligned for applying a silicone material over the edge. A straight edge or alignment tool may be used for aligning the edge of the pattern piece. During a third stage 284 , the silicone is applied to the edge in an uncured state. Due to the uncured state of the silicone, the silicone tends to at least partially encapsulate and/or bind with the free ends of the fibers at the edge of the pattern piece. The silicone may be applied along a straight edge of a pattern piece or may be applied in a pattern that follows the contour of the edge of the pattern piece, e.g. the silicone may follow the contour of a curved edge. The silicone may also be applied to an interior region of the pattern piece that is remote from an edge. The silicone may be applied along paths that are curved, S-shaped and/or non-continuous (e.g. silicone provided in a dotted pattern). During a fourth stage 286 , the pattern piece may be pulled back from the alignment edge and the silicone cured during a fifth curing stage 288 . During the curing stage, the silicone may be cured using air or heat.
FIG. 14 shows a system for producing a finished edge on a cut pattern piece, in accordance with certain preferred embodiments of the present invention. The system 300 includes a conveyor 302 having a belt 304 that is movable over rollers 306 . The belt 304 moves over the rollers 306 in the direction indicated by arrow 308 . The system includes a paper storage roll 310 from which an absorbent material such as paper 312 is unwound. The absorbent paper 312 is guided into engagement with the conveyor belt 304 so that it is positioned over a top surface of the conveyor belt before a cut pattern piece is positioned on the conveyor belt. The system 300 also includes a second roll 314 that collects the absorbent paper at a point located downstream from the first roll 310 .
The system also includes a dispensing head 316 that applies silicone material over a cut pattern piece placed atop conveyor belt 304 , and a retractor subassembly 318 that pulls the cut pattern piece off the absorbent paper 312 after the silicone material has been deposited atop the fabric. System 300 also includes a heater 320 having one or more heating coils 322 for heating the silicone applied to the fabric. During the heating process, the heat cures the silicone to permanently bind the silicone to the fabric. The system also includes one or more temperature sensors 324 provided in thermal communication with the top surface of the conveyor belt 304 so as to monitor the surface temperature of the conveyor belt.
Referring to FIGS. 14 and 15A , the system 300 includes a first stage 326 where cut pattern piece 220 is placed atop absorbent paper 312 , with the edge 222 of the piece 220 aligned with a guide having alignment face 330 . In other preferred embodiments, the first stage 326 may have alignment fingers that mechanically align the edge of the pattern piece. After the pattern piece has been aligned, the conveyor belt 304 moves the piece 220 downstream in the direction of arrows 308 to a second stage 332 where silicone material is deposited onto the pattern piece 220 . At stage 332 , a dispenser 316 for silicone dispenses a first silicone bead 262 over the outer edge 222 of the pattern piece 220 . Simultaneously, the dispenser 316 deposits a spaced web of second silicone beads 268 over a region of the pattern piece that is inward of the edge 222 .
Referring to FIGS. 14 and 15B , conveyor belt 304 continues to move the pattern piece 220 downstream to retractor stage 334 . At retracting stage 334 , retractor 336 moves from a retracted position 338 to an extended position 340 for engaging a section of pattern piece 220 . Once the retractor 336 engages the pattern piece 220 , the retractor retracts from position 340 to retracted position 338 to pull the pattern piece 220 off the absorbent paper 312 . As the piece 220 is pulled of the paper 312 , the first silicone bead 262 at the edge 222 is broken from its engagement with the paper 312 to provide a smooth edge of silicone at the outer edge 222 of the pattern piece 220 . Once the piece has been pulled of the paper 312 , the pattern piece 220 is moved downstream along conveyor 304 to a curing stage 342 . At the curing stage 342 , the deposited silicone material is cured using heat. Referring to FIG. 14 , the curing stage has a heater 320 having heating coils 322 that produce heat. In preferred embodiments, the heating stage may include six (6) heating stations, each heating station having one or more heating elements. In one particular preferred embodiment, the heating elements are set at 600° F. so that the surface temperature of the conveyor 304 is between 260° F. and 275° F. In highly preferred embodiments, the surface temperature should be between about 268° F.-272° F. The temperature sensor 324 is interconnected with a controller 344 that may change the temperatures of the heating elements 322 depending on ambient conditions. For example, in warmer ambient temperatures, the heating elements 322 may be operated at lower temperatures than would be required under cooler ambient conditions. In certain preferred embodiments, the pattern piece and the silicone deposited on the piece are preferably cured for approximately 30 second to two minutes and more preferably about one minute.
Referring to FIG. 15C , after the pattern piece 220 and the cured silicone 262 , 268 exits oven 324 , the pattern piece moves downstream along conveyor belt 304 to stacking station 344 . At stacking station 344 , the pattern piece having the cured silicone is removed from the conveyor 304 by a stacker 346 that is moveable between a first position 348 and a second position 350 . In the second position 350 , the stacker 346 engages pattern piece 220 . The stacker 346 then moves to the first position 348 . As the stacker moves between the second and first positions, the pattern piece 320 is moved in the direction D 1 for being placed atop a stack 352 . After a sufficient number of pattern pieces 220 have been place atop stack 352 , the stack may be placed in a package for shipment to another location, i.e. an assembly facility.
FIG. 16 shows a dispenser 316 for silicone, in accordance with certain preferred embodiments of the present invention. A series of openings are provided at the bottom of the dispenser 316 . The openings include an elongated opening 354 adjacent the first end 356 of the dispenser and a series of smaller openings 358 that extend between elongated opening 354 and a second end 360 of the dispenser 316 . In operation, high pressure is provided inside the dispenser to dispense the silicone material through the openings 354 , 358 . The openings 354 , 358 are preferably arranged along a straight line that extends between the first end 356 and the second end 360 of the dispenser 316 .
FIG. 17A shows the dispenser 316 depositing silicone onto a cut pattern piece 220 . The silicone is dispensed in a pattern that includes thicker first silicone bead 262 deposited at the edge of the pattern piece and a series of smaller second silicone beads 268 that are deposited inwardly from the edge. The second beads 268 are spaced from one another. As shown in FIG. 17A , the first silicone bead 262 has a width W 1 that is substantially greater than the width W 2 of the second silicone beads 268 . In addition, the second silicone beads are spaced from one other so that gaps 270 are present between the second silicone beads. Another gap 272 is present between first silicone bead and a first one of the second silicone beads 268 A.
FIG. 17B shows the dispenser head 316 as the dispenser deposits silicone beads 262 , 268 over a top surface 230 of pattern piece 220 . The silicone is deposited as the conveyor belt 304 moves fabric 220 in a direction indicated by arrow 308 . As the pattern piece 220 passes the dispensing head 316 , the silicone material 262 , 268 is deposited onto the top surface of the pattern piece 220 .
In another preferred embodiment of the present invention, a spread is made of stretchable fabric. Referring to FIG. 18 , the spread 420 is more stretchable in a first axial direction designated Y than a second axial direction designated X. Pattern pieces 438 are cut from the spread 420 . Referring to FIGS. 18 and 19 , at least one of the cut pattern pieces 438 A has a first unfinished edge 422 that extends in a third axial direct designated Z that traverses or crosses the first axial direction Y. The direction of the unfinished edge 422 can be readily modified depending upon adjustability and fit requirements. A curable polymer such as silicone is disposed over the first unfinished edge 422 for engaging free ends of fibers at the edge 422 . The polymer is then cured for binding the free ends of the fibers and finishing the edge.
Although the present invention is not limited by any particular theory of operation, it is believed that the stretch characteristics of fabric may be used to provide garments having more adjustability and better fit. Thus, in one embodiment, an edge may be cut that extends in a direction parallel to the direction of stretch of the fabric. In another embodiment, an edge may be cut that extends in a direction perpendicular to the direction of stretch of the fabric. In still another embodiment, an edge may be cut that extends in a direction that crosses the direction of stretch of the fabric. Thus, the direction of the cut edge may be readily modified based upon the use to which the cut pattern piece will be put.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore contemplated that numerous modifications may be made to the illustrated embodiments and that other arrangements may be made without departing from the spirit and scope of the present invention as defined by the appended claims.
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An undergarment includes at least one piece of fabric that forms the undergarment. The undergarment has leg openings. The fabric includes edges that surround the leg openings, whereby at least one of the edges surrounding the leg openings has a plurality of fibers and at least some of the fibers have free ends terminating at the at least one of the edges surrounding the leg openings. A bead of a cured polymer is disposed over the at least one of the edges surrounding the leg openings. The cured polymer bead forms a finished edge that is stretchable for adjusting to movement of the fabric.
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This application claims the priority benefit under 35 U.S.C. section 119 of U.S. Provisional Patent Application No. 60/935,402 entitled “Styrenated Phenol Ethoxylates In Emulsion Polymerization”, filed Aug. 10, 2007, which is in its entirety herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to emulsion polymerizing ethylenically unsaturated monomers. This invention also relates to emulsion polymerization of ethylenically unsaturated monomers by using styrenated surfactants as the primary emulsifier. The instant invention also relates to a process for the preparation of a polymer dispersion by free radical polymerization of an aqueous monomer emulsion. The present invention further relates to a method for production of waterborne polymer and copolymer dispersions comprising monomer units derived from at least one polymerizable ethylenically unsaturated monomer. The polymer and copolymer dispersions are obtained in a free radical emulsion polymerization process performed in an aqueous media and in the presence of at least one styrenated surfactant In a further aspect the present invention refers to the use of said polymer or copolymer dispersion.
BACKGROUND OF THE INVENTION
Emulsion polymerization is the most important industrial method for manufacture of aqueous dispersion of polymers. Emulsion polymerization is typically performed in an aqueous medium in the presence of a surfactant and a water soluble initiator and is usually rapidly producing high molecular weight homo or copolymers at high solids content and low dispersion viscosity. Its application requires the emulsification of the monomer in a medium, usually water, through the use of emulsifiers. These are supplied in addition to the other ingredients that go into most polymerizations, such as the initiator and chain transfer agents. The use and type of emulsifier determines many of the characteristics of the produced polymer or copolymer, which is typically a latex (stable colloidal suspension of polymer particles in a continuous phase, usually water). Moreover, the emulsifier usually cannot be completely removed from the latex. For this reason, and because of the great unpredictability of the efficacy of a given surface-active agent as an emulsifier in polymerization, many compounds that would theoretically be useful are not.
It is also known that emulsion polymerization requires the use of a surfactant to form a stable emulsion of monomers and to prevent coagulation of the product polymer. Surfactants are generally categorized into two types: either non-polymerizable, or polymerizable, that is co-polymerizable with the monomers for polymer formation. A problem which has arisen with the use of non-polymerizable surfactants is that they remain as a residue in the product polymer and, as they can be extracted by water, they make the product sensitive to water. Surfactants are also categorized as anionic, cationic, non-ionic or zwitterionic depending on their chemical makeup.
With the customary emulsion polymerization processes, suitable latices have been difficult to obtain since the latices usually contain particles of varying size and are either too fine or too large. Various proposals have heretofore been made to overcome these difficulties but not with the ultimate success desired. For example, the use of various different emulsifiers and catalysts have been proposed. Also, varying the conditions of polymerization has been suggested. However, in most of these cases, too much coagulation occurred with the resulting latex containing too much coagulum or partially agglomerated particles which precipitate reducing the yield. Further, the shelf life of such latices leave much to be desired. It is desirable to have latices which change very little during storage with respect to viscosity and have and maintain good heat stability.
The final product resulting from emulsion polymerization is normally an opaque, grey or milky-white dispersion of high molecular weight polymer(s) at a solids content of typically 30-60% in water. Said dispersion typically comprises acrylic, methacrylic and crotonic acid homo and copolymers, methacrylate and acrylate ester homo or copolymers, vinyl acetate homo or copolymers, vinyl and vinylidene chloride homo or copolymers, ethylene homo or copolymers, styrene and butadiene homo or copolymers, acrylamide homo or copolymers, butadiene-acrylonitrile copolymers, styrene-acrolein copolymers and/or where applicable carboxylated versions. Traditional applications for such aqueous dispersions are adhesives, binders for fibres and particulate matter, protective and decorative coatings, dipped goods, foam, paper coatings, backings for carpet and upholstery, modifiers for bitumens and concrete and thread and textile modifiers. More recent applications include biomedical applications as protein immobilisers, visual detectors in immunoassays, as release agents, in electronic applications as photoresists for circuit boards, in batteries, conductive paint, copy machines and as key components in molecular electronic devices.
Ethoxylated Styrenated Phenols have been widely disclosed as effective and efficient pigment dispersants in a variety of applications. U.S. Pat. No. 6,736,892 (2004) discloses anionic Sytrenated Phenol Ethoxylates as pigment dispersants in water based ink and coating applications. U.S. application 0235877 A1 (2005) discloses fatty acid esters of Styrenated Phenol Alkoxylates as effective and efficient pigment dispersants for solvent based systems. U.S. Pat. No. 5,035,785 (1991) discloses nonionic Styrenated Phenol Ethoxylates as effective and efficient pigment dispersants in electrodeposition baths. The dispersants were also found to increase film build and dramatically improve film appearance and maintain the improved film appearance in this application. Thus the utility of Styrenated Phenol Ethoxylates, both anionic and nonionic, in separating and stabilizing pigment particles against aggregation has been well known and demonstrated in both aqueous and non-aqueous systems. In these applications, these surfactants are added as part of the formulation comprising the resin used as a binder or film former, the pigment paste or dispersion, and other additives such as coalescing aids, viscosity modifiers, and other additives well known to those familiar with the art.
In emulsion polymerization of ethylenically unsaturated monomers, it is well known to those familiar with the art that surfactants are necessary and essential ingredients required for the polymerization reaction to occur in the aqueous phase. It is also well known to those familiar with the art that surfactants further function by stabilizing the latex particles against aggregation from shear or mechanical force and also stabilize the latex particles from aggregation due to the addition of electrolyte to the latex. In the emulsion polymerization process, since the radical polymerization takes place inside the surfactant formed micelles, the surfactants in emulsion polymerization are essential components in the manufacture of the latex. Benjamin B. Kline and George H. Redlich, “The Role of Surfactants in Emulsion Polymerization”, Surfactant Science Series , 26, 1988) It is also well known to those skilled in the art that the selection of surfactant type and level is also the determining factor in many emulsion properties, in particular the particle size of the latex particles. Low particle size is highly desirable in pigmentation and results in higher gloss in the final film or coating.
We have now found that the Styrenated Phenol Ethoxylates are useful as surfactants in the emulsion polymerization of ethylenically unsaturated monomers. The use of both anionic and nonionic Styrenated Phenol Ethoxylates in the emulsion polymerization process provides latexes with small particle size and small particle size distributions. Furthermore, latexes prepared using Styrenated Phenol Ethoxylates have excellent mechanical and chemical stability. The Styrenated Phenol Ethoxylates of the present invention may also be used in combination with conventional surfactants to improve latex properties.
SUMMARY OF THE INVENTION
The present invention provides a process for the emulsion polymerization of at least one ethylenically unsaturated monomer containing at least one carbon-to-carbon double bond, said process comprising polymerizing said ethylenically unsaturated monomer in an aqueous medium in the presence of a water-soluble initiator and a surfactant of the formula:
wherein n =1, 2 or 3; x is 1-100; Z − is selected from the group consisting of SO 3 − or PO 3 2 − ; and M + is selected from the group consisting of Na + , K 30 , NH 4 + , and an alkanolamine.
The present invention also provides a process for the emulsion polymerization of at least one ethylenically unsaturated monomer containing at least one carbon-to-carbon double bond, said process comprising polymerizing said ethylenically unsaturated monomer in an aqueous medium in the presence of a a water-soluble initiator and a surfactant of the formula:
wherein n=1, 2 or 3; x is preferably 1-100.
The instant invention further provides a process for the emulsion polymerization of at least one ethylenically unsaturated monomer containing at least one carbon-to-carbon double bond, said process comprising polymerizing said ethylenically unsaturated monomer in an aqueous medium in the presence of a water-soluble initiator and a mixture of surfactants of the formula I and II:
wherein n=1, 2, 3; x is preferably 1-100; Z can be either SO 3 − or PO 3 2− , and M + is Na + , K + , NH 4 + , or an alkanolamine.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed towards the emulsion polymerization of ethylenically unsaturated monomers in the presence of a anionic surfactant of formula (I)
where n=1, 2, 3; x is preferably 1-100, more preferably from about 5 to 60, and most preferably from about 5 to 40; Z can be either SO 3 − or PO 3 2− , and M + is Na + , K + , NH 4 + , or an alkanolamine.
The present invention is further directed towards the emulsion polymerization of ethylenically unsaturated monomers in the presence of a nonionic surfactant of formula (II)
where n=1, 2, 3; X is preferably 1-100. more preferably from about 5 to 60, and most preferably from about 5 to 40.
The compounds of formulas (I) and (II) may be used separately or in combination in the emulsion polymerization. More commonly they are used in combination. When used in combination, the ratio of compounds of formula (I) to compounds of formula (II) is not limited but is dictated by the desired emulsion properties. Surfactants of formulas (I) and (II) may also be used in combination with other surfactants that are commonly used in the art When used in combination, the ratio of surfactants is not specific but is commonly optimized based on the nature of the ethylenically unsaturated monomers present in a given formulation. The total amount of surfactants of formulas (I) and formula (II) that may be used in the present invention is preferably from about 0.1% to about 20% based on total weight of the monomer, more preferably from about 0.2% to about 10%, and most preferably from about 0.5% to about 7% based on the total weight of the monomer. The compounds of formulas (I) and (II) may also be used in combination with conventional surfactants in order to improve emulsion properties.
Surfactants that are commonly used in the emulsion polymerization process include both anionic and nonionic molecules. Commonly utilized anionic surfactants in the emulsion polymerization process include sodium alkylbenzene sulfonates, alkyldiphenyloxide disulfonates, ethoxylated alkylphenol sulfates and phosphates, alkyl sulfosuccinates, and sulfates and phosphates of fatty alcohols, etc. Commonly utilized nonionic surfactants include linear and branched alcohol ethoxylates, and alkylphenol ethoxylates, particularly octylphenol ethoxylates. When used in combination with other surfactants the ratios are not limited but are also dictated by the desired emulsion properties.
Suitable monomers that may be polymerized by the practice of the present invention include numerous ethylenically unsaturated monomers such as vinyl monomers or acrylic monomers. Typical vinyl monomers suitable for use in accordance with the present invention include, but are not limited to, vinyl esters such as vinyl acetate, vinyl propionate, vinyl benzoate, etc; vinyl aromatic hydrocarbons such as styrene, methyl styrenes, other vinyl aromatics such as vinyl toluenes, vinyl napthalenes, divinyl benzene, etc. Halogenated vinyl monomers such as vinyl chloride, vinylidene chloride, etc. may also be used.
Suitable acrylic monomers which may be used in accordance with the present invention comprise compounds with acrylic functionality such as alkyl acrylates and methacrylates, acrylate acids and methacrylate acids as well as acrylamides and acrylonitrile. Typical acrylic monomers include, but are not limited to methyl acrylate and methyl methacrylate, ethyl, propyl, and butyl acrylate and methacrylate, benzyl acrylate and methacrylate, cyclohexyl acrylate and methacrylate, decyl and dodecyl acrylate and methacrylate, etc. Other typical acrylic monomers include hydroxy alkyl acrylates and methacrylates such as hydroxypropyl and hydroxyethyl acrylate and methacrylate, acrylic acids such as methacrylic and acrylic acid, and amino acrylates and methacrylates. It will be recognized by those familiar with the art that other unsaturated monomers which are suitable for free radical addition polymerization may also be used in accordance with the present invention.
Numerous free radical forming compounds are utilized as catalysts in the emulsion polymerization process. Typically compounds used as catalysts are those that from free radicals via thermal decomposition, referred to in the art as “thermal initiators” or combinations of compounds that form free radicals via oxidation/reduction reactions. Such catalysts are combinations of an oxidizing agent and a reducing agent and are commonly referred to in the art as “redox initiators.” Either thermal or redox catalysts may be used in the practice of the present invention.
Typical catalysts utilized as thermal initiators include persulfates, specifically potassium persulfate, sodium persulfate, ammonium persulfate and the like. Typical redox initiators include combinations of oxidizing agents or initiators such as peroxides, specifically benzoyl peroxide, t-butyl hydroperoxide, lauryl peroxide, hydrogen peroxide, 2,2′-diazobisisobutyronitrile, and the like. Typical reducing agents include sodium bisulfite, sodium formaldehyde sulfoxylate, sodium hydrosulfite, and ascorbic and isoascorbic acid. The catalyst or initiator is employed in an amount preferably from 0.1 to 3 weight percent of the total monomer weight, and most preferably from about 0.1 to 1 weight percent of the total monomer charge.
Other additives or components which are known to those skilled in the art may also used in accordance with the present invention. These include chain transfer agents, which are used to control molecular weight, additives to adjust pH, and compounds utilized as protective colloids which provide additional stability to the latex particles.
Any of the conventional methods employed in the emulsion polymerization process may also be used in accordance with the present invention. These include both standard and pre-emulsion monomer addition techniques as well as staged monomer addition.
EXAMPLES
The following examples and comparative examples are intended to illustrate the usefulness of the invention and are not to be construed as limiting or defining the entire scope of the invention in any way.
All reactions were carried out in a 1500 mL glass reactor equipped with a four-blade stainless steel agitator, nitrogen gas inlet, thermocouple connected to a digital temperature controller, reflux condenser, and inlets for the addition of monomer mixture and catalyst solutions. Emulsion viscosities were measured using a Brookfield LVT Viscometer using a # 2 spindle at 30 rpm. Particle size measurements were run on a Brookhaven 90Plus Particle Size Analyzer.
The Styrenated Phenol Ethoxylates of the present invention will be referred to in an abbreviated fashion. For example, the Sodium Sulfate salt of Distyrenated Phenol containing 20 moles of ethylene oxide will be referred to as DSP (POE 20) Sodium Sulfate, etc. Rhodacal® DS-4, Abex® JKB, and Abex® EP-120 are registered trademarks of Rhodia corporation. Triton® X-405 is a registered trademark of Dow Corporation.
Example 1
687.0 grams of deionized water, 33.0 grams of a 50 percent solution of DSP (POE 20) Sodium Sulfate, and 15.0 grams of DSP (POE 40) were added to the reaction kettle and agitation was commenced. Oxygen was removed from the solution by nitrogen sparge and the solution was heated to 65° C. Next a monomer mixture of 333.0 g methyl methacrylate, 333.0 g of butyl acrylate and 6.0 g of methacrylic acid was prepared. 67.0 g (10%) of the monomer mixture was charged to the reaction kettle. A catalyst solution consisting of 5.0 g potassium persulfate in 100.0 g deionized water was then prepared, and 10% of the catalyst solution was then charged to the reaction kettle. A trace of ferrous sulfate was then added. The reaction mixture exothermed to 70-75° C. The remaining monomer mixture and catalyst solution were then metered in to the reaction kettle over a period of two hours. During the addition, the temperature of the reaction was maintained between 70-75° C. After the addition of monomer and catalyst was complete, the reaction mixture was held at 70-75° C. for an additional 30 minutes. The reaction mixture was then cooled to 40° C. and 4 grams of ammonium hydroxide in 20 mL deionized water was added slowly to the reaction kettle. After stirring for an additional 15 minutes, the emulsion was filtered through a 150 micron filter bag. The emulsion properties are shown in Table 1.
TABLE 1
Emulsion
Properties
Solids
46.2
pH
8.7
Coagulum
<0.05%
Viscosity (centipoise)
430
Mean Particle Size (nm)
112.9
Polydispersity Index
0.124
Mechanical Stability
Good
Chemical Stability*
Good
*1M CaCl 2
Comparative Example 1
687.0 grams of deionized water, 72.0 grams of a 22% solution of Sodium Doceylbenzene Sulfonate (Rhodacal® DS-4), and 18.7 grams of an 80% solution of Octylphenol (POE 40) (Triton® X-405) were added to the reaction kettle and agitation was commenced. Oxygen was removed from the solution by nitrogen sparge and the solution was heated to 65° C. Next a monomer mixture of 333.0 g methyl methacrylate, 333.0 g of butyl acrylate and 6.0 g of methacrylic acid was prepared. 67.0 g (10%) of the monomer mixture was charged to the reaction kettle. A catalyst solution consisting of 5.0 g potassium persulfate in 100.0 g deionized water was then prepared and 10% of the catalyst solution was then charged to the reaction kettle. A trace of ferrous sulfate was then added. The reaction mixture exothermed to 70-75° C. The remaining monomer mixture and catalyst solution were then metered in to the reaction kettle over a period of two hours. During the addition, the temperature of the reaction was maintained between 70-75° C. After the addition of monomer and catalyst was complete, the reaction mixture was held at 70-75° C. for an additional 30 minutes. The reaction mixture was then cooled to 40° C. and 4 grams of ammonium hydroxide in 20 mL deionized water was added slowly to the reaction kettle. After stirring for an additional 15 minutes, the emulsion was filtered through a 150 micron filter bag. The emulsion properties are shown in Table 2.
TABLE 2
Emulsion
Properties
Solids
46.0
pH
8.5
Coagulum
0.1%
Viscosity (centipoise)
55
Mean Particle Size (nm)
220.0
Polydispersity Index
0.309
Mechanical Stability
Good
Chemical Stability*
Poor
*1M CaCl 2
Example 2
687.0 grams of deionized water, 72.0 grams of a 22% solution of Sodium Doceylbenzene Sulfonate (Rhodacal® DS-4), and 15.0 grams of DSP (POE 40) were added to the reaction kettle and agitation was commenced. Oxygen was removed from the solution by nitrogen sparge and the solution was heated to 65° C. Next a monomer mixture of 333.0 g methyl methacrylate, 333.0 g of butyl acrylate and 6.0 g of methacrylic acid was prepared. 67.0 g (10%) of the monomer mixture was charged to the reaction kettle. A catalyst solution consisting of 5.0 g potassium persulfate in 100.0 g deionized water was then prepared and 10% of the catalyst solution was then charged to the reaction kettle. A trace of ferrous sulfate was then added. The reaction mixture exothermed to 70-75° C. The remaining monomer mixture and catalyst solution were then metered in to the reaction kettle over a period of two hours. During the addition, the temperature of the reaction was maintained between 70-75° C. After the addition of monomer and catalyst was complete, the reaction mixture was held at 70-75° C. for an additional 30 minutes. The reaction mixture was then cooled to 40° C. and 4 grams of ammonium hydroxide in 20 mL deionized water was added slowly to the reaction kettle. After stirring for an additional 15 minutes, the emulsion was filtered through a 150 micron filter bag. The emulsion properties are shown in Table 3.
TABLE 3
Emulsion
Properties
Solids
46.0
pH
8.3
Coagulum
<0.1%
Viscosity (centipoise)
240
Mean Particle Size (nm)
105.0
Polydispersity Index
0.166
Mechanical Stability
Good
Chemical Stability*
Moderate
*1M CaCl 2
The properties of the emulsions in the above examples demonstrate the usefulness of the present invention. The combination of the Styrenated Phenol anionic and nonionic surfactants in example 1 yielded an emulsion with significantly lower particle size than the emulsion prepared from sodium doceylbenzene sulfonate and ethoxylated octylphenol in comparative example 1. Furthermore, the replacement of the standard nonionic surfactant, ethoxylated octylphenol, with DSP (POE 40) in example 2 yielded an emulsion with significantly lower particle size and particle size distribution.
Example 3
687.0 grams of deionized water, 24.0 grams of a 50 percent solution of DSP (POE 20) Sodium Sulfate, and 7.9 grams of DSP (POE 40) were added to the reaction kettle and agitation was commenced. Oxygen was removed from the solution by nitrogen sparge and the solution was heated to 65° C. Next a monomer mixture of 288.0 g styrene, 210.0 g of ethyl acrylate and 26.0 g of methacrylic acid was prepared. 52.4 g (10%) of the monomer mixture was charged to the reaction kettle. A catalyst solution consisting of 5.0 g potassium persulfate in 100.0 g deionized water was then prepared and 10% of the catalyst solution was then charged to the reaction kettle. A trace of ferrous sulfate was then added. The reaction mixture exothermed to 70-75° C. The remaining monomer mixture and catalyst solution were then metered in to the reaction kettle over a period of four hours. During the addition, the temperature of the reaction was maintained at 80° C. After the addition of monomer and catalyst was complete, the reaction mixture was held at 80° C. for an additional 30 minutes. The reaction mixture was then cooled to 40° C. and 8 grams of ammonium hydroxide in 20 mL deionized water was added slowly to the reaction kettle. After stirring for an additional 15 minutes, the emulsion was filtered through a 150 micron filter bag. The emulsion properties are shown in Table 4.
TABLE 4
Emulsion
Properties
Solids
39.0
pH
8.8
Coagulum
<0.2%
Viscosity (centipoise)
26
Mean Particle Size (nm)
108.8
Polydispersity Index
0.205
Mechanical Stability
Good
Chemical Stability*
Good
*1M CaCl 2
Comparative Example 2
687.0 grams of deionized water, 40.0 grams of a 30% solution of C10-C12 fatty alcohol (POE 15) Ammonium Sulfate (Abex® JKB), and 9.8 grams of an 80% solution of Octylphenol (POE 40) (Triton® X-405) were added to the reaction kettle and agitation was commenced. Oxygen was removed from the solution by nitrogen sparge and the solution was heated to 65° C. Next a monomer mixture of 288.0 g styrene, 210.0 g of ethyl acrylate and 26.0 g of methacrylic acid was prepared. 52.4 g (10%) of the monomer mixture was charged to the reaction kettle. A catalyst solution consisting of 5.0 g potassium persulfate in 100.0 g deionized water was then prepared and 10% of the catalyst solution was then charged to the reaction kettle. A trace of ferrous sulfate was then added. The reaction mixture exothermed to 70-75° C. The remaining monomer mixture and catalyst solution were then metered in to the reaction kettle over a period of four hours. During the addition, the temperature of the reaction was maintained at 80° C. After the addition of monomer and catalyst was complete, the reaction mixture was held at 80° C. for an additional 30 minutes. The reaction mixture was then cooled to 40° C. and 8 grams of ammonium hydroxide in 20 mL deionized water was added slowly to the reaction kettle. After stirring for an additional 15 minutes, the emulsion was filtered through a 150 micron filter bag. The emulsion properties are shown in Table 5.
TABLE 5
Emulsion
Properties
Solids
39.2
pH
8.6
Coagulum
<0.2%
Viscosity (centipoise)
14
Mean Particle Size (nm)
127.7
Polydispersity Index
0.254
Mechanical Stability
Good
Chemical Stability*
Good
*1M CaCl 2
Example 4
687.0 grams of deionized water, 40.0 grams of a 30% solution of C10-C12 fatty alcohol (POE 15) Ammonium Sulfate (Abex® JKB), and 7.9 grams of DSP (POE 40) were added to the reaction kettle and agitation was commenced. Oxygen was removed from the solution by nitrogen sparge and the solution was heated to 65° C. Next a monomer mixture of 288.0 g styrene, 210.0 g of ethyl acrylate and 26.0 g of methacrylic acid was prepared. 52.4 g (10%) of the monomer mixture was charged to the reaction kettle. A catalyst solution consisting of 5.0 g potassium persulfate in 100.0 g deionized water was then prepared and 10% of the catalyst solution was then charged to the reaction kettle. A trace of ferrous sulfate was then added. The reaction mixture exothermed to 70-75° C. The remaining monomer mixture and catalyst solution were then metered in to the reaction kettle over a period of four hours. During the addition, the temperature of the reaction was maintained at 80° C. After the addition of monomer and catalyst was complete, the reaction mixture was held at 80° C. for an additional 30 minutes. The reaction mixture was then cooled to 40° C. and 8 grams of ammonium hydroxide in 20 mL deionized water was added slowly to the reaction kettle. After stirring for an additional 15 minutes, the emulsion was filtered through a 150 micron filter bag. The emulsion properties are shown in Table 6.
TABLE 6
Emulsion
Properties
Solids
39.4
pH
8.7
Coagulum
<0.2%
Viscosity (centipoise)
20
Mean Particle Size (nm)
79.5
Polydispersity Index
0.094
Mechanical Stability
Good
Chemical Stability*
Good
*1M CaCl 2
The properties of the styrene acrylic emulsions in example 3 and example 4 again demonstrate the usefulness of the present invention. The Styrenated Phenol Ethoxylates yielded emulsions with smaller particle size compared to the emulsion synthesized using the conventional polymerization surfactants.
The following additional examples further illustrate the usefulness of the invention. The surfactants of the present invention again yielded emulsions with smaller particle size compared with the emulsion prepared using the conventional surfactant combination of Nonylphenol (POE 30) Ammonium Sulfate and Octylphenol (POE 40).
Example 5
687.0 grams of deionized water, 50.0 grams of a 30% solution of DSP (POE 40) Ammonium Sulfate, and 15.0 grams of DSP (POE 40) were added to the reaction kettle and agitation was commenced. Oxygen was removed from the solution by nitrogen sparge and the solution was heated to 65° C. Next a monomer mixture of 134.4 g methyl methacrylate, 532.0 g of butyl acrylate and 6.0 g of methacrylic acid was prepared. 67.0 g (10%) of the monomer mixture was charged to the reaction kettle. A catalyst solution consisting of 5.0 g potassium persulfate in 100.0 g deionized water was then prepared and 10% of the catalyst solution was then charged to the reaction kettle. A trace of ferrous sulfate was then added. The reaction mixture exothermed to 70-75° C. The remaining monomer mixture and catalyst solution were then metered in to the reaction kettle over a period of two hours. During the addition, the temperature of the reaction was maintained between 70-75° C. After the addition of monomer and catalyst was complete, the reaction mixture was held at 70-75° C. for an additional 30 minutes. The reaction mixture was then cooled to 40° C. and 4 grams of ammonium hydroxide in 20 mL deionized water was added slowly to the reaction kettle. After stirring for an additional 15 minutes, the emulsion was filtered through a 150 micron filter bag. The emulsion properties are shown in Table 7.
TABLE 7
Emulsion
Properties
Solids
45.6
pH
8.5
Coagulum
<0.1%
Viscosity (centipoise)
140
Mean Particle Size (nm)
125.7
Polydispersity Index
0.032
Mechanical Stability
Good
Chemical Stability*
Good
*1M CaCl 2
Comparative Example 3
687.0 grams of deionized water, 50.0 grams of a 30% solution of Nonylphenol (POE 30) Ammonium Sulfate (Abex® EP-120), and 18.7 grams of an 80% solution of Octylphenol (POE 40) (Triton® X-405) were added to the reaction kettle and agitation was commenced. Oxygen was removed from the solution by nitrogen sparge and the solution was heated to 65° C. Next a monomer mixture of 134.4 g methyl methacrylate, 532.0 g of butyl acrylate and 6.0 g of methacrylic acid was prepared. 67.0 g (10%) of the monomer mixture was charged to the reaction kettle. A catalyst solution consisting of 5.0 g potassium persulfate in 100.0 g deionized water was then prepared and 10% of the catalyst solution was then charged to the reaction kettle. A trace of ferrous sulfate was then added. The reaction mixture exothermed to 70-75° C. The remaining monomer mixture and catalyst solution were then metered in to the reaction kettle over a period of two hours. During the addition, the temperature of the reaction was maintained between 70-75° C. After the addition of monomer and catalyst was complete, the reaction mixture was held at 70-75° C. for an additional 30 minutes. The reaction mixture was then cooled to 40° C. and 4 grams of ammonium hydroxide in 20 mL deionized water was added slowly to the reaction kettle. After stirring for an additional 15 minutes, the emulsion was filtered through a 150 micron filter bag. The emulsion properties are shown in Table 8.
TABLE 8
Emulsion
Properties
Solids
45.6
pH
8.7
Coagulum
<0.1%
Viscosity (centipoise)
110
Mean Particle Size (nm)
131.2
Polydispersity Index
0.040
Mechanical Stability
Good
Chemical Stability*
Good
*1M CaCl 2
Example 6
687.0 grams of deionized water, 50.0 grams of a 30% solution of Nonylphenol (POE 30) Ammonium Sulfate (Abex® EP-120), and 15.0 grams of DSP (POE 40) were added to the reaction kettle and agitation was commenced. Oxygen was removed from the solution by nitrogen sparge and the solution was heated to 65° C. Next a monomer mixture of 134.4 g methyl methacrylate, 532.0 g of butyl acrylate and 6.0 g of methacrylic acid was prepared. 67.0 g (10%) of the monomer mixture was charged to the reaction kettle. A catalyst solution consisting of 5.0 g potassium persulfate in 100.0 g deionized water was then prepared and 10% of the catalyst solution was then charged to the reaction kettle. A trace of ferrous sulfate was then added. The reaction mixture exothermed to 70-75° C. The remaining monomer mixture and catalyst solution were then metered in to the reaction kettle over a period of two hours. During the addition, the temperature of the reaction was maintained between 70-75° C. After the addition of monomer and catalyst was complete, the reaction mixture was held at 70-75° C. for an additional 30 minutes. The reaction mixture was then cooled to 40° C. and 4 grams of ammonium hydroxide in 20 mL deionized water was added slowly to the reaction kettle. After stirring for an additional 15 minutes, the emulsion was filtered through a 150 micron filter bag. The emulsion properties are shown in Table 9.
TABLE 9
Emulsion
Properties
Solids
45.3
pH
8.3
Coagulum
<0.1%
Viscosity (centipoise)
280
Mean Particle Size (nm)
116.4
Polydispersity Index
0.040
Mechanical Stability
Good
Chemical Stability*
Good
*1M CaCl 2
All patents, patent applications and publications cited in this application including all cited references in those applications, are hereby incorporated by reference in their entirety for all purposes to the same extent as if each individual patent, patent application or publication were so individually denoted.
While the many embodiments of the invention have been disclosed above and include presently preferred embodiments, many other embodiments and variations are possible within the scope of the present disclosure and in the appended claims that follow. Accordingly, the details of the preferred embodiments and examples provided are not to be construed as limiting. It is to be understood that the terms used herein are merely descriptive rather than limiting and that various changes, numerous equivalents may be made without departing from the spirit or scope of the claimed invention.
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The present invention relates to the use of Styrenated Phenol Ethoxylates as surfactants in emulsion polymerization. The present invention further relates to the use of both anionic and nonionic Styrenated Phenol Ethoxylates in emulsion polymerization. Latexes with small average particle and narrow particle size distributions are obtained. Prepared latexes also have low coagulum levels and exhibit excellent mechanical and chemical stability.
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This is a divisional of application Ser. No. 07/911,599 filed on Jul. 10, 1992, now U.S. Pat. No. 5,380,301.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to catheters. More specifically, the present invention relates to a method of attaching a catheter hub to the end of a catheter tube, and an improvement in strain relief therebetween.
2. Prior Art
Medical catheters generally comprise a flexible catheter tube which is permanently attached at one end to a rigid hub. The hub functions as a connector to allow quick connection of a syringe or the like to the catheter. Because bending forces applied to the catheter tube tend to be concentrate at the hub/catheter tube juncture, a strain relief is usually incorporated into the hub/catheter tube juncture to help avoid collapse of the catheter tube due to these periodic force concentrations which occur during use.
Strain relief devices are traditionally formed of a material which is more flexible than the hub and less flexible than the catheter tube. The strain relief device is generally formed of a sufficient length to allow attachment of one end thereof to the hub while allowing the opposite end to extend a substantial distance along the catheter tube beyond the hub/catheter tube juncture. With such a strain relief device in place, bending forces applied to the tube at the juncture area are resisted by the strain relief device and prevented from concentrating sufficiently at the juncture to cause collapse of the catheter tube. The strain relief device thereby functions to "relieve" the strain at the juncture by spreading bending forces along a larger length of the catheter tube.
Although strain relief devices of this type have in the past functioned adequately to relief the strain of bending forces at a hub/catheter tube juncture, they have nevertheless failed to aid in strengthening the juncture against axial forces, i.e., forces along the longitudinal axis of the catheter tube which tend to pull the catheter tube away from the hub nor significantly aided in forming or strengthening the hub/catheter tube attachment itself. Longitudinal ("pulling") forces can arise during the use of a catheter through any number of commonly occurring accidents or mishaps, and can lead to disastrous consequences for a patient who may heavily rely on the proper functioning of the catheter.
For example, serious if not fatal consequences can result from incidental hub/catheter tube separation when the catheter is in use in a patient, especially when the catheter is placed within an artery or vein. A release of the catheter tube subsequent to separation from its hub can actually resulted in the catheter tube becoming lost in the patient's cardiovascular system. Alternatively, the incidental separation of a catheter tube from its hub, if gone unnoticed, may prevent the infusion of important medicaments or other fluids into a patient. Obviously, in each instance the results can be disastrous for the patient.
A major manufacturing problem occurring with prior art catheters which makes it difficult to form a strain relief which can also inhibit separation due to pulling forces as well as prevent kinking due to bending forces includes the difficulty in securely attaching the relatively flexible catheter tube of a particular polymeric material to the relatively rigid hub of different polymeric material in a secure manner. Secure catheter tube/hub attachment is especially problematic since many polymeric materials are incompatible for secure and reliable attachment by adhesive, solvent, heat, or other chemical bonding. It can be necessary therefore to attach the catheter tube to the hub by means of a mechanical attachment, which is apart from and in addition to the strain relief, and which functions independently of the strain relief to inhibit separation due to pulling forces.
Czuba et al., U.S. Pat. No. 4,391,029, is exemplary of prior art catheter assemblies which include the attachment of a catheter tube to a hub by means of a mechanical attachment which is separate and in addition to the strain relief. Czuba et al.'s catheter includes a catheter tube end which is enlarged relative to the remainder of the catheter tube, and which is sized to fit within the hub. A rigid tubular funnel is inserted into the lumen of the catheter tube to prevent any subsequent collapse and/or passage of the enlarged end of the catheter tube through the relatively constricted portion of the hub should there be an attempt to pull the catheter out of the hub. As can be seen in the Czuba et al. patent, the strain relief of the Czuba et al. device is completely separate from the enlarged end of the catheter tube and the rigid tubular funnel.
Prior art catheter/hub connection methods such as described in Czuba et al. above, while functioning well to prevent inadvertent separation of the catheter tube and hub, nevertheless are somewhat difficult to manufacture and relatively expensive due to the added elements and materials used, and due to the manufacturing procedures necessitated thereby.
There therefore exists a need in the art to develop a catheter having a catheter tube/hub connection which is inexpensive in materials and manufacturing, and which can secure the connection therebetween regardless of the materials composing the catheter tube or the hub, in a secure inseparable relationship. Further, there exists a need in the art to develop a strain relief between a catheter tube and hub which can function both to prevent inadvertent kinking or bending of the catheter tube while in use, and to inhibit separation due to applied longitudinal pulling forces.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of manufacturing a catheter which includes attachment of a catheter tube to a hub in a secure manner to prevent separation of the catheter tube from the hub during use.
It is another object of the present invention to provide a method of manufacturing a catheter which allows secure attachment of a catheter tube to a hub by the strain relief, even though the strain relief and hub are made of materials which would be incompatible for attachment as by an adhesive or solvent bonding process.
It is a further object of the present invention to provide a catheter having a strain relief which mechanically attaches with the hub in such a manner that attachment forces tend to increase whenever separation forces such as longitudinal pulling forces are applied thereto.
It is also an object of the present invention to provide a method of manufacturing a catheter which includes an insert molding procedure in which an insert molding is formed about the catheter tube and hub to form the attachment therebetween.
It is also an object of the present invention to provide a method of manufacturing a catheter in which the insert molding process which forms the attachment between the catheter tube and hub also forms the strain relief therefore.
These and other objects and advantages are realized in a presently preferred embodiment of the present invention, which is shown by way of example and not necessarily by way of limitation, of a catheter which includes a hub member formed to include a basket shaped extension on the distal end thereof having a plurality of uniformly spaced longitudinally directed ribs forming openings therethrough which extend from the distal end of the hub member to a generally annular end piece, with the end piece forming a central cylindrical opening therein which is slightly larger than the outer diameter of the catheter tube which is to be adjoined with the hub.
The catheter also includes a catheter tube which is connected to the hub by an insert molding process in which the catheter tube is positioned within the opening of the end piece of the hub to extend along the internal bore of the hub, and a core pin is then inserted into the proximal end of the hub through the lumen of the catheter tube to seal the interior of the catheter tube and the bore of the hub proximal of the catheter tube. The hub, catheter tube and core pin are then inserted into a mold and material is injected through the openings between the ribs of the basket of the hub and form along the hub bore between the exterior of the catheter tube and the interior surface of the hub bore, to be stopped only by the core pin. The injection mold also includes formation of an outer extension which extends around a portion of the exterior of the hub end beyond the distal end of the hub a specified length along the exposed catheter tube to complete the formation of the strain relief.
Due to the presence of a relief cavity in the mold, injection of the molding material into the mold causes a portion of the bore of the hub to be enlarged in its internal diameter. Upon cooling of the injection material, the resultant forces caused by the hub wall attempting to contract to its original shape and the resulting forces caused by cooling of the injected material, generate a very strong mechanical grip along the catheter tube. Due to the effect of the interior shape of the hub bore on the injected material forming the strain relief and residual hoop stresses in the hub wall caused by its expansion, subsequent attempts to withdraw the catheter tube from the hub cause an increase in the gripping forces applied against the catheter tube by the strain relief.
The mechanical-type attachment between the strain relief and the hub of the present invention allows the strain relief and hub to be formed of materials which may otherwise be incompatible for other types of attachment, such as adhesive or bonding type attachment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a catheter formed in accordance with the principles of the present invention;
FIG. 2 shows a perspective view of a catheter hub formed in accordance with the principles of the present invention;
FIG. 3 shows a cross-sectional view of the catheter taken along line III--III of FIG. 1;
FIG. 4 shows a cross-sectional view of the catheter hub taken along line IV--IV of FIG. 2;
FIG. 5 is a cross-sectional view of the catheter hub taken along line V--V of FIG. 2;
FIG. 6 is a cross-sectional view of the catheter taken along line VI--VI of FIG. 1;
FIG. 7 is a cross-sectional view of a catheter tube and hub properly positioned in an insertion molding apparatus including a core pin placed through the catheter tube; and,
FIG. 8 is a cross-sectional view of the same apparatus shown in FIG. 7 after molding material forming the attachment and strain relief, has been injected into the mold cavity.
DETAILED DESCRIPTION OF THE INVENTION
As shown in the exemplary drawings for the purposes of illustration, an embodiment of a catheter made in accordance with the principles of the present invention, referred to generally by the reference numeral 10, is provided which includes attachment of a catheter tube to a hub through insert molding of a strain relief attachment in such a manner that resultant forces between the strain relief and hub form a mechanical attachment which increase its gripping force in response to attempted withdrawal of the catheter tube from the hub.
More specifically, as shown in FIG. 1, the catheter 10 of the present invention includes a hub 11 and a catheter tube 12 surrounded at their juncture by a strain relief 13. The catheter tube 12 is preferably formed of a fairly soft flexible PVC or polyurethane having a relatively low durometer hardness, and includes one or more lumens 14 formed therein. The hub 11 is formed of a more rigid material, preferably polypropylene, having a relatively high durometer hardness.
The strain relief 13 is preferably formed of a material such as polyurethane or PVC having a flexibility and durometer hardness which is preferably greater than that of the tube 12, yet less than that of the hub 11. The strain relief 13 is molded about the catheter tube 12 and hub 11 in a manner as will be explained in detail below, so as to form a mechanical connection between the hub and the strain relief 13 which does not rely on compatibility of the materials forming the strain relief 13 or hub 11 for secure attachment as do adhesive or solvent bonding type connections of many prior art devices. The attachment between the catheter tube 12 and the strain relief 13 may also be mechanical in nature or may be partly formed by slight mixing of materials therebetween during the injection molding process, or a combination of both attachment types.
As best shown in FIG. 2, the hub 11 is formed to a slightly tapering generally elongate cylindrical shape and includes a fitting 15 on the proximal end thereof for attachment to a syringe or the like in a well known manner. The fitting 15 as shown includes a threaded attachment, however any well known fitting used for attaching a hub to a syringe or other medical device useful with catheters is anticipated by the present invention and would be considered an obvious substitution for the fitting 15. The hub 11 is formed of a generally smooth tapered outer surface 16 on which is preferably formed a pair of wing members 17 useful as gripping surfaces to assist a user in attaching the hub 11 to a syringe or the like.
The distal end of the hub 11 has a longitudinally extending basket 18 formed thereon which includes preferably four longitudinally extending ribs 19 joined together at their distal ends by an annular end piece 20. As best shown in FIGS. 2 and 4, the annular end piece 20 has formed therein a central cylindrical opening 21 which is positioned coaxially with the central longitudinal axis of the hub 11.
As shown in FIG. 4, the hub 11 forms a bore 22 which is generally cylindrical within the area of the basket 18, and is slightly tapered from the proximal end of the hub 11 to adjacent the basket 18.
As is best shown in FIG. 5, the ribs 19 of the basket 18 are separated to form openings 23 into the bore 22. These openings 23 allow injection molding material to freely pass through the basket 18 into the bore 22 of the hub 11 during manufacture of the strain relief 13 as will be explained below.
It should be understood that the main purpose of the basket 18 is to form openings such as openings 23 through the hub 11 into the bore 22 through which injected molding material forming the strain relief 13 can pass. The present invention is not intended to be limited to the basket 18 as described with respect to the preferred embodiment only except to the extent wherein the hub 11 includes at least one opening therein, independent of the opening through which the catheter tube 12 is placed, through which injected material may pass. Also, although it is preferred that no loose ends extend from the distal end of the hub 11, the annular end piece 20 need not necessarily be present, or may be extensively modified. The main purpose of the annular end piece 20 is to assist in holding the catheter tube 12 in a central position within the hub 11 during movement of injection material into the bore 22.
As shown in FIG. 3, the strain relief 13 is formed about the catheter tube 12 and the hub 11, and extends along the catheter tube 12 a predetermined distance from the distal end of the hub 11 in order to provide support to the catheter tube 12 against kinking thereof due to bending forces during use. The strain relief 13 also extends within the bore 22 of the hub 11 and secures the entire portion of the catheter tube 12 enclosed within the bore 22.
The proximal end of the strain relief 13 is formed into a conically shaped surface 24 directly adjacent the proximal end 25 of the catheter tube 12. The surface 24 is designed to be located within the hub 11 at a position which will cause it to be directly distal of the tip (shown in dashed lines) of any fully inserted male fitting of a syringe or the like, in order to limit as much as possible the volume of dead space 29 between the tip of the syringe or like device, and the distal end 25 of the catheter tube 12. The minimization of the total volume of dead space 29 helps minimize distortion, and improve signal response of real time fluid pressure measurements which may be performed with the aid of the catheter 10.
The strain relief 13 is formed in continuous contact with the catheter tube 12 along the entire length of the strain relief 13 including the clearance area 26 between the catheter tube 12 and the central cylindrical opening 21 of the annular end piece 20. Also, as can be seen in FIG. 6, the strain relief 13 completely encapsulates the ribs 19 of the basket 18 of the hub 11. This integral interconnection between the hub 11 and the strain relief 13 permanently fixes the strain relief 13 relative to the hub 11 without any necessity of adhesive or solvent bonding material. As will be explained below with respect to the method of manufacturing of the catheter 10 of the present invention, the strain relief 13 securely grips the catheter tube 12 due to residual hoop stresses in the hub wall 28 and residual contraction forces within the strain relief 13. Further, fluid pressure against the conical proximal surface 24 which may be caused by injection of fluid into the dead space 29 by a syringe or the like, will cause a force along the cylindrical wedged portion of the strain relief 13 within the bore 22. This force also tends to increase the gripping force of the strain relief 13 against the catheter tube 12.
The method of manufacture of the catheter 10 of the present invention is as follows.
FIG. 7 shows a cross section of a mold 30 which is formed to allow insert molding of the strain relief 13 about the hub 11 and catheter tube 12.
The catheter tube 12 is inserted into the hub 11 so as to pass directly through the central cylindrical opening 21 in the annular end piece 20 and into bore 22 to a position approximately longitudinally adjacent the most proximal position of the cavity relief 33.
A core pin 36 is then inserted into the opening 31 of the mold 30 and through the lumen 14 of the catheter tube 12. The core pin 36 is of identical tapered dimension as the interior surface 27 of the bore 22, and forms a generally conical surface 37 which narrows the diameter of the core pin 36 to approximately the diameter of the lumen 14 of the catheter tube 12. As is clearly evident, the conical core pin surface 37 operates to form the conical proximal surface 24 of the strain relief 13 during the molding process.
As is shown, the hub 11, with catheter tube 12 and core pin 36 placed therein, is inserted into a first opening 31 in the mold 30 until the fitting 15 thereof abuts against shoulder 32 and the catheter tube 12 is pinched within the end opening 35. In this position, the external surface 16 of the hub 11 is completely surrounded and contacted by the mold 30 except at the position of cavity relief 33 and the distal end of the hub 11 which includes the basket 18. The remaining cavity 34 of the mold 30, as is clearly evident, is formed to the outer dimensions of the portion of the strain relief 13 which extends around the catheter tube 12 and the basket 18. Cavity 34 is designed to accept material used to mold the strain relief 13 while cavity relief 33 is designed to allow outward radial expansion of a portion of the hub wall 28 during molten material injection as will be explained momentarily.
The mold 30 also includes a gate 38 through which material forming the strain relief 13 is injected. The gate 38 is preferably formed at approximately a 45° angle from the longitudinal axis of the catheter hub 11 in order to minimize deflection of the catheter tube 12 due to the movement of injection material into the mold 30.
The mold 30 is formed to cause surfaces 39 and 40 to function as "shut off" surfaces against the passage of molding material in a well known manner. Also, the core pin 36 is designed to allow venting therepast, both through the proximal end of the hub 11 and through the bore 14 in a well known manner.
The cavity 34 extends to a position 41 which extends slightly beyond the most proximal position of the ribs 19 in the basket 18 in order to increase the length of the critical leak path of fluid. The "critical leak path" is defined as the most likely possible path of leakage of fluid past the strain relief 13 should leakage occur. This path would be the path taken by fluid injected into the dead space 29 which moved between the strain relief 13 and the inner surface 27 of the hub wall, and from there through the opening 23 between the ribs 19 and along the exterior surface 16 of the hub 11 until it escaped beyond the lip 42 of the strain relief 13. Although leakage along this path is very unlikely, the slight extension of the lip 42 in the proximal direction past the most proximal end of openings 23 tends to increase the critical leak path of the catheter 10, and thus reduce the possibility of leakage.
As best shown in FIG. 8, when material is injected into the cavity 34, it passes through the openings 23 of the basket 18 and into the bore 22. Further injection of material then completely fills the remainder of the cavity 34 to form the remainder of the strain relief 13. Excess pressure after complete filling of the cavity 34 causes the portion of the hub wall 28 adjacent the cavity relief 33 to be expanded into the cavity relief 33.
During cooling of the strain relief material, slight radial contraction thereof causes it to tighten around the basket 18 and also around the catheter tube 12. Further, cooling contraction in the longitudinal direction of the strain relief material located within the section of the hub core 22 which is slightly tapered in the distal direction, causes the catheter strain relief material to be drawn toward and wedged within the distal end of the hub 11, thus further increasing the gripping force of the strain relief 13 against the catheter tube 12. Also, residual hoop stresses within the expanded portion of the hub wall 28 exert continued contraction forces against the strain relief material adjacent thereto, which transfers through the adjacent strain relief material to also increase the gripping force against the catheter tube 12.
The cavity relief 33 is preferably formed of a series of flat annular surfaces which form a generally central location of greatest depth. The cavity relief 33 extends from a position parallel to the proximal most extent of the conical core pin surface 37 when properly positioned within the hub 11, to a position distal of the end 25 of the catheter tube 12. The cavity relief 33 is formed to a predetermined depth which will allow elastic expansion of the hub wall 28 thereinto but does not allow sufficient expansion of the hub wall 28 to cause permanent inelastic deformation thereof. The depth of the cavity relief 33 is preferably designed to allow an elastic expansion of the hub wall 28 equal to at least twice the expected radial shrinkage of the strain relief material during cooling, but no more than 50% of its elastic expansion limit.
The expansion of the hub wall 28 is intentionally designed to be at least twice the expected radial shrinkage of the strain relief material when cooled in order to allow the finished catheter 10 to have residual hoop stresses residing in the expanded portion of the hub wall 28 which can exert pressure on the strain relief 13 adjacent thereto to force it into a tight grip against the catheter tube 12. In this way, the radial shrinkage of the material forming the strain relief 13 during cooling thereof is compensated for by the residual hoop stresses in the wall 28 of the hub 11, and the longitudinal shrinkage of the material forming the strain relief 13 due to cooling is compensated for by the forced drawing or wedging of the material toward the distal end of the hub 11. Further, in use, pressure against the conical surface 24 caused by injection fluid also causes a wedging of the adjacent portions of the strain relief material into the distal end of the hub 11.
As is well known, over extended periods of time polymeric materials under stress will tend to "creep", meaning molecular movement on the microscopic level will occur which may cause some loss of residual stresses therein. The design of the catheter 10 of the present invention, due to the expansion of the hub wall 28 to several times the necessary expansion to compensate for the radial cooling contraction of the strain relief material is sufficient to ensure that residual hoop stresses remain in the hub 11 notwithstanding the long term effects of "creep" within the hub material.
Once the strain relief material is injected into the mold 30 to completely fill the cavity 34 and cause expansion of the hub wall 28 to fill the cavity 33, and the strain relief material has been allowed to cool, the catheter 10 is removed from the mold 30 and the core pin 36 is removed from the catheter 10.
As is evident, fluid pressure exerted against the conical proximal surface 24 of the strain relief 13 will force the portion of the strain relief 13 thereat, which is in the tapered area of the bore 22 of the hub 11, to be forced distally and further wedged into the narrowing diameter area of the core 22. The wedging effect caused by fluid pressure against the conical proximal surface 24 increases the gripping forces between the strain relief 13 and the catheter tube 12.
It is anticipated that any combination of hub and catheter tube materials may be used in the present invention, and attached by the strain relief 13 in the manner as described in the present method of manufacture, without regard to material composition compatibilities between the catheter tube 12, the strain relief 13, or the hub 11.
It will be apparent from the foregoing that, while particular embodiments of the invention have been illustrated and described, various modifications can be made thereto without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.
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A catheter is disclosed which includes a mechanical connection between the strain relief thereof and the hub. The strain relief operates both to secure the catheter tube to the hub and to provide strain relief for the catheter tube. The strain relief connection is assisted in gripping the catheter tube by intentional overstressing of the catheter hub during manufacture thereof to expand the hub wall and generate residual hoop stresses therein which assist in securing the catheter tube within the hub.
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BACKGROUND OF THE INVENTION
This invention relates to the removal of soil from fabric, and, more particularly, to a process for improving the dislodging of soil from the fabric and preventing its redeposition onto the fabric.
Garment dry cleaning is currently performed commercially using organic solvents such as perchloroethylene or petroleum derivatives. These solvents pose a health hazard, are smog-producing, and/or are flammable. The use of dense-phase carbon dioxide (both liquid and supercritical) as a dry-cleaning solvent medium resolves the health and environmental concerns posed by conventional solvents. An additional benefit is that its use reduces secondary waste streams associated with processes that employ conventional solvents. A dry-cleaning process that uses liquid carbon dioxide as a cleaning medium is described in U.S. Pat. No. 5,467,492. In one embodiment, the fabric is placed into a perforated basket within a pressure vessel, and then submerged into a pool of liquid carbon dioxide. The liquid carbon dioxide and the fabric in the pool are agitated by an incoming flow of liquid carbon dioxide that induces a tumbling action of the fabric. The liquid carbon dioxide solvent promotes the removal of the soluble soils through their dissolution, and the mechanical action of the fabric tumbling promotes the expulsion of the soil.
One of the disadvantages of this liquid carbon dioxide process is that it must be performed within a pressure system, and thus has associated high capital costs. An apparatus and method are described in U.S. Pat. No. 5,651,276 to expel soils from fabrics by gas jets at ambient pressure. This gas jet process may be practiced using the apparatus of the liquid carbon dioxide process described above, as a step of an overall fabric dry-cleaning process, or in a separate, low-cost apparatus.
In this process, the dislodged soil is desirably entrained in the gas and thereafter removed in a mechanical filter. The gas jet process promotes the dislodging of the soil from the fabric, the entraining of the soil in the gas flow, and the collecting of the soil using a filter before it is redeposited back onto the fabric. Although existing gas jet techniques achieve these objectives to some extent, it is always desirable to improve the efficiency of the gas jet process even further.
There is a need for an approach that realizes the advantages of the gas jet process, while increasing the effectiveness of the dislodging of the soil from the fabric and reducing its redeposition back onto the fabric prior to removal of the soil from the gas flow by filtration. The present invention fulfills this need, and further provides related advantages.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and method for cleaning soiled fabric using a gas jet. The approach improves the removal of soil from the fabric and also reduces the fraction of the dislodged soil that is redeposited back onto the fabric before it may be removed from the system by filtration. The present technique otherwise retains the benefits of the conventional gas jet cleaning approach.
In accordance with the invention, a method for cleaning fabrics comprises the steps of providing a piece of fabric having soil therein, and contacting the piece of fabric with a jet of an ionized soil-dislodging gas to dislodge the soil therefrom. Desirably, dislodged soil material is captured by an electrostatic filter to prevent it from redepositing on the fabric. The technique may be used in conjunction with an electrostatic spotting compound that concentrates the effect of the ionized gas, or more generally without such an electrostatic spotting compound.
An associated apparatus for cleaning a fabric having soil therein comprises a container having an interior in which the fabric is received, a gas jet nozzle directed into the interior of the container, a source of a pressurized gas communicating with an inlet of the gas jet nozzle, a gas jet manifold extending from the source to the gas jet nozzle, and a gas ionizer disposed to ionize the pressurized gas passing through the gas jet nozzle. The gas ionizer preferably comprises a corona discharge source. The gas ionizer is preferably positioned in the gas jet manifold, but it may be positioned at any location where it is effective in at least partially ionizing the gas flow. Desirably, an electrostatic filter charged oppositely to the ions captures dislodged soil material and prevents it from redepositing on the fabric.
The pressurized gas preferably flows at a pressure drop of from about 30 to about 300 pounds per square inch, gauge (psig), but may be pressurized at pressures of up to about 1000 psig for some applications. The method and apparatus are otherwise desirably operated at ambient pressure. The contact of the pressurized gas to the fabric dislodges particulate soil. Non-particulate soil may be mobilized and/or particulated with a spotting compound. The spotting compound is selected to enhance the effect of the ionized gas in dislodging the particles from the fabric. Once the soil is dislodged and entrained into the gas, the electrostatic charge imparted to the soil particles aids in repelling them from the fabric, aids in preventing their redeposition onto the fabric before they may be filtered from the gas, and aids in their capture by the electrostatic filter.
The result of this approach is an improvement in the efficiency of removing soil from the fabric. The fabric is cleaned more rapidly and effectively than in the absence of the ionization of the cleaning gas. The present approach, when operated at ambient pressure, adds little to the capital and operating costs of the apparatus and method. Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. The scope of the invention is not, however, limited to this preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block flow diagram of an approach for practicing the present invention;
FIG. 2 is a diagrammatic view of an apparatus for agitating fabric with a gas jet at the fabric;
FIG. 3 is a schematic sectional view of a gas jet manifold, illustrating the gas ionizer;
FIGS. 4A and 4B illustrate the removal mechanism of soil from fabric, wherein FIG. 4A illustrates the ionization and FIG. 4B represents the removal of the soil;
FIGS. 5A and 5B illustrate the removal mechanism of soil from fabric with the aid of an electrostatic spotting compound, wherein FIG. 5A illustrates the ionization and FIG. 5B represents the removal of the soil; and
FIG. 6 is a perspective view of the perforated cylinder showing the relative positions of the notches and manifolds.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts a preferred approach for practicing the fabric cleaning method of the invention. A piece of fabric is provided, numeral 20. The fabric may be of any operable type, including both woven and nonwoven fabrics. The fabric may be of a wide variety of weights and thread densities. Typically, the greater the weight and the greater the thread density, the higher the pressure drop across the gas jet nozzles utilized in a subsequent step.
The fabric is optionally treated with an electrostatic spotting compound, numeral 22. The fabric may have a region of non-particulate soil, or may have a region with an especially heavy local concentration of a particulate soil. The spotting compound is used to treat such regions to reduce their resistance to dislodging of the soil and/or to chemically alter the soil. The selected compound also aids in concentrating the effect of the ionized gas used in a subsequent step. Examples of operable electrostatic spotting compounds include silicone compounds (such as silicone emulsions, anionically stabilized water-based silicone elastomers, methyl hydrogen silicone, cationic SiOH functional compounds) and polytetrafluoroethylene compounds (such as Caled Water and Stain Repellent made by Caled Co.). Such chemicals adhere to the soil spot and hold the charge of the ions contacted to the spot. The combined action of the chemicals, the momentum of the gas jets, and the repulsion of the ionized gas aid in repelling the soil of the spot from the fabric, thereby dislodging the soil from the fabric. The electrostatic spotting compound is typically applied locally to the fabric, where there is a noticeable spot of soil.
The electrostatic spotting compound is often furnished as a liquid, but it is used only to moisten the fabric and not as a general cleaning medium as is water in a conventional washing machine.
The fabric is treated with the electrostatic spotting compound, step 22, by any operable approach. Typically, the electrostatic spotting compound is applied to the fabric by spraying, dipping, rubbing, or other operable approach that achieves full contact of the compound to the fabric. The electrostatic spotting compound is typically applied prior to placing the fabric into the cleaning apparatus. The electrostatic spotting compound is allowed to remain in contact with the fabric for a period of time to permit it to react with the soil of the spot. The length of time required for the electrostatic spotting compound to function depends upon the compound, the nature of the fabric, and the type and concentration of the soil.
The treated fabric is contacted with a gas jet of an ionized particle-dislodging gas, numeral 24. The gas jet dislodges and expels the soil particles from the fabric, causing them to separate from the fabric. The dislodged particles include both the soil initially present as particles, and any soil that is converted from a non-particulate form to a particulate form by the treatment in step 22. This simultaneous removal of the original particulate soil and the particulated non-particulate soil provides a significant improvement and advantage over the conventional dry-cleaning approach. Conventional dry cleaning practice requires that the spotting to remove non-particulate soils be completed first, followed by the general dry cleaning operation to remove particulate soils. In the present case, the treated fabric is agitated by the gas jet in a single operation to remove both the non-particulate soil and the particulate soil, reducing cleaning time and costs.
The ionized particle-dislodging gas forming the gas jet may be of any operable gas and at any operable gas pressure. Operable gases include air (which is preferred), a major component of air such as nitrogen or oxygen, carbon dioxide, water, nitrogen oxide, carbon monoxide, chlorine, bromine, iodine, nitrous oxide, sulfur dioxide, and mixtures thereof, or any other gas (including gas mixtures) having an ionization potential of less than about 14 electron volts at atmospheric pressure and room temperature. The particle-dislodging gas is preferably furnished and used in the gaseous phase, which is usually its most inexpensive form. The particle-dislodging gas may instead be furnished in a condensed solid or liquid phase, and then vaporized prior to ionization. The preferred gas pressure drop across the gas jet nozzle is from about 30 pounds per square inch, gauge (psig) to about 300 psig, although pressures up to about 1000 psig may be used in some cases such as heavy fabrics.
The particle-dislodging gas is at least partially ionized. In ionization, initially neutral gas molecules are dissociated to form a positively charged portion and a negatively charged portion. Techniques and apparatus to accomplish the ionization of gas flows are well known in the art for other purposes, and may be utilized here as well. A preferred ionization technique and apparatus will be described subsequently.
The duration of the contacting step 24 depends upon the nature of the apparatus used, the nature and extent of the soiling, and the size of the load of fabric being processed. Typically for a normal load of fabric in the apparatus discussed next in relation to FIG. 2, the exposure time is from about 30 seconds to about 5 minutes. This exposure time is considerably shorter than required for conventional dry cleaning or wet washing, and the fabric leaves the processing dry and fresh smelling.
Additives may be introduced during the contacting step 24. For example, an odorizing compound may be contacted to the fabric to impart a pleasant odor to the fabric. Examples of odorizing compounds are perfumes, and essential natural or synthetic oils.
An anti-static compound may be introduced at the end of the contacting step 24 to dissipate the electrostatic charges remaining at the end of the step 24. The antistatic compound is entrained into the gas jets of the particle-dislodging gas or introduced separately. The anti-static compound aids in dissipating the static electricity intentionally generated by the use of the ionized gas earlier in the contacting step, and other static electricity generated during the cleaning process. The static electricity, if not dissipated in this way, tends to cause the fabric to adhere to itself, resulting in twisting of the fabric. Examples of operable anti-static compounds include, but are not limited to, alcohol ethoxylates, alkylene glycol, or glycol esters.
Other additives as desired, such as soaps and sizing agents, may also be introduced during the step of contacting 24.
The present inventors are interested in commercial and home application of the invention, and a practical commercial and home apparatus 30 that may be used in the contacting step 24 is illustrated in FIG. 2. The apparatus 30 includes a contacting chamber 32 with a perforated basket 36 therein. The perforated basket may be coated with an electrically nonconducting material such as polytetrafluororethylene. The contacting chamber 32 and the perforated basket 36 are cylindrical in cross section with a cylindrical axis 37 (extending out of the plane of the illustration). The perforated basket 36 is smaller in cylindrical diameter than the contacting chamber 32. Optionally but preferably, a stationary electrostatic filter 34 in the form of a wire mesh cylinder coaxial with the cylindrical axis 37 is located outside the perforated basket 36 but within the contacting chamber 32. The stationary electrostatic filter 34 aids in capturing charged particles removed from the fabric being cleaned to prevent their redeposition on the fabric, in a manner to be described subsequently.
The perforated basket 36 may optionally be mounted on a rotational support for rotation about the cylindrical axis 37 and provided with a rotation drive motor to permit it to be rotated in the manner of a conventional clothes dryer. This rotational movement of the perforated basket 36 provides an agitation to the fabric within the perforated basket 36, in addition to the movement produced by the contacting of the pressurized gas flow to the fabric. When such a rotational capability is provided, during the contacting step 24 of the present invention the perforated basket 36 may optionally be locked into a fixed position, or the perforated basket 36 may be rotated while the gas jets function. Garment paddles 35 may also be provided as projections extending inwardly from the perforated basket into its interior 38. These garment paddles 35 enhance the movement of the fabric, aid in separating the individual articles within the interior of the basket 36, and prevent the individual articles from twisting together and interfering with the particle dislodging by the gas jets. There may also be provided a cabinet that encloses the contacting chamber 32, and an exterior door in the cabinet to allow access to the interior 38 of the perforated basket 36.
A piece of fabric 39 which is to be agitated by the gas jets is placed into the interior 38 of the perforated basket 36. Typically, several pieces of fabric are cleaned at once. All or some of the pieces may have been treated with the electrostatic compound in step 22, but all of the pieces of fabric need not have been treated the same way in respect to step 22.
Positioned between an inner surface 40 of the contacting chamber 32 and an outer surface 42 of the perforated basket 36 is at least one, and preferably several, gas jet manifolds 44 (or, equivalently, individual gas jets, not shown) In the preferred cylindrical design, the gas jet manifolds 44 extend parallel to the cylindrical axis 37. The manifolds 44 (or individual gas jets) may be affixed to the outer surface 42 of the perforated basket 36, affixed to the inner surface 40 of the contacting chamber 32, or separately supported. Preferably, the manifolds 44 (or individual gas jets) are affixed to the inner surface 40 of the contacting chamber 32, or separately supported.
A number of gas jet nozzles 46 are provided in each manifold 44 (or as the termination of individual gas jets), with the gas flows from the nozzles 46 directed inwardly into the interior 38 of the perforated basket 36. To accommodate this configuration, circumferential notches 36a, shown in FIG. 6, extend through the perforated basket 36 perpendicular to the cylindrical axis 37 so that the high pressure gas emitted from the gas jet nozzles 46 or the gas jets does not contact the wall of the perforated basket 36 and lose its momentum, and instead is directed fully against the fabric 39. The manifolds 44, gas jet nozzles 46, and garment paddles 35 are positioned to promote reversible garment agitation to prevent garment roping, tangling, and strangling during the contacting step 24. Rotation of the perforated basket 36 about the axis 37 and the presence of the garment paddles 35 can also aid in this effort. In the contacting step 24, the particle-dislodging gas flows through the manifolds 44, through the nozzles 46, and into the interior 38 of the perforated basket 36 (by way of the notches 36a) to contact the fabric 39.
The gas stream that contacts the fabric 39 in the contacting step 24 is first partially or completely ionized before it contacts the fabric. The ionization of the gas stream preferably is accomplished prior to its passage through the gas jet nozzles 46, but it may be accomplished as the gas passes through the gas jet nozzles or even after the gas has passed through the gas jet nozzles 46 but before it contacts the fabric.
FIG. 3 illustrates a preferred ionization device, a corona generator 80 located within the gas jet manifold 44 that ionizes the gas flow just before it passes through the gas jet nozzle 46. To ionize the gas, an electrode 82 is placed within the interior of the gas jet manifold 44. The electrode 82 is preferably a wire supported by insulators along the axial center of the manifold 44. In the illustrated embodiment, the wall of the manifold 44 is electrically grounded. The electrode 82 is biased relative to the electrostatic filter 34 by a voltage source 84. The electrode 82 may be electrically negatively biased, as illustrated, or it may be electrically positively biased. The selection of the sense of the bias is made according to the nature of the particle-dislodging gas that is flowed, and whether its molecules may be negatively or positively ionized. For the case of air, the preferred gas, the molecules may be negatively biased, and a negative bias is applied to the electrode 82 as illustrated. The bias voltage applied to the electrode 82 is selected as required to produce ionization of the gas in the size of manifold used and for the selected gas, but is typically on the order of about 50,000 volts for the case of air. The biasing voltage applied by the voltage source 84 may be DC, AC, or a modified wave form such as a square wave. The negative ionization voltage applied to the electrode 82 produces a corona discharge within the gas flow through the interior of the gas flow manifold 44. The gas molecules flowing through the corona discharge produce negatively charged ions 86, in the case where air is used as the particle-dislodging gas.
Generally, a corona discharge is produced by a non-uniform electrostatic field such as between a thin wire or electrode 82 and a plate or tube such as the wall of the manifold 44. Application of a high voltage between the electrode 82 and the wall of the manifold 44 generates a region of high electric field strength, which in the presence of a gas results in an electric breakdown of the gas, causing it to become electrically conductive, or a corona. Thus, in the corona region, electrons are accelerated to a velocity sufficient to knock an electron from a molecule in the air upon collision and thereby create a positive ion and an electron. Within the corona region, this ionization takes place in a self-sustaining avalanche which produces a dense cloud of free electrons and positive ions around the electrode 82. There are two types of corona discharge that can be generated. The positive corona is generated with a center electrode 82 charged with a positive voltage and the wall of the manifold 44 has a charge which is relatively negative with respect to the center electrode 82. In this case electrons move rapidly to the center electrode 82 and the positive ions stream away from the center electrode 82 to the wall of the manifold 44 in a unipolar "ion wind" of positive ions. Alternatively, a negative corona is generated with the center electrode 82 charged with a negative voltage and the wall of the manifold 44 positive relative to the center electrode 82. In this case, electrons created in the gas are repelled toward the wall of the manifold 44. As the electrons flow away from the electrode 82, their velocity decreases due to the decreased field strength. As their velocity slows, the electrons ionize electronegative gases such as oxygen to form negative ions, which are repelled toward the wall of the manifold 44. Thus, for both positive and negative coronas, ions migrate from the electrode 82 to the wall of the manifold 44.
The ions 86, together with non-ionized gas molecules, flow through the gas flow nozzle 46 and into the interior 38 of the basket 36, to impact against the fabric 39. It is not required that the entire gas flow be ionized. Any non-ionized gas molecules that pass through the gas flow nozzle 46 simply accomplish conventional gas jet cleaning of the fabric, and no damage is done to the fabric. The density of ions 86 within the gas flow passing through the gas flow nozzle 46 is greater than zero and is typically about 10 5 per cubic centimeter, but this density may vary over a wide range without adversely affecting the operability of the invention.
Preferably, at least one injector 48 is also provided and directed inwardly into the interior 38 of the perforated basket 36 through the notches 36a. As with the manifolds 44, it is preferred that the injectors 48 are affixed to the wall of the chamber 32 with the flows from the injectors 48 directed through the notches 36a in the perforated basket 36. Any additives, such as an anti-static compound and/or an odorizing compound, that are contacted to the fabric during the contacting step 24 may be introduced through the injectors 48. Such additives may instead be entrained into the particulate-dislodging gas and introduced through the nozzles 46.
The particulate-dislodging gas is pressurized by a compressor 50 (or supplied from a pressurized gas bottle or condensed gas source, not shown) and supplied to the manifolds 44 through a first piping system 52. The first piping system 52 includes manually operated or processor-controlled valves 54 to distribute the gas flow and, optionally, a filter 56 to filter the incoming gas and a heater 58 to heat the incoming gas to a desired temperature. The particulate-dislodging gas is pressurized by the compressor 50, flows through the first piping system 52 to the manifolds 44, is at least partially ionized, and is introduced into the interior 38 of the perforated basket 36 through the nozzles 46 by flow through the notches 36a. The gas flow contacts the fabric 39 to dislodge particles, and then contacts the electrostatic filter 34 and flows out of the contacting chamber 32 through an exit pipe 60. A mechanical particulate filter 62 removes the particulate from the gas flowing in the exit pipe 60 which had not already been captured by the electrostatic filter 34, so that it is not released into the air and the environment.
Additives such as soaps, sizing agents, anti-static compounds and/or odorizing compounds are supplied to the injectors 48 from additive sources 64 through a second piping system 66. The second piping system 66 includes manually operated or processor-controlled valves 68 to select the types, amounts, and timing of the additive addition, a mixer 70 as necessary, and manually operated or processor-controlled valves 72 to distribute the additives to the injectors 48 and/or to the manifolds 44 as desired. Any additives that are not reacted with the fabric in the interior 38 of the perforated basket 36 leave the contacting chamber 32 through the electrostatic filter 34 and the exit pipe 60, and are entrapped in the exit filter 62.
The operability of the present invention does not depend upon any particular mechanism of operation. FIGS. 4A, 4B, 5A, and 5B present schematic depictions of the manner in which the invention is believed to function, but these illustrations should not be interpreted as limiting of the invention.
FIG. 4A illustrates the effect of the use of the ionized gas on the piece of fabric 39 having soil particles 90 therein, and FIG. 4B shows the mechanism of the removal of the soil particles 90. As shown in FIG. 4A, ions 92, in this case negatively charged ions, migrate to and contact the fabric 39, giving it a negative static surface charge. Some of the ions 92 also contact and adhere to the soil particles 92, which assume a negative charge as a result. The negative charges repel each other, but the resulting force is typically not sufficient to itself dislodge the soil particles 92 from the fabric 39. Instead, the pressurized flow of gas tends to loosen and dislodge the soil particles 92 from the fabric 39. As shown in FIG. 4B, the negatively charged soil particles 92 are electrostatically repelled from the fabric 39, thereby accelerating their dislodging from the fabric 39 and also reducing their tendency to redeposit back on the fabric 39 before they can be swept out of the perforated basket 36 and to the electrostatic filter 34. The soil particles 92 are trapped on the electrostatic filter 34 to prevent their redeposition onto the fabric 39, and those which are not trapped flow to the exit pipe 60 and thence to the mechanical filter 62.
A similar mechanism is believed to be operable where the electrostatic spotting compound is used, as illustrated in FIGS. 5A and 5B. Ions, here the negatively charged ions 92, migrate to both the fabric 39 and to patches of the spotting compound 94, FIG. 4A, which both become negatively charged. The spotting compound had been previously applied in step 22 to absorb or particularize non-particulate soil in the fabric, and the patches of the spotting compound 94 therefore contain soil. The action of the pressurized gas loosens and dislodges the patch of the spotting compound 94, which is repelled from the fabric 39 so that it does not redeposit back upon the fabric. The spotting compound 94 is similarly trapped on the electrostatic filter 34, or swept out of the system to the filter 62. Although FIGS. 5A-5B do not show individual soil particles 90, in a usual case where a piece of fabric contains both soil particles 90 and has been spotted with patches of the spotting compound 94, both of the mechanisms of FIGS. 4A-4B and 5A-5B will be simultaneously operable.
In a preferred manner of operation, the fabric is treated in step 22, allowed to stand for a period of time to permit the electrostatic spotting compound to function, and then placed into the interior 38 of the perforated basket 36. The gas jets are operated by passing gas through the manifolds 44 and nozzles 46, agitating the fabric to dislodge particulate matter from the fabric, step 24. As the gas passes through the manifolds 44, it is ionized as discussed previously, so that the gas exiting the nozzles 46 is partially or fully ionized. The gas jets impacting upon the fabric promote the particle expulsion from the fabric, both by physical and electrostatic mechanisms. Redeposition of soil on the fabric is discouraged by the capturing of the particulate on the electrostatic filter 34, which carries a charge opposite to that of the charged soil particles, thereby increasing the efficiency and speed of the cleaning operation. The additives, where used, are added through the injectors 48 as appropriate. The particulate matter dislodged from the fabric is entrained into the gas flow leaving the perforated basket 36, where it is attracted to and retained upon the electrostatic filter 34. The gas flow and any remaining particulate matter not retained on the electrostatic filter 34 leaves the contacting chamber 32 and passes into the exit pipe 60, where the remaining particulate matter is entrapped in the exit filter 62. After the fabric is cleaned and the corona generator 80 is turned off, an anti-static compound may be introduced to negate the electrostatic effects utilized in the cleaning operation.
Although a particular embodiment of the invention has been described in detail for purposes of illustration, various modifications and enhancements may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims.
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A piece of soiled fabric is cleaned by contacting it with a jet of an ionized soil-dislodging gas to dislodge the soil therefrom. The ionized gas and the use of an oppositely charged electrostatic filter aid in preventing redeposition of the soil onto the fabric. The fabric may be agitated while it is contacted with the gas jet. A portion of the piece of fabric may be treated with an electrostatic spotting compound that enhances the effect of the ionized gas and may also enhance the removal of the soil. An apparatus for accomplishing the cleaning includes a container having an interior in which the fabric is received, a gas jet nozzle directed into the interior of the container, a source of a pressurized gas communicating with an inlet of the gas jet nozzle, a gas jet manifold extending from the source to the gas jet nozzle, and a gas ionizer disposed to ionize the pressurized gas passing through the gas jet nozzle.
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This application claims priority from Canadian Patent Application No. 2,411,955, filed Nov. 15, 2002, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to the field of embroidery machines, and more specifically, to a system and method for reducing thread breakage due to needle puncture during the embroidery process.
BACKGROUND OF THE INVENTION
Industrial high-speed embroidery machines generally have a workpiece support table which is mounted for movement along several axes relative to a needle carrying sewing head. The support table is driven by stepper motors which are responsive to signals from a computer control system. The signals are generated according to a digitized pattern. The workpiece is then moved under the sewing instruments through a desired path.
Typically, the sewing head includes a drive shaft to vertically reciprocate a swingable needle to penetrate a fabric to be embroidered and also to reciprocate a thread take-up lever to supply an upper thread from a supply and to tighten a stitch to be formed.
Thread breakage is a significant problem in high speed embroidering systems. It is estimated that thread breakage occurs once every few minutes in a 1000 stitch per minute machine. Effective upper thread tension control is considered important to achieving accurate stitching. If the upper thread tension is not properly controlled prior to needle penetration, thread breakage can occur. In particular, if there is too much slack in the upper thread, thread can wrap around the point of the needle, prevent loop seizure, break the thread, or interfere with correct stitch formation.
Several devices are known for controlling upper thread tension and hence for preventing thread breakage, as for example U.S. Pat. Nos. 4,320,712, 4,590,879 and 4,616,583.
Other systems for reducing thread breakage function by controlling the position of the needle thread relative to the descending needle to avoid contact between the two. For example in U.S. Pat. No. 4,706,589 to Tsukioka, a needle thread guide is disclosed for a button holing sewing machine. The needle thread guide is provided at the needle bar frame and located adjacent to the needle entry protects the needle thread from being struck by the needle when the workpiece is fed during button holing. The guide guides the needle thread outwardly when the needle descends, thus the needle thread positioned lower than the needle eye is protected from being struck by the needle. The guide is associated with the oscillating motion of the needle, but its direction of oscillation is opposite to the direction of needle oscillation, and its amplitude is almost twice the amplitude of the needle. A similar thread deflection device for zigzag stitching is disclosed in U.S. Pat. No. 4,949,657 to Hanyu, et al.
One shortcoming of these devices is that their mechanics limit their ability to effectively adapt to varying stitch and workpiece characteristics prevalent in modem high speed automated embroidery machine applications.
A need therefore exists for an improved method and system for reducing thread breakage due to the needle contacting the needle thread as it penetrates the fabric and that allows for the effective adaptation to varying stitch and workpiece characteristics and that is not limited by sewing machine mechanics.
SUMMARY OF THE INVENTION
The invention provides a method of preventing needle thread breakage between the needle and workpiece of an automated embroidery machine system by introducing an indirect path between a first needle penetration point and a next needle penetration point in the workpiece. The characteristics of the indirect path are determined by a sequence of instructions stored in the data processing system associated with the automated embroidery machine system. An advantage of the present invention is that it requires minimal or no modification of existing automated embroidery machine mechanics.
According to one aspect of the invention, a method is provided for minimizing contact between a needle point and a needle thread in a computer controlled embroidery machine, to prevent breakage of the needle thread by the needle point upon penetration of a workpiece by the needle during stitching. The method includes the steps of: determining a first straight path between a current needle penetration location and a next needle penetration location; and, moving to the next needle penetration location along a second non-straight path so that the needle thread is pulled away from the needle point.
Preferably, the method further includes the steps of: determining a probability of needle thread breakage for the first straight line path; and, selecting said second non-straight path if the probability is within a predetermined range.
Preferably, the shape of the second non-straight path is variable. Preferably, the shape of the second non-straight path includes sinusoids, curves, arcs, and straight lines. Preferably, the shape is modified in response to variables including thread tension, thread strength, thread diameter, stitch length, workpiece thickness, workpiece material, sewing speed, acceleration, speed of movement, and the distance between the needle point and the workpiece.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may best be understood by referring to the following description and accompanying drawings which illustrate the invention. In the drawings:
FIG. 1A is a perspective view illustrating a first automated embroidery machine system in accordance with the prior art;
FIG. 1B is a perspective view illustrating a second automated embroidery machine system in accordance with the prior art;
FIG. 1C is a perspective detail view illustrating the stitching instruments and bobbin assembly of the automated embroidery machine system of FIG. 1B ;
FIG. 1D is a perspective detail view illustrating the stitching instruments of the automated embroidery machine system of FIG. 1B ;
FIG. 2 is a block diagram of an exemplary data processing system for implementing the invention according to one embodiment;
FIGS. 3A and 3B are top views illustrating the positional relationship between needle thread, needle eye, direction of threading into the needle eye, and the position of an operator in accordance with the prior art;
FIGS. 3C and 3D are side views corresponding to FIGS. 3A and 3B , respectively;
FIG. 4 is a top view illustrating an embroidery machine needle and areas about the needle of differing thread breakage probability in accordance with one embodiment of the invention;
FIG. 5 is a graph illustrating direct and indirect paths for workpiece movement between needle penetration locations in accordance with one embodiment of the invention; and,
FIG. 6 is a flow chart illustrating a general method for guiding a needle thread for an automated embroidery machine to prevent breakage of the needle thread by the point of the needle according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, numerous specific details are set forth to provide a thorough understanding of the invention. However, it is understood that the invention may be practiced without these specific details. In other instances, well-known software, circuits, structures and techniques have not been described or shown in detail in order not to obscure the invention. The term data processing system is used herein to refer to any machine for processing data, including the computer and control systems described herein. In the drawings, like numerals refer to like structures or processes.
Referring to FIG. 1A , there is shown a perspective view illustrating a first automated embroidery machine system in accordance with the prior art. In FIG. 1A , the automated embroidery machine system is shown generally by the numeral 100 . The automated embroidery machine system 100 includes an embroidery machine 1 mounted on a plateform 2 in operative association with a movable workpiece support table 3 . The workpiece support table 3 is moved under the stitching instruments 4 along tracks 5 and 6 by stepping motors 7 and 8 . Data processing system 200 generates signals to activate motors 7 and 8 to move workpiece support table 3 through a path determined by a digitized embroidery pattern which is input to data processing system 200 . The stitching instruments 4 generally consist of needle 10 , presser foot 11 , thread feed 14 , and a bobbin assembly (not shown) located underneath the workpiece support table 3 . Presser foot 11 is reciprocated by a cam in timed relation with needle 10 and may be retracted at the end of the sewing operation by air cylinder 12 . Generally, presser foot 11 has an opening 13 through which needle 10 passes during the stitching operation. Thread feed 14 consists of a variety of eyes and pulleys and generally guides thread 15 from a supply spool (not shown) through a variable tension device 16 to the needle 10 .
Referring to FIG. 1B , there is shown a perspective view illustrating a second automated embroidery machine system 1100 in accordance with the prior art. In addition, FIGS. 1C and 1D are perspective detail views illustrating the stitching instruments 4 and bobbin assembly 1009 and the stitching instruments 4 , respectively, of the automated embroidery machine system 1100 of FIG. 1 B. Rather than using tracks 4 , 6 and stepping motors 7 , 8 , the second automated embroidery machine system 1100 may use more modern linear or servo motors. In addition, the second automated embroidery machine system 1100 may use multiple stitching instrument heads 1101 , 1102 , each containing multiple stitching instruments 4 , along with tensioners including eyes, pulleys, and guides.
Referring to FIG. 2 , there is shown a block diagram of an exemplary data processing system for implementing the invention according to one embodiment. In FIG. 2 , the exemplary data processing system is shown generally by the numeral 200 . The data processing system 200 includes an input device 210 , a central processing unit or CPU 220 , memory 230 , a display 240 , and an embroidery machine interface 250 . The input device 210 may be a keyboard, mouse, trackball, or similar device. The CPU 220 may include dedicated coprocessors and memory devices. The memory 230 may include RAM, ROM, databases, or disk devices. The display 240 may include a computer screen or terminal device. And, the embroidery machine interface 250 may include inputs and outputs for receiving and sending data and commands to and from the embroidery machine 1 and its stepping motors 7 and 8 . The data processing system 200 has stored therein data representing sequences of instructions which when executed cause the method described herein to be performed. Of course, the data processing system 200 may contain additional software and hardware a description of which is not necessary for understanding the invention.
Referring to FIGS. 3A and 3B , there are shown top views illustrating the positional relationship between needle thread 24 , needle eye 2 a , direction of threading into the needle eye 2 a , and the position of an operator M in accordance with the prior art. Referring to FIGS. 3C and 3D , there are shown side views corresponding to FIGS. 3A and 3B , respectively. The needle eye 2 a of needle 10 is threaded by a needle thread 24 which has a portion of the needle thread 24 a which is positioned above the needle eye 2 a , and a portion of needle thread 24 b which is positioned below the needle eye 2 a . Under such a positional relationship, when a workpiece 22 is fed in the direction of D, the needle thread portion 24 b positioned below the needle eye 2 a is positioned toward the operator's side M in relation to the needle's position as shown in FIGS. 3A and 3C . By contrast, when the workpiece 22 is fed in the direction of C, the needle thread portion 24 b positioned below the needle eye 2 a is positioned partly toward the rear side of the needle and away from the operator's side as shown in FIGS. 3B and 3D . Therefore, it is possible that the needle 10 sticks the needle thread portion 24 b when the needle 10 descends, thereby cutting the needle thread 24 .
Referring to FIG. 4 , there is shown a top view illustrating an embroidery machine needle 10 and areas about the needle of differing thread breakage probability in accordance with one embodiment of the invention. As a workpiece 22 mounted on workpiece support table 3 is moved under the control of data processing system 200 in direction C, from a first needle penetration location A to a next needle penetration location B along a path 460 , the probability of breakage of the needle thread 24 varies. The probability of needle thread breakage decreases as the location of the next needle penetration location B shifts to the left right side 410 or left side 420 of the operator M with respect to direction C and the needle eye 2 a . The highest probability of breakage area 430 is aligned with direction C and the needle eye 2 a . Areas of decreasing probability of thread breakage 440 , 450 are found to the left and right of direction C and the needle eye 2 a.
Referring to FIGS. 1A through 4 , according to the present invention, sequences of instructions are stored in the memory 230 of data processing system 200 to control stepping motors 7 and 8 through interface 250 to move workpiece 22 mounted on workpiece support table 3 from the first needle penetration location A to the next needle penetration location B along an indirect path 470 . By moving the workpiece 22 along an indirect path 470 between needle penetration locations A, B, the needle thread portion 24 b positioned below the needle eye 2 a is guided away from the needle point thus preventing breakage by the needle point upon penetration of the workpiece 22 by the needle 10 during stitching.
Referring to FIG. 5 , there is shown a graph illustrating direct and indirect paths 460 , 470 for workpiece movement between needle penetration locations A, B in accordance with one embodiment of the invention. In FIG. 5 , first needle penetration location A is shown at the origin of the x and y axes in the plane of the workpiece 22 . Next needle penetration location B is shown at a point along the y-axis. In effect, the selection of an indirect path 470 introducing a component of movement to the path from A to B along the x-axis. This movement along the x-axis allows needle thread portion 24 b to slide along the needle below the needle eye 2 a away from the needle point. In this way, the needle thread portion 24 b positioned below the needle eye 2 a is guided away from the needle point thus preventing breakage by the needle point upon penetration of the workpiece 22 by the needle 10 during stitching.
Selection of an indirect path 470 is optional. In addition, the shape of the indirect path 470 is variable. The data processing system 200 determines the need for an indirect path based on factors including the location of needle penetration locations A, B relative to the direction of threading through the needle eye 2 a . Typically, an indirect path 470 would be selected by the data processing system 200 for next needle penetration locations B lying in areas of high probability of needle thread breakage 430 as illustrated in FIG. 4 . The data processing system 200 may determine the shape of the indirect path 470 based on factors including the probability of needle thread breakage. Thus, for next needle penetration locations B lying in a high probability of needle thread breakage area 430 the degree of distortion of the indirect path 470 may be greater than the degree of distortion of the indirect path for next needle penetration locations B located in areas of decreasing probability of needle thread breakage 440 , 450 . The shape of the indirect path 470 is variable and may include sinusoids, curves, arcs, and straight lines. Other factors in determining the need for an indirect path and the shape of the indirect path include thread tension, thread strength, thread diameter, stitch length, workpiece thickness, workpiece material, sewing speed, acceleration, speed of movement, and the distance between the needle point and the workpiece. Note that it is important to keep the needle thread straight.
Referring to FIG. 6 , there is shown a flow chart illustrating a general method for guiding a needle thread 24 for an automated embroidery machine 1 , the needle thread 24 extending between the eye of a needle 2 a and a workpiece 22 being stitched when the needle 10 is above the workpiece 22 , to prevent breakage of the needle thread 24 by the point of the needle upon penetration of the workpiece 22 by the needle 10 during stitching, according to one embodiment of the invention. In FIG. 6 , the flow chart is shown generally by numeral 600 . At step 601 , the method starts. At step 602 , a first needle penetration location and a next needle penetration location are read. At step 603 , a path for movement of the workpiece 22 between the first needle penetration location A and the next needle penetration location B is determined, wherein the path is selectively indirect. This step of determining a path can include the following: determining a probability of needle thread breakage for a direct path 460 between the first needle penetration location A and the next needle penetration location B; and, selecting an indirect path 470 if the probability is within a predetermined range. At step 604 , the workpiece 22 is moved along the path 460 , 470 from the first needle penetration location A to the next needle penetration location B, thereby guiding the needle thread 24 away from the needle point. At step 605 , the method ends.
Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the spirit and scope of the invention as outlined in the claims appended hereto.
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A method for minimizing contact between a needle point and a needle thread in a computer controlled embroidery machine, to prevent breakage of the needle thread by the needle point upon penetration of a workpiece during stitching. The method includes the steps of: determining a first straight path between a current needle penetration location and a next needle penetration location; and, moving to the next needle penetration location along a second non-straight path so that the needle thread is pulled away from the needle point.
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This application claims benefit of provisional application No. 60/062,708 filed Oct. 22,1997.
FIELD OF THE INVENTION
The present invention relates to read channels and more particularly to a Digital Video Disk (DVD) read channel.
BACKGROUND OF THE INVENTION
Currently, DVD read channels use a bit-by-bit detection scheme because of its simplicity. The performance of the bit-by-bit detection scheme is acceptable for the DVD-Video channel which operates at the clock frequency of 26.14 MHz (1X). Recently, higher clock frequencies are required for DVD-ROM applications, for example, 6X=157 MHz, 10X=261 MHz). The simple bit-by-bit detection is not sufficient to achieve the reliable performance for such high speed channels. Even in the low frequency applications, the high performance and low cost detector is desirable because it enables the cost reduction of other components.
The Partial Response Maximum-Likelihood, PRML, algorithm has been widely used in magnetic recording fields for improving performance, but the PRML algorithm is not acceptable for the DVD read channel because the spectrum of the wave forms from the DVD disk is difficult to equalize to partial response target spectrum.
Recently, the use of a Viterbi detector without partial response equalization has been examined, (by Hideki Hayashi et al, PIONEER R & D p. 37-43, Vol. 6 No. 2 1996 in Japanese). They reported that the error rate was reduced to be more than 2 order of magnitude. They used a 6-state trellis scheme, and 32 bits survival path memories. The detector is composed of 3000 gates, and one A to D converter.
The use of a Maximum Likelihood detector (ML detector) such as a Viterbi detector can improve the performance, but the circuit is much more complicated than that of the bit-by-bit detector, and the maximum operation speed is limited by the Add-Compare-Select, ACS, operation of the Viterbi detector.
SUMMARY OF THE INVENTION
The present invention provides improved performance and a low cost detection apparatus and method. The detection of the present invention is capable of higher operation speed than a Viterbi detector.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a DVD read out signal eye-pattern;
FIG. 2 illustrates second level detection;
FIG. 3 illustrates third level detection;
FIG. 4 illustrates waveform of the present invention;
FIG. 5 illustrates at two state trellis diagram;
FIG. 6 a illustrates a first error path near zero cross points;
FIG. 6 b illustrates a second error path near zero cross points;
FIG. 6 c illustrates a third error path near zero cross points;
FIG. 7 illustrates a six state trellis diagram;
FIG. 8 illustrates a detector;
FIG. 9 illustrates a detector with correction;
FIG. 10 illustrates a performance chart of detectors;
DETAILED DESCRIPTION
Bit-by-Bit Detection
Read-out signals from a DVD disk have many signal levels. The typical eye-pattern is shown in FIG. 1 . Detection errors occur dominantly at signals near zero-cross transitions because the amplitude of the read-out signal becomes minimum there. (FIG. 2, FIG. 3 ).
2-Level Detection
In FIG. 2, we assume the signal value=0.5 and the noise value=n k−1 at sample time k−1, and the signal value=0.5 and the noise value=n k at the sample time k. The sample values near the transitions are:
y k−1 =−0.5+ n k−1 (1)
y k =+0.5+ n k (2)
The error of y k−1 occurs when n k−1 >0.5
The error of y k occurs when n k <−0.5
3-Level Detection
If the sample points of FIG. 2 are shifted by 0.5T, the signal values at k−1, k, and k+1 will be −1, 0, 1 respectively, (FIG. 3 ). The sample values near the transitions are:
y k−1 =−1+ n k−1 (3)
y k =0+ n k (4)
y k−1 =+1+ n k+1 (5)
The error of y k−1 occurs when n k−1 >0.5.
The error of Y k occurs when n k >0.5 or n k <−0.5.
The error of y k+1 occurs when n k+1 <−0.5
This 3-level detection method has approximately the same error threshold as the above 2-level detection method. With the 3-level detection the signal value may be less than ±1.
The 3-level detection method is effective in the following ML detection.
Viterbi Detection
The ML detection such as Viterbi detection requires that the read-out signals have some correlation to each other. The following two kinds of correlation in DVD channels can be utilized:
Signal Level Correlation
The use of the three level signals shown in FIG. 3 enables the ML detection because the correlation exists in these 3 levels. This correlation eliminates such read-out signal sequences as <−1,1>, <−1,0,0,1>, <−1,0,−1> and so on.
When the signal level correlation is applied to Viterbi detector, all the sample signals must be limited to 3 levels by using limiter circuits to calculate branch metrics correctly, (FIG. 4 ). The Viterbi detector needs only a 2-state trellis which has 3 level signals (−1,0,1) as shown in FIG. 5 .
SNR Improvement by Signal Level Correlation
The Viterbi detector has the 3 worst case error paths near zero-cross points, (FIG. 6 a, b, c ). In FIG. 6 a, when n k−1 +n k <1, the two sample values y k−1 and y k are close to the correct path, and the detection will be done correctly. When n k−l +n k >1 the sample values y k−1 and y k are close to the error path, and the detection error will occur. The error threshold of the Viterbi detector is n k−1 +n k >1.
It is n k +n k+1 ,−1 in the pattern shown in FIG. 6 b. It is n k−1 −n k+1 >1 in FIG. 6 c.
These detection thresholds improve the SNR by 3 dB statistically over the bit-by-bit detection (n k >0.5 or n k <−0.5) if the noise at each sample point is time independent.
Code Constraints Correlation
The DVD channel uses the {fraction (8/16)} modulation code. This code is a (d=2, k=10) code. The d is the minimum zero run length between two ones, and k is the maximum zero run length between two ones. After NRZI conversation, the minimum transition period is 3T and the maximum transition period is 11T. (The T is the period of code clock.) In this code, the d=2 constraint can be used for the ML detection. This eliminates 1T and 2T patterns from the detected data sequences. The 1T's (010 and 101) and 2T's (0110 and 1001) are invalid in NRZI→NRZ {fraction (8/16)} modulation code.
A 6-state Trellis is necessary to remove 1T and 2T patterns. The 6-state Trellis diagram shown in FIG. 7 uses both the signal level correlation and the code correlation.
−y( 0 )+y( 1 ) Detection
The y 0 +y 1 detection of the present invention uses 3-level signals as shown in FIG. 3 and FIG. 4, but the limitations of the amplitude of sample values is not required. After the adjacent two sample addition (y 0 +y 1 ), 2-level decision is accomplished as follows:
If y ( 0 )+ y ( 1 )>=0,→1
If y ( 0 )+ y ( 1 )<0,→0
If the worst (minimum) signal case shown in FIG. 3, from equations (3), (4), and (5).
y ( 0 )+ y ( 1 )= y k−1 +y k =−1+ n k−1 +n k (6)
y ( 0 )+ y ( 1 )= y k +y k+1 =+1+ n k +n k+1 (7)
These equations show the error that occurs when n k−1 =n k >1 or n k +n k+1 <−1.
This error threshold is same as that of the Viterbi detector with level correlation. The added signals (1 and −1) of the equations of (6) and (7) are the worst case of the y( 0 )+y( 1 ) detector.
The value of the added signals in any other sample points is always 1< or <−1. This y( 0 )+y( 1 ) detection algorithm is valid for the d>=1 code. The
The y( 0 )+y( 1 ) detection is better than the Viterbi detector with level correlation because the y( 0 )+y( 1 ) detection eliminates pattern error in FIG. 6 c.
FIG. 8 shows the block diagram of the basic y( 0 )+y( 1 ) detector. The analog to digital converter is not used. The analog track and hold circuits ( 100 , 102 ) make one sample time delay. The output of track and hold circuit ( 102 ) is input to comparator ( 104 ).
y( 0 )+y( 1 ) Detector with 2T Pattern Corrections
The basic y( 0 )+y( 1 ) detector does not utilize the code correlation. The additional circuit shown in FIG. 9 can remove 2T pattern errors. The y( 0 )+y( 1 ) detector is virtually free of 1T pattern errors.
When the 2T pattern is detected (x 0 , x−1, x−2, x−3=0110 or 1001), the error must exist in either x 0 or x−3. The correction is done as follows:
The current y ( 0 )+ y ( 1 ) is compared with the y− 3+ y− 2.
If the y( 0 )+y( 1 ) detection is wrong and the y−3+y−2 detection is correct, the absolute value of y( 0 )+y( 1 ) is smaller than the absolute value of y−3+y−2 in most cases.
When the error pattern x 0 , x−1, x−2, x−3=0110, if y−3+y−2<y 0 +y 1 , then x 0 is corrected to 1 else x−3 is corrected to 1.
When the error pattern x 0 , x−1, x−2, x−3=1001, if y−3+y−2<y 0 +y 1 then x−3 is corrected to 0 else x 0 is corrected to 0.
The performance of the y( 0 )+y( 1 ) detector with 2T correction is approximately the same as the 6-state Viterbi detector.
The block diagram shown in FIG. 9 is for d=2 code channels.
For d=1 code channels such as 1,7 code, the 1T pattern (010 or 101) correction must be done in the similar method.
Performance Comparisons
FIG. 10 illustrates the performance comparison of the present invention.
The y( 0 )+y( 1 ) detector with 2T pattern correction and the 6-state Viterbi detector showed the best and same performance. Both detectors utilize both level correlation and code correlation.
The simple y( 0 )+y( 1 ) detector and 2-state Viterbi detector is about 3 dB better than the bit-by-bit detection. Both detectors utilize only the level correlation.
The 6-state Viterbi which utilizes only the code correlation shows a little improvement.
Other Features of y( 0 )+y( 1 ) detector
Easier realization of the high data rate channel.
The Viterbi detector requires branch metric calculations and path metric calculations. The y( 0 )+y( 1 ) detector requires only one addition. The y 0 +y 1 detector does not need a high speed A to D converter.
The y( 0 )+y( 1 ) detector has better phase error detection
The Viterbi detector requires long survival path memories, 20 bits or more. This results in a fairly long time to get a final decision. The y 0 +y 1 detector does not have the path memories. The decision is fast.
The phase error detection circuit for timing recovery needs some detected data. The phase error detection circuit with the y( 0 )+y( 1 ) detector can use the high quality data from the y( 0 )+y( 1 ) detector, but the phase error detection circuit with the Viterbi detector cannot use the high quality data from the Viterbi detector because of the too long latency. The additional simple detection circuit which has fast detection but low quality must be used.
The y( 0 )+y( 1 ) detector has no limiter setting
The Viterbi detector needs an amplitude limiter to get 30 level targets shown in FIG. 4 . The best setting of the limiter value is not so easily obtained because disks and read channel have many variations. The unfit setting degrades the SNR performance. The y( 0 )+y( 1 ) detector does not need the limiters.
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The present invention implements a maximum likelihood detector for optical disk drive without using a Viterbi detector. The detection algorithm that includes y 0+ y 1 detection is very simple by requiring only one adder and one comparator, and not survival path memories.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates broadly to gas-operated automatic and semi-automatic guns, especially rifles. More particularly, it concerns the improvement of such guns by addition of unique exterior surface configurations on their barrels.
2. Description of the Prior Art
There is a need to reduce the weight of guns that soldiers carry and an equally critical need to increase the endurance of the guns. Soldiers, especially those within the Special Operations Command, now fire their weapons much more than in the past and have actually gotten the guns so hot that projectiles will come thru the side of the hot barrels during prolonged gun battles. A serious problem gun designers must face, therefore, is how to both reduce the weight of barrels in guns without damaging their strength and also have them dissipate the heat faster so they can withstand as many as 500 rounds of continuous fire without a projectile exiting the side of the barrel.
It is known to create depressions in the outside walls of gun barrels to improve their strength, weight and accuracy, e.g., see U.S. Pat. No. 6,324,780.
It is also known that heat transfer through tube walls can be improved by creating rows of concave depressions on the outsides of the tube walls, e.g., see U.S. Pat. Nos. 5,577,555 and 5,992,512.
The present invention provides further advancements in weight reduction and heat release from barrels of gas-operated automatic and semi-automatic guns, especially rifles.
OBJECTS
A principal object of the invention is the provision of improvements in construction of gas-operated automatic and semi-automatic guns, especially rifles, by providing their barrels with unique exterior surface configurations.
Further objects include:
1. The modification of gas-operated automatic and semi-automatic guns to reduce the weight of their barrels while retaining the barrels' original stiffness. 2. The modification of gas-operated automatic and semi-automatic guns to make their barrels dissipate heat faster so the guns can withstand as many as 500 rounds of continuous fire without being destroyed by the projectiles moving thru the barrels. 3. The provision of improvements in guns that have particular application to the M16/M4 series of rifles.
Other objects and further scope of applicability of the present invention will become apparent from the detailed descriptions given herein; it should be understood, however, that the detailed descriptions, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent from such descriptions.
SUMMARY OF THE INVENTION
The stated objects are accomplished in accordance with the invention by providing gas-operated automatic or semi-automatic guns with a barrel having a muzzle section defined by a muzzle peripheral surface and a breech section defined by a breech peripheral surface with unique exterior surface configurations on one or both of the peripheral surfaces of the muzzle and breech sections.
In accordance with the invention, the breech section and/or muzzle section of the gun barrel has a longitudinal portion P of its peripheral surface encircled with an array of concave depressions each defined by a depression opening, selected from circular openings and oblong openings, of predetermined area machined in the peripheral surface and by a predetermined maximum depth.
In preferred embodiments of the guns of the invention, the longitudinal portion P of its breech peripheral surface has a predetermined first peripheral surface area A 1 before it is machined to reduce the weight and increase surface area. After machining, the total surface area of the longitudinal portion P of the barrel has a predetermined second peripheral surface area A 2 that includes the remaining surface area of the longitudinal portion P and the combined surface areas of the concave depressions. The ratio A 2 /A 1 advantageously is in the range 1.17 and 1.42 and this ratio depends upon the specifics of the barrel involved. This represents a 17% to 42% increase in the total surface area.
Where the concave depressions have circular openings all of the same size, the combined total surface area of the concave depressions A 2 CD is approximated by the equation A 2 CD=N×2πRD wherein N is the total number of concave depressions, R is the approximate radius of the circular opening of the concave depressions and D is the average predetermined depth of the depression. The remaining surface area of the longitudinal portion LP of breech peripheral surface after the concave depressions are made is approximated by the equation A 2 LP=(P×C)−(N×πR 2 ). The total surface area following the addition of the concave depressions is A 2 =A 2 CD+ 2 LP. Similar computations can be made by those skilled in the art, particularly with the assistance of computers, for muzzles of the invention having oblong opening depressions or combinations of circular opening sizes or combinations of circular and oblong opening depressions.
When the muzzle section is provided with concave depressions of the invention, similar surface area data and ratios apply.
Further, in preferred embodiments, the predetermined maximum depth of the concave depressions is between about 42% and 54% percent of the thickness of the breech section measured at the longitudinal position of the relevant concave depression.
The concave depressions are created in accordance with the invention by use of ball end mills or equivalent circular machining tools of selected diameter to remove a circular or oblong depression through the barrel surface and into the gun barrel to the predetermined depth. Advantageously, the concave depressions are of equal size and are arranged in honeycomb fashion. Alternative arrangements include alternate rows of two size circular depressions, oblong depressions of one size, alternate rows of two size oblong depressions and alternate rows of oblong depressions with circular depressions.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention can be obtained by reference to the accompanying drawings in which:
FIG. 1 is a sectional view of the left side of a gas operated automatic gun having a bisectional barrel with its breech section containing exterior surface configurations of the improved type provided by the invention.
FIG. 2 is a side elevation view of breech section of the gun shown in FIG. 1 .
FIG. 3 is a side elevation of a portion of a gun barrel, with the right side partially shown in section, in accordance with the invention in which all the surface depressions therein are circular.
FIG. 4 is a side elevation of a portion of a gun barrel in accordance with the invention in which the surface depressions therein are a mixture of circular and oblong depressions.
FIG. 5 is a side elevation of a portion of a gun barrel in accordance with the invention in which all the surface depressions therein are oblong.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in detail to the drawings beginning with FIG. 1 , the improved gun 2 of the invention comprises a barrel 4 having a breech section 6 defined by a breech front portion 8 and a breech rear portion 10 plus a demountable and interchangeable muzzle section 12 defined by a muzzle front portion 14 and a muzzle rear portion 16 .
The gun 2 includes chamber 18 that is defined by a rear end 20 and front end 22 . Chamber 18 is operatively connected at its front end 22 to breech rear portion 10 .
The receiver 24 constitutes a major component of the gun 2 . The rear end 20 of chamber 18 is operatively mounted to receiver 24 to accept ammunition therein in known fashion. Also, an actuation cylinder 26 is mounted to the receiver 24 .
Located within the receiver 24 there is a mechanical system 28 operated by the actuation cylinder 26 to perform the gun functions of unlocking, extraction, ejection, feeding and relocking,
The breech section 6 comprises a rifled bore 30 that extends forward from the front end 22 of the chamber 18 and the muzzle section 12 comprises a smooth bore 32 .
An auxiliary muzzle attachment 34 is threaded onto the muzzle front portion 14 .
Referring now also to FIGS. 2 & 3 , the breech section 6 of barrel 4 has a longitudinal portion P of its peripheral surface 36 encircled with an array of concave depressions 38 each defined by a circular opening 40 of predetermined area machined in the peripheral surface 36 and by a predetermined maximum depth D.
The longitudinal portion of breech peripheral surface 36 has a first peripheral surface area prior to the addition of concave depressions 38 of A 1 =P×C, where P equals the length of the longitudinal portion P and C equals the average circumference of the peripheral surface 36 along distance P. The total surface area after the addition of concave depressions 38 is the combined total surface area of the concave depressions 38 plus the remaining surface area of the longitudinal portion of breech peripheral surface 36 . The combined total surface area of the concave depressions A 2 CD is approximated by the equation A 2 CD=N×2πRD wherein N is the total number of concave depressions 38 , R is the radius of the spherical surface of concave depressions 38 and D is the average predetermined maximum depth of the concave depressions 38 . The remaining surface area of the longitudinal portion of breech peripheral surface 36 after the concave depressions are machined is approximated by the equation A 2 LP=(P×C)−(N×πR 2 ) wherein R is the approximate average radius of the openings of concave depressions 38 at surface 36 . The total surface area following the addition of the concave depressions 38 is A 2 =A 2 CD+A 2 LP.
In preferred embodiments, the predetermined maximum depth D of the concave depressions 38 is between about 42% and 54% percent of the thickness T of the breech section measured at the longitudinal position of the relevant concave depression 38 .
Referring to FIG. 4 , the breech section 6 A has a portion of its peripheral surface 36 A encircled with an array of concave depressions consisting of a mixture of circular concave depressions 38 A each defined by a circular opening 40 A of predetermined area machined in the peripheral surface 36 A and oblong depressions 38 B each defined by an oblong opening 40 B of predetermined area machined in the peripheral surface 36 A.
Referring to FIG. 5 , the breech section 6 B has a portion of its peripheral surface 36 B encircled with an array of oblong depressions 38 B each defined by an oblong opening 40 B of predetermined area machined in the peripheral surface 36 B.
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Gas-operated automatic and semi-automatic guns are improved by providing their barrels with unique exterior surface configurations to reduce the weight of their barrels while retaining the barrels' original stiffness and to cause the barrels to dissipate heat faster.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a Continuation of U.S. application Ser. No. 14/695,089 filed on Apr. 24, 2015, which is a Continuation of U.S. application Ser. No. 12/964,299 filed Dec. 9, 2010 now U.S. Pat. No. 9,022,409 issued May 5, 2015, which is a Continuation of U.S. application Ser. No. 11/286,654 filed Nov. 23, 2005 now U.S. Pat. No. 7,874,570 issued Jan. 25, 2011, which the applications are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The invention generally pertains to trailers and specifically to trailers designed for a tight turning radius.
[0003] Prior art trailers have been designed which provide a tight turning radius; however, these trailers use complicated structures to turn the trailer's wheels.
[0004] U.S. Pat. No. 1,600,635, issued to Isachsen on Sep. 21, 1926, shows an arrangement of a frame 11, and a steering rod 7 independent of the frame 11. The steering rod 7 is fastened to crank arm 3, then secured to a knuckle joint 4, and connected to a second knuckle joint 4′ using arms 5 and a connecting bar 8. This complicated structure functions to turn the wheels 10.
[0005] U.S. Pat. No. 2,450,215 issued to Wilson on Sep. 28, 1948, uses multiple arms and steering links 29 and 14. This complicated structure functions to turn the wheels 14.
[0006] U.S. Pat. No. 2,092,683, issued to Stidham on September 1937, shows a non-conventional system using parallel cable 32 and a draw frame system 21. These two systems must operate together in order to turn the wheels 14.
[0007] The above-subject patents are all structures which function to permit the wheels to turn on stub axles. Unfortunately, each is a complicated structure and includes multiple moving parts.
[0008] Therefore, there is a need to produce a simplified structure with fewer moving parts to reduce costs associated with manufacturing, tooling and assembly.
[0009] Additionally, the complicated structures limit the amount of weight that may be placed upon them. Accordingly, it is a still further objective of the present invention to provide a trailer that may have a high maximum payload for hauling a great amount of weight associated with farm products such as spray tanks, fertilizer, and seed.
[0010] These and other objectives will become apparent from the following specification and drawings.
BRIEF SUMMARY OF THE INVENTION
[0011] The foregoing objectives may be achieved using a tow behind steerable caddy trailer having a main frame assembly having opposite ends, a wheel pivotally attached to each end of the main frame assembly, a pair of swinging arms pivotally attached to the main frame assembly and extending forward from the main frame. The swinging arms are spaced apart from one another such that each swinging arm is positioned adjacent a wheel. The swinging arms can be maintained parallel or non-parallel to one another. The trailer has a support structure attached to the main frame assembly that can support a platform, tank, hopper, etc. Additionally, it has been contemplated that tracks could be used in place of the wheels for supporting platforms, tanks and hoppers exceeding the weight limits for a wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of a tow behind steerable caddy.
[0013] FIG. 2 is a top view of the tow behind steerable caddy.
[0014] FIG. 3 is a side view of the tow behind steerable caddy.
[0015] FIG. 4 is a rear view of the tow behind steerable caddy.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] With reference to FIGS. 1-4 , numeral 10 refers to a tow behind steerable caddy. The tow behind steerable caddy trailer 10 is designed to follow behind a tractor, an implement pulled by a tractor, or other vehicle.
[0017] The trailer 10 is designed to follow in the tracks of the towing vehicle to navigate tight turning radiuses. The tow behind steerable caddy trailer 10 thus may negotiate tight turning radiuses in a field with very few end rows or with equipment that has a very narrow operating width.
[0018] The steerable caddy trailer 10 has a main frame assembly 12 illustrated as a metal square tube. The main frame assembly 12 has opposite ends 14 , a top side 16 , a bottom side 18 , a front side 20 , and a back side 22 . Angled end caps 26 are attached at each end 14 of the main frame assembly 12 . It has been contemplated that the end caps 26 could also be a vertical endcap rather than an angled endcap 26 . A vertical endcap may be used in conjunction with a track or in applications requiring additional structural strength to support heavy loads.
[0019] A spindle assembly 28 is pivotally attached at each end 14 of the main frame assembly 12 . The spindle assembly 28 has a base plate 30 and a top plate 34 connected by an angled extension 36 which ends in a vertical surface with a spindle 40 for a wheel 44 . The base plate 30 and top plate 34 are attached to the angled end cap 26 by a pivot pin 42 . The spindle assembly has a vertical support 38 which strengthens the connection of the base plate 30 and the top plate 34 to strengthen the spindle assembly 28 .
[0020] A forward base member 32 is provided to extend from the base plate 30 and has a hole for connecting a first end of a tie rod 70 .
[0021] Swinging arms 46 extend from the main frame assembly 12 . Each swinging arm member 46 has a rear end 48 that pivotally attaches to the main frame assembly 12 . The rear end 48 has a top support 50 and a bottom support 52 , which extends above and below the main frame assembly 12 to pivotally attach to a cylinder 54 at the back side 22 of the main frame assembly 12 by a pivot pin 61 . The bottom support 52 also has a hole for receiving a front end of tie rod 70 . A front end 58 of the swinging arm members 46 has an adapter 60 for attaching to a rigid cross member, such as the exemplary rigid cross member shown in FIG. 1 in dashed lines. The rigid cross member could be a piece of square tubing (as shown). The rigid cross member could also be a bumper, a vehicle, a tractor or other farm implement. It is preferred that the swinging arm members 46 be pivotally mounted to a rigid cross member. For example, attaching a hitch to the adapter 60 and a ball to both ends of the rigid cross member (as shown in FIG. 1 in dashed lines) allows the swinging arm members 46 to pivot about the balls. Similarly, swinging arm members 46 could also be pivotally attached to a bumper or another rigid cross member as part of a farm implement.
[0022] In FIG. 1 , the swinging arm members 46 are shown parallel to each other and the tires 44 are shown perpendicular to the main frame assembly 12 . However, the swinging arm members 46 need not be parallel to each other for the trailer 10 to steer. Adjusting the swinging arm members 46 affects the turning radius of the steerable caddy trailer 10 . Regardless of the configuration, whether the swinging arm members 46 are parallel or moved inward closer to each other, the tie rods 70 can be adjusted to keep the tires perpendicular to the main frame assembly 12 .
[0023] A platform support 62 is provided that has side supports 64 and a front support 66 connecting the two side supports 64 and sub-platform supports 68 . The platform support 62 balances the weight of a platform, tank, hopper or other evenly towards the front and back of the main frame assembly 12 .
[0024] In operation, the caddy is pulled behind the implement and/or vehicle by pivotally connecting the swinging arm members 46 to a rigid cross member. Should the towing vehicle or farm implement turn left this will simultaneously cause the left swinging arm 72 to shift rearward toward the main frame assembly 12 and the right swinging arm 74 to shift forward away from the main frame assembly 12 . Shifting the left swinging arm 72 rearward towards the main frame assembly causes the tie-rod linkage 70 to move the spindle assembly such that the left wheel 76 steers right. Similarly, shifting the right swinging arm 74 forward away from the main frame assembly causes the tie-rod linkage 70 to move the spindle assembly such that the right wheel 78 steers right, also. Thus, when the towing vehicle turns left the wheels 44 on the steerable caddy 10 turn right so as to track the towing vehicle.
[0025] Should the towing vehicle or farm implement turn right this will simultaneously cause the left swinging arm 72 to shift forward away from the main frame assembly 12 and the right swinging arm 74 to shift rearward toward the main frame assembly 12 . Shifting the left swinging arm 72 forward away from the main frame assembly causes the tie-rod linkage 70 to move the spindle assembly such that the left wheel 76 steers left. Similarly, shifting the right swinging arm 74 rearward toward the main frame assembly causes the tie-rod linkage 70 to move the spindle assembly such that the right wheel 78 steers left, also. Thus, when the towing vehicle turns left the wheels 44 on the steerable caddy 10 turn right so as to track the towing vehicle.
[0026] In either instance after the towing vehicle turns left or right and returns to driving a straight course, the wheels 44 return to a position perpendicular to the main frame assembly 12 . In this fashion, the steerable caddy trailer is maintained in virtually the same turning radius as the vehicle and/or implement.
[0027] The invention has been shown and described above with the preferred embodiments, and it is understood that many modifications, substitutions, and additions may be made which are within the intended spirit and scope of the invention. From the foregoing, it can be seen that the present invention accomplishes at least all of its stated objectives.
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A steerable caddy trailer is provided that has an improved structure including a main frame assembly, spindle assemblies attached to each end of the main frame for attachment of a wheel, a pair of swinging arms forwardly extending from the main frame and pivotally attached to the main frame, and tie rods connecting the swinging arms with the spindle assembly such that pivoting of the swinging arms steers the wheel.
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This application claims the benefit of U.S. provisional application Ser. No. 60/004,400, filed Sep. 27, 1995.
FIELD OF THE INVENTION
The invention relates to an apparatus for separating vapor from fuel and more particularly to an apparatus for separating vapor from diesel fuel for use in a diesel engine.
BACKGROUND OF THE INVENTION
In producing mechanical power in an internal-combustion engine, both fuel and air are needed to create the combustion to form the expanding gas and the mechanical power. The fuel and air are mixed in an internal-combustion engine using a fuel injector or a carburetor. A fuel injector delivers fuel or a fuel-air mixture to the cylinders of the internal-combustion engine by means of pressure from a pump. The fuel or fuel-air mixture mixes with the air in the cylinder.
Modern day internal-combustion engines use computers to control the engine including the metering of fuel into the cylinders. While the computer can monitor various conditions of the engine, such as temperatures and pressures, not all properties of all elements and conditions can be monitored. Such elements that are typically not monitored are the properties of the fuel. The computer, therefore, is programmed that the fuel is of a standard quality including a minimum amount of air entrained in the fuel.
While the standard quality of the fuel is critical with gasoline internal-combustion engine, the amount of air entrained in the fuel is more critical with diesel engines. With diesel engines, the fuel is not mixed with air prior to being injected into the cylinder. The air that is mixed with the fuel is a known quantity determined by the volume of the cylinder. The diesel is controlled by the amount of fuel injected into the cylinder.
Another difference is that diesel engines bum a fuel oil (diesel fuel) instead of gasoline. Furthermore, diesel engines differ from gasoline engines in that the ignition of fuel is caused by compression of air in its cylinders instead of by a spark. Another area in which diesel engines differ from gasoline engines is that in conventional diesel only a portion of the fuel pumped to the engine is used, the excess fuel, which is entrained with air, is returned to the fuel tank.
It has been recognized that if air is entrained in the fuel prior to injection into the cylinder, the performance of the engine suffers. It has, therefore, been recognized that it is desirable to remove the air vapor from the fuel prior to the fuel injectors, so that when the fuel injector adds fuel to the cylinder there will not be too much air and too little fuel.
One prior art patent, Ekstam, U.S. Pat. No. 5,355,860, which recognizes the detriment in having air entrained in the fuel, discloses a system that has components for removing water and particles from the fuel in addition to the air. The air removal portion of the system has a vessel with an upper housing portion and a lower canister portion which is threadably connected to the upper housing. The lower canister receives a replaceable filter cartridge. The filter cartridge is connected to a threaded portion of a filter receiver that has a port or an aperture connected to the engine. In addition, the vessel has an overflow tube which is ported to the fuel tank.
Fuel enters the vessel through an inlet from a particle filter in this patent. The level of the fuel in the filter is above the replaceable filter cartridge. The fuel passes through the filter to a center passage on the way to the engine. The patent purports that air bubbles are retained on the outside surface of the filter and allowed to float up and away from the filter media. The bubbles are purported to float out of the overflow tube.
It would be desirable to effectively remove vapor from the fuel.
SUMMARY OF THE INVENTION
This present invention is directed to a fuel/vapor separator apparatus for de-vaporizing fuel entrained with vapor and returning the vapor to a reservoir. The apparatus has a hollow canister defining a separation chamber. The canister has an input port for receiving the fuel entrained with vapor, an output port in communication with the engine for removal of the de-vapored fuel from the chamber, and a vapor port for removal of the released vapor from the chamber. A screen element is located in the separation chamber of the canister between the input port and the output port for agitating the fuel to release the vapor from the fuel. The apparatus has a valving arrangement for connecting the vapor port to the reservoir.
The valving arrangement has at least three ports. The vapor port of the canister is in communication with the first port of the valving arrangement. The reservoir is in communication with the second port of the valving arrangement, and ambient air is in communication with the third port. The valving arrangement has a conduit with a control pin for selecting the venting of the separation chamber through the vapor port to either the fuel tank or ambient air.
In a preferred embodiment, the hollow canister has a second screen element located in the separation chamber between the screen element and the output port for limiting any foaming from reaching the output port.
One object, feature, and advantage resides in the screen element located in the separation chamber of the canister between the input port and the output port agitating the fuel to release the vapor from the fuel.
Another object, feature, and advantage resides in the valving arrangement of the fuel/vapor having a quadruplet of ports that permits a fuel cartridge to be easily and efficiently drained, without a significant loss of fuel.
An additional object, feature, and advantage resides in the ability to change a filter cartridge when the engine is running, if desired.
Moreover, an additional object, feature, and advantage resides in not being required to prime the fuel system after changing filters.
Further objects, features, and advantages of the present invention will become more apparent to those skilled in the art as the nature of the invention is better understood from the accompanying drawings and detailed descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawing forms which are presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a sectional view of a hollow canister that defines a separation chamber according to the invention. A valving arrangement, a fuel filter cartridge, a fuel tank, and a fuel pump are shown schematically.
FIG. 2 is sectional view of the valving arrangement in a normal operating position;
FIG. 3 is a schematic view of fuel/vapor separator in relation to a diesel engine;
FIG. 4 is a sectional view of the valving arrangement in a fuel filter cartridge draining position;
FIG. 5 is a view similar to FIG. 1 in the fuel filter cartridge draining position;
FIG. 6 is a view similar to FIG. 1 in an out-of-fuel condition; and
FIGS. 7A and 7B are an alternative embodiment of fuel/vapor separator showing several alternative features.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like numerals indicate like elements and where prime (' and ") indicate(s) counterparts of such like elements, there is shown in FIG. 1 a fuel/vapor separator device in accordance with the present invention designated generally as 10.
The fuel/vapor separator apparatus 10, shown in FIG. 1, includes a hollow canister 12 that defines a separation chamber 14. A supply tube 16 extends through the base 18 of the canister 12 and terminates at a point near the top of the separation chamber 14. The bottom section 20 of the supply tube 16 is threaded and extends down below the bottom surface 22 of the canister base 18. The threaded bottom section 20 of the supply tube 16 is adapted to engage a fuel filter cartridge 24, wherein the fuel filter cartridge 24 is held in place by the threaded bottom section 20 of the supply tube 16 and seats against the bottom surface 22 of the canister base 18. Fuel filter cartridges for diesel fuel engines are well known in the art. Any such fuel filter cartridge of the proper size and specification can be used in conjunction with the present invention.
A supply port 30 is formed in the canister base 18. The supply port 30 is connected to the fuel pump 32 and receives a flow of fuel from the fuel tank, or a reservoir, 34. The supply port 30 directs the flow of fuel into the fuel filter cartridge 24. The fuel filter cartridge 24 filters the fuel in the traditional manner and directs the filtered fuel into the supply tube 16. The filtered fuel travels through the supply tube 16 and is expelled from the open top end of the supply tube 16 near the top of the separation chamber 14. In normal operation of a preferred embodiment, the separation chamber 14 is completely filled with fuel. The apparatus 10 typically rims in a range of 14 to 60 pounds per square inch (psi). The temperature of the apparatus 10 is dependent on several factors including ambient temperature, and the type of diesel engine to which the apparatus is connected.
An upper metal screen element 38 is attached to the supply tube 16 near the top of the separation chamber 14. In a preferred embodiment, the screen element 38 forms an inner enclosed area 39 bounded by a pair of frustum of cones with the bases joined. As the filtered fuel leaves the supply tube 16, gravity pulls the fuel through the upper metal screen element 38. The passage of the fuel through the metal screen element 38 agitates the fuel and helps to break the surface tension of the fuel, thereby enabling air and vapor bubbles to leave the liquid fuel. The word agitate is used here to mean upset or disturb the fuel or cause the fuel to move with violence or sudden force; the elements of the apparatus located in the separation chamber 14 do not move themselves.
As the fuel passes through the upper metal screen element 38, the fuel collects in the bottom of the separation chamber 14. An exit port or output port 40 is disposed in the canister base 18 at the bottom of the separation chamber 14. A second metal screen element 42 is disposed at the bottom of the separation chamber 14 to help separate any foaming of the collected fuel from the liquid fuel at the bottom of the separation chamber 14 during certain operations, as explained below. The exit port 40 is disposed below the second metal screen element 42. The exit port 40 is joined to the fuel injection system or carburetor of the diesel engine, as seen in FIG. 3. As such, the diesel engine is supplied with only liquid fuel, whereas excess air and vapor bubbles have been removed by the process agitation in the separation chamber 14. Since the fuel now contains much less air and vapor bubbles than does ordinary fuel, the fuel burns more evenly and significantly improves the performance of the engine, such as increased gas mileage and power.
As can be seen in FIG. 1, the air and vapor separated from the fuel in the separation chamber 14 passes through a vapor port 44 at the top of the canister 12. The vapor port 44 is coupled to a valving arrangement 46. During normal operation, the valving arrangement 46 couples the vapor port 44 to a return line 48 that leads back to the fuel tank 34. As a result, the vapor is recycled back to the fuel tank 34 where it may condense back into liquid fuel. The schematic of the valving arrangement 46 illustrated in FIG. 1 is shown in an arrangement for a normal engine running scenario, wherein the separated vapor from the separation chamber 14 is returned to the fuel tank 34. A small percentage of diesel fuel may also pass through the vapor port 44 back into the fuel tank 34. The remaining functions of the valving arrangement 46 are for changing the fuel filter cartridge 24 during maintenance when the engine is not running, as will later be explained.
A drain conduit 50 is disposed within the canister base 18. The drain conduit 50 is coupled to the valving arrangement 46 at one end. The opposite end of the drain conduit 50 extends into the supply tube 16. An extension tube 52 couples to the drain conduit 50, thereby effectively extending the drain conduit 50 well into the fuel filter cartridge 24. During maintenance, when it is desired to change the fuel filter cartridge 24, the valving arrangement 46 is configured so that the drain conduit 50 is directly coupled to the return line 48, as explained below.
Referring to FIG. 2 there is shown one preferred embodiment of the valving arrangement 46. The valving arrangement 46 shown has a threaded end 60 that enables the valving arrangement 46 to be directly coupled to the drain conduit 50 in the base 18 of the canister 12. The valving arrangement 46 has a central conduit 62 that communicates with the drain conduit 50. Three attachment ports 64, 66, and 68 extend into the sides of the valving arrangement 46, wherein each of the attachment ports 64, 66, and 68 communicates with the central conduit 62. The first attachment port 64 is coupled to the fuel return line 48, as seen in FIG. 1, that leads back to the fuel tank. The second attachment port 66 is coupled to the vapor port 44, as seen in FIG. 1, in the top of the canister 12. Lastly, the third attachment port 68 is coupled to an air port that is vented to the ambient atmosphere.
Within the valving arrangement 46 is disposed a control pin 70. The control pin 70 terminates at one end with a threaded cap 72 that threadably engages the end of the valving arrangement 46. As such, by either loosening or tightening the threaded cap 72, the position of the control pin 70 within the central conduit 62 can be selectively altered. The control pin 70 seals with the central conduit 62 by the use of three O-rings 74, 75, 76. By changing the position of the control pin 70 and the O-rings 74, 75, 76 in the central conduit 62, the flow between the various attachment ports 64, 66, and 68 can be controlled.
The control pin 70 has been advanced to its deepest position within the central conduit 62, as shown in FIG. 2. At this position, the first O-ring 74 seals against a lip 78 within the central conduit 62, thereby preventing the flow of fuel from the drain conduit 50 into the central conduit 62. At the shown position, the third attachment port 68, which leads to ambient venting, is also isolated. The configuration shown in FIG. 2 illustrates the position of the valving arrangement 46 when the engine is running. In this circumstance, the second attachment port 66 communicates with the first attachment port 64, thereby attaching the vapor port 44, shown in FIG. 1, to the fuel return line 48 shown in FIG. 1. As a result, vapor passes through the valving arrangement 46 and is recycled to the fuel tank.
A schematic of the fuel/vapor separator device 10 in relation to the diesel engine 82 and the fuel tank 34 is shown in FIG. 3. The fuel pump 32, also referred to as a transfer pump, pulls the fuel from the fuel tank 34 and pass it through a removable primary filter 84 prior to reaching the fuel pump 32. The primary filter 84 removes both water and particles in the fuel.
The fuel is then pumped by the fuel pump 32 to the supply port 30, as seen in FIG. 1, on the canister 12. The fuel passes through the fuel filter cartridge 24, which is capable of removing finer particles than the primary filter 84 and in addition any water not trapped in the primary filter 84. The fuel then enters the separation chamber 14 described above. The fuel that has been de-vapored flows through the exit port 40 to the engine 82. The fuel flows in the engine 82 through the fuel rail or gallery 86, shown in hidden line, with a portion of the fuel being injected into the cylinders to be combusted to generate power. The excess fuel leaves the engine 82 through the fuel return or fuel spill 88 and is returned to the fuel tank 34.
The vapor and fuel which exits the separation chamber 14 through the vapor port 44 flows through the valving arrangement 46 to merge with the excess fuel and return to the fuel tank 34. The valving arrangement 46 is shown removed from the canister 12 for clarity. The drain conduit 50 of the fuel/vapor separator device 10 is shown connected to the valving arrangement 46. The air port 90 is likewise connected to the valving arrangement. It is recognized that diesel engines 82 vary, and the diesel engine 82 may include injectors and an injector pump.
Referring to FIG. 4, the valving arrangement 46 is shown in an orientation for draining the fuel filter cartridge 24, as seen in FIG. 5, prior its replacement. In this orientation, the threaded cap 72 is loosened, thereby retracting the control pin 70 within the central conduit 62. As the control pin 70 retracts, the first O-ring 74 separates from the lip 78 within the central conduit 62. This enables fuel to flow from the drain conduit 50 into the first attachment port 64. As a result, fuel being drained from the canister 12 through the drain conduit 50 is directed back into the fuel tank. Furthermore, when the control pin 70 is positioned into the retracted position shown, the second attachment port 66 is coupled to the third attachment port 68. This enables air to vent through the valving arrangement 46 and into the vapor port 44 of the separator canister 12. The air flows from an air vent, coupled to the third attachment port 66, through the central conduit 62 and out through the second attachment port 66 to the vapor port at the top of the separator canister 12.
Referring to FIG. 5, with the drain conduit 50 coupled to the fuel return line 48, the valving arrangement 46, as seen in FIG. 4, vents the canister 12 by coupling the vapor port 44 to the ambient air. With the top of the canister vented to the ambient atmosphere, the fuel in the supply tube 16 drops into the filter cartridge 24, thereby forcing the fuel in the filter cartridge 24 out through the drain conduit 50. This flow creates a syphon which draws the fuel out of the fuel filter cartridge 24, through the fuel return line 48, and back into the fuel tank 34. The syphon action drains the fuel filter cartridge 24 until the fuel level in the fuel filter cartridge 24 drops below the bottom of the drain conduit extension tube 52. At this point, practically no fuel is left within the fuel filter cartridge 24. This allows the fuel filter cartridge 24 to be replaced without spilling fuel and without loosing any significant amount of fuel in the filter cartridge 24.
Although the syphon action drains the fuel in the supply tube 16 and the fuel filter cartridge 24, the syphon action does not drain the fuel held in the separation chamber 14 below the level of the top of the supply tube 16. As such, the separation chamber 14 remains filled to the level of the top of the supply tube 16 when the fuel filter cartridge 24 is removed. To prevent fuel from splashing into the top of the supply tube 16 when the fuel filter cartridge 24 is removed, a syphon tube 54 is provided that extends over the top edge of the supply tube 16. The syphon tube 54 hooks over the top of the supply tube 16 and extends a short distance below the top of the supply tube 16. As a result, when the supply tube 16 is drained, a syphon is created in the syphon tube 54 that drains the separation chamber 14 to a point well below the level of the top of the supply tube 16. Consequently, the fuel is much less likely to splash through the upper metal screen element 38 and into the supply tube 16 when the fuel filter cartridge 24 is removed.
After the fuel filter cartridge 24 is replaced, it may be desirable, but not necessary, to prime the filter cartridge 24 with fuel in order to ensure the rapid starting of the engine. For such a reason, a priming closure 56 is provided at the top of the canister 12. By pouring fuel into the priming closure 56, the fuel fills the separation chamber 14 and flows into the supply tube 16. As a result, the fuel filter cartridge 24 fills with fuel and the system is primed.
Referring to FIG. 6, if the fuel in the fuel tank 34 falls below a level where the fuel pump 32 can pump fuel into the fuel filter cartridge 24 and up the supply tube 16 in the separation chamber 14, the level of fuel will drop in the separation chamber 14 as the engine 82 receive fuel from the exit port 40. The upper surface of the fuel, which is exposed to the layer of air, will foam. The second metal screen 42 helps to separate any foaming of the collected fuel from the liquid fuel at the bottom of the separation chamber. The exit port 40 is disposed below the second metal screen element 42 and therefore is exposed to only liquid fuel during normal operations.
Upon refilling the fuel tank 34, the fuel pump 32 pumps fuel through the supply port 30 into the fuel filter cartridge 24 and up through the supply tube 16 into the separation chamber 14. The air located in the separation chamber 14 will be vented out through the vapor port 44, making priming unnecessary.
An alternative embodiment of the fuel/vapor separator apparatus 10' is shown in FIG. 7. The fuel/vapor separator apparatus 10' has an upper metal screen element 38' attached to the supply tube 16 near the top of the separation chamber 14'. The relative position of where the screen element 38' is connected to the supply tube 16' is lower, and not directly adjacent to the top of the supply tube 16. Similar to the first embodiment, the metal screen element 38' forms an inner enclosed area 39' bounded by a pair of frustum of cones with the bases joined and the portion directly above the supply tube 16' is solid.
Similar to the first embodiment, the fuel/vapor separator appartus 10' has a syphone tube 54' that extends over the top edge of the supply tube 16'. The syphon tube 54' hooks over the top of the supply tube 16' and extends a short distance below the top of the supply tube 16'. As a result, when the supply tube 16' is drained, a syphon is created in the syphon tube 54' that drains the separation chamber 14 to a point well below the level of the top of the supply tube 16. In contrast to the first embodiment, because of the relatvie position of the screen element 38', the syphon tube 54' does not extend through the screen element 38'. Therefore, it is not possible for even a small amount of fuel to pass through the syphon tube 54' into the separation chamber without passing through the screen element. However, similar to the first embodiment, the fuel is much less likely to splash into the supply tube 16 when the fuel filter cartridge 24 is removed.
Another alterative is that the fuel/vapor separator apparatus 10' has an exit tube 94 connected to an exit port or output port 40'. The exit port 40' is disposed in the canister base 18' at the bottom of the separation chamber 14'. The exit tube 94 has a pair of ports, a main port 96 and an idle port 98, which open into the separation chamber 14'. The ports 96 and 98 allow the fuel to flow from the separation chamber 14' into the exit tube 94 and into the exit port 40'. The main port 96 is located below the second metal screen element 42', but above the idle port 98. The exit tube 94 has a cylindrical top with a vent 100, and a ball float 102 located within the tube 94.
During normal operation, the separation chamber 14' is full with fuel and the ball float 102 floats to the top of the exit tube 94 where the ball float 102 is limited from moving because of the cylindrical top. If the fuel in the fuel tank 34, as seen in FIG. 3, falls below a level where the fuel pump 32 can pump the fuel, the fuel level in the separation chamber 14' will drop as the engine receives fuel from the exit port 40'. As the fuel drops in the separation chamber 14', the ball float 102 drops. The ball float 102 continues to drop until the ball float 102 blocks the main port 96 and reaches an orifice 104 or constriction in the exit tube 94. The orifice 104 prevents the ball float 102 from dropping further. With the main port 96 closed by the ball float 102, the engine is limited to the quantity of fuel that can pass through the idle port 98. This reduction in fuel results in the engine dropping down to an idle speed.
Similar to the first embodiment, the fuel/vapor separator apparatus 10' has a second metal screen element 42' disposed at the bottom of the separation chamber 14 to help separate any foaming of the collected fuel from the liquid fuel at the bottom of the separation chamber 14. The metal screen element 42' is located just above the main port 96.
An alternative valving arrangement 46' is shown in FIGS. 7A and 7B. The fuel/vapor separator 10' has a single valve 106 connected to the drain conduit 50'. This valve is typically closed and is open when it is desired to drain the fuel filter cartridge, as seen in FIG. 5. The fuel being drained from the fuel filter cartridge through the drain conduit 50' is directed back into the fuel tank.
In addition, the valving arrangement has a manifold 108 carried by the hollow canister 12'. In the embodiment shown, the manifold 108 is carried at the top of the canister 12' and is spaced by an insulating material 110. The manifold 108 has an input port 112 and an output port 114. The fuel returning from the engine and the fuel return 88, as seen in FIG. 3, enters the input port 112 and the output port 114 and is in communication with the fuel tank 34. The manifold 108 in addition has a vent receiving port 116 through which the vapor and the fuel from the separation chamber 14' that passes through the vapor port 44' is connected to the fuel tank 34. In addition the manifold 108 has a port 118 which is connected to a valve that is coupled to an air port that is vented to the ambient atmosphere. This valve is normally closed.
When it is desired to drain the fuel filter cartridge 24, as seen in FIG. 7A, both valves associated with the valving arrangement 46' are open. The drain conduit 50' is connected to the fuel tank and the vapor port 44' is connected to the ambient air. Similar to the first embodiment, when the top of the canister vented to the ambient atmosphere, the fuel in the supply robe 16' drops into the filter cartridge 24, thereby forcing the fuel in the filter cartridge 24 out through the drain conduit 50'. This flow creates a syphon which draws the fuel out of the fuel filter cartridge 24, through the fuel return line 48 and back into the fuel tank 34. The syphon action drains the fuel filter cartridge 24 until the fuel level in the fuel filter cartridge 24 drops below the bottom of the drain conduit extension tube 52.
One distinction from the first embodiment, is that the return line from the engine is vented to the ambient air also at this point. The fuel tank is normally vented. These valves would not be open when the engine is running and no fuel would be pumped out of the port.
In either embodiment, it is possible to remove and replace the fuel filter cartridge 24 while the engine is running as seen in FIG. 3. In order to remove and replace the fuel filter cartridge 24, the valving arrangement 46 or 46' are not changed from their normal operation position. The primary filter 84 is removed first. In removing the primary filter 84, the fuel pump 32, or transfer pump, can not pull any fuel from the fuel tank 34 since the primary filter 84 is part of the path. The fuel pump 32 pumps air into the fuel filter cartridge 24 therein emptying the fuel into the separation chamber 14. The fuel filter cartridge 24 can then be removed. The separation chamber 14 or 14' acts in an empty fuel tank stage as described above with respect to FIGS. 6 or 7A. When the fuel filter cartridge 24 and primary filter 84 are replaced, the fuel pump 32 refills the filters with fuel and the air that has entered the system is vented through the vapor port 44 or 44'. The system does not need to be primed since the line from the exit port 40 or 40' to the engine always contains fuel.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes therefore and, accordingly, references should be made to appended claims, rather than to the foregoing specification, as indicating the scope of the invention. For example, the attachment ports 64, 66, 68 on the valving arrangement could be threaded in order to receive a threaded pipe connector. Similarly, numerous other mechanical valving means could be used in place and instead of the valving arrangement described. The operation of such valving means could be mechanical, as is shown, or may be electrically or pneumatically driven.
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A fuel/vapor separator apparatus for de-vaporizing fuel entrained with vapor has a hollow canister defining a separation chamber. The canister has an input port for receiving the fuel entrained with vapor, an output port in communication with the engine for removal of the de-vapored fuel from the chamber, and a vapor port for removal of the released vapor from the chamber. A screen element is located in the separation chamber of the canister between the input port and the output port for agitating the fuel to release the vapor from the fuel. The apparatus has a valving arrangement for connecting the vapor port to the reservoir. The valving arrangement has at least three ports. The vapor port of the canister is in communication with the first port of the valving arrangement. The reservoir is in communication with the second port of the valving arrangement, and ambient air is in communication with the third port. The valving arrangement has a conduit with a control pin for selecting the venting of the separation chamber through the vapor port to either the fuel tank or the ambient air.
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FIELD OF THE INVENTION
The field of this invention is tools run downhole preferably on cable and which operate with on board power to perform a downhole function and more particularly wellbore debris cleanup.
BACKGROUND OF THE INVENTION
It is a common practice to plug wells and to have encroachment of water into the wellbore above the plug. FIG. 1 illustrates this phenomenon. It shows a wellbore 10 through formations 12 , 14 and 16 with a plug 18 in zone 16 . Water 20 has infiltrated as indicated by arrows 22 and brought sand 24 with it. There is not enough formation pressure to get the water 20 to the surface. As a result, the sand 24 simply settles on the plug 18 .
There are many techniques developed to remove debris from wellbores and a good survey article that reviews many of these procedures is SPE 113267 Published June 2008 by Li, Misselbrook and Seal entitled Sand Cleanout with Coiled Tubing: Choice of Process, Tools or Fluids? There are limits to which techniques can be used with low pressure formations. Techniques that involve pressurized fluid circulation present risk of fluid loss into a low pressure formation from simply the fluid column hydrostatic pressure that is created when the well is filled with fluid and circulated or jetted. The productivity of the formation can be adversely affected should such flow into the formation occur. As an alternative to liquid circulation, systems involving foam have been proposed with the idea being that the density of the foam is so low that fluid losses will not be an issue. Instead, the foam entrains the sand or debris and carries it to the surface without the creation of a hydrostatic head on the low pressure formation in the vicinity of the plug. The downside of this technique is the cost of the specialized foam equipment and the logistics of getting such equipment to the well site in remote locations.
Various techniques of capturing debris have been developed. Some involve chambers that have flapper type valves that allow liquid and sand to enter and then use gravity to allow the flapper to close trapping in the sand. The motive force can be a chamber under vacuum that is opened to the collection chamber downhole or the use of a reciprocating pump with a series of flapper type check valves. These systems can have operational issues with sand buildup on the seats for the flappers that keep them from sealing and as a result some of the captured sand simply escapes again. Some of these one shot systems that depend on a vacuum chamber to suck in water and sand into a containment chamber have been run in on wireline. Illustrative of some of these debris cleanup devices are U.S. Pat. No. 6,196,319 (wireline); U.S. Pat. No. 5,327,974 (tubing run); U.S. Pat. No. 5,318,128 (tubing run); U.S. Pat. No. 6,607,607 (coiled tubing); U.S. Pat. No. 4,671,359 (coiled tubing); U.S. Pat. No. 6,464,012 (wireline); U.S. Pat. No. 4,924,940 (rigid tubing) and U.S. Pat. No. 6,059,030 (rigid tubing).
The reciprocation debris collection systems also have the issue of a lack of continuous flow which promotes entrained sand to drop when flow is interrupted. Another issue with some tools for debris removal is a minimum diameter for these tools keeps them from being used in very small diameter wells. Proper positioning is also an issue. With tools that trap sand from flow entering at the lower end and run in on coiled tubing there is a possibility of forcing the lower end into the sand where the manner of kicking on the pump involves setting down weight such as in U.S. Pat. No. 6,059,030. On the other hand, especially with the one shot vacuum tools, being too high in the water and well above the sand line will result in minimal capture of sand.
What is needed is a debris removal tool that can be quickly deployed such as by slickline and can be made small enough to be useful in small diameter wells while at the same time using a debris removal technique that features effective capture of the sand and preferably a continuous fluid circulation while doing so. A modular design can help with carrying capacity in small wells and save trips to the surface to remove the captured sand. Other features that maintain fluid velocity to keep the sand entrained and further employ centrifugal force in aid of separating the sand from the circulating fluid are also potential features of the present invention. Those skilled in the art will have a better idea of the various aspects of the invention from a review of the detailed description of the preferred embodiment and the associated drawings, while recognizing that the full scope of the invention is determined by the appended claims.
One of the issues with introduction of bottom hole assemblies into a wellbore is how to advance the assembly when the well is deviated to the point where the force of gravity is insufficient to assure further progress downhole. Various types of propulsion devices have been devised but are either not suited for slickline application or not adapted to advance a bottom hole assembly through a deviated well. Some examples of such designs are U.S. Pat. Nos. 7,392,859; 7,325,606; 7,152,680; 7,121,343; 6,945,330; 6,189,621 and 6,397,946. US Publication 2009/0045975 shows a tractor that is driven on a slickline where the slickline itself has been advanced into a wellbore by the force of gravity from the weight of the bottom hole assembly.
SUMMARY OF THE INVENTION
A wellbore cleanup tool is run on slickline. It has an onboard power supply and circulation pump. Inlet flow is at the lower end into an inlet pipe that keeps up fluid velocity. The inlet pipe opens to a surrounding annular volume for sand containment and the fluid continues through a screen and into the pump for eventual exhaust back into the water in the wellbore. A modular structure is envisioned to add debris carrying capacity. Various ways to energize the device are possible. Other tools run on slickline are described such as a cutter, a scraper and a shifting tool.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section view of a plugged well where the debris collection device will be deployed;
FIG. 2 is the view of FIG. 1 with the device lowered into position adjacent the debris to be removed;
FIG. 3 is a detailed view of the debris removal device shown in FIG. 2 ;
FIG. 4 is a lower end view of the device in FIG. 3 and illustrating the modular capability of the design;
FIG. 5 is another application of a tool run on slickline to cut tubulars;
FIG. 6 is another application of a tool to scrape tubulars without an anchor that is run on slickline;
FIG. 7 is an alternative embodiment of the tool of FIG. 6 showing an anchoring feature used without the counter-rotating scrapers in FIG. 6 ;
FIG. 8 is a section view showing a slickline run tool used for moving a downhole component;
FIG. 9 is an alternative embodiment to the tool in FIG. 8 using a linear motor to set a packer;
FIG. 10 is an alternative to FIG. 9 that incorporates hydrostatic pressure to set a packer;
FIG. 11 illustrates the problem with using slicklines when encountering a wellbore that is deviated;
FIG. 12 illustrates how tractors are used to overcome the problem illustrated in FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 2 shows the tool 26 lowered into the water 20 on a slickline or non-conductive cable 28 . The main features of the tool are a disconnect 30 at the lower end of the cable 28 and a control system 32 for turning the tool 26 on and off and for other purposes. A power supply, such as a battery 34 , powers a motor 36 , which in turn runs a pump 38 . The modular debris removal tool 40 is at the bottom of the assembly.
While a cable or slickline 28 is preferred because it is a low cost way to rapidly get the tool 26 into the water 20 , a wireline can also be used and surface power through the wireline can replace the onboard battery 34 . The control system can be configured in different ways. In one version it can be a time delay energized at the surface so that the tool 26 will have enough time to be lowered into the water 20 before motor 36 starts running. Another way to actuate the motor 36 is to use a switch that is responsive to being immersed in water to complete the power delivery circuit. This can be a float type switch akin to a commode fill up valve or it can use the presence of water or other well fluids to otherwise complete a circuit. Since it is generally known at what depth the plug 18 has been set, the tool 26 can be quickly lowered to the approximate vicinity and then its speed reduced to avoid getting the lower end buried in the sand 24 . The control system can also incorporate a flow switch to detect plugging in the debris tool 40 and shut the pump 38 to avoid ruining it or burning up the motor 36 if the pump 38 plugs up or stops turning for any reason. Other aspects of the control system 32 can include the ability to transmit electromagnetic or pressure wave signals through the wellbore or the slickline 28 such information such as the weight or volume of collected debris, for example.
Referring now to FIGS. 3 and 4 , the inner details of the debris removal tool 40 are illustrated. There is a tapered inlet 50 leading to a preferably centered lift tube 52 that defines an annular volume 54 around it. Tube 52 can have one or more centrifugal separators 56 inside whose purpose is to get the fluid stream spinning to get the solids to the inner wall using centrifugal force. Alternatively, the tube 52 itself can be a spiral so that flow through it at a high enough velocity to keep the solids entrained will also cause them to migrate to the inner wall until the exit ports 58 are reached. Some of the sand or other debris will fall down in the annular volume 54 where the fluid velocity is low or non-existent. As best shown in FIG. 3 , the fluid stream ultimately continues to a filter or screen 60 and into the suction of pump 38 . The pump discharge exits at ports 62 .
As shown in FIG. 4 the design can be modular so that tube 52 continues beyond partition 64 at thread 66 which defines a lowermost module. Thereafter, more modules can be added within the limits of the pump 38 to draw the required flow through tube 52 . Each module has exit ports 58 that lead to a discrete annular volume 54 associated with each module. Additional modules increase the debris retention capacity and reduce the number of trips out of the well to remove the desired amount of sand 24 .
Various options are contemplated. The tool 40 can be triggered to start when sensing the top of the layer of debris, or by depth in the well from known markers, or simply on a time delay basis. Movement uphole of a predetermined distance can shut the pump 38 off. This still allows the slickline operator to move up and down when reaching the debris so that he knows he's not stuck. The tool can include a vibrator to help fluidize the debris as an aid to getting it to move into the inlet 50 . The pump 38 can be employed to also create vibration by eccentric mounting of its impeller. The pump can also be a turbine style or a progressive cavity type pump.
The tool 40 has the ability to provide continuous circulation which not only improves its debris removal capabilities but can also assist when running in or pulling out of the hole to reduce chances of getting the tool stuck.
While the preferred tool is a debris catcher, other tools can be run in on cable or slickline and have an on board power source for accomplishing other downhole operations. FIG. 2 is intended to schematically illustrate other tools 40 that can accomplish other tasks downhole such as honing or light milling. To the extent a torque is applied by the tool to accomplish the task, a part of the tool can also include an anchor portion to engage a well tubular to resist the torque applied by the tool 40 . The slips or anchors that are used can be actuated with the on board power supply using a control system that for example can be responsive to a pattern of uphole and downhole movements of predetermined length to trigger the slips and start the tool.
FIG. 5 illustrates a tubular cutter 100 run in on slickline 102 . On top is a control package 104 that is equipped to selectively start the cutter 100 at a given location that can be based on a stored well profile in a processor that is part of package 104 . There can also be sensors that detect depth from markers in the well or there can more simply be a time delay with a surface estimation as to the depth needed for the cut. Sensors could be tactile feelers, spring loaded wheel counters or ultrasonic proximity sensors. A battery pack 106 supplies a motor 108 that turns a ball shaft 110 which in turn moves the hub 112 axially in opposed directions. Movement of hub 112 rotates arms 114 that have a grip assembly 116 at an outer end for contact with the tubular 118 that is to be cut. A second motor 120 also driven by the battery pack 106 powers a gearbox 122 to slow its output speed. The gearbox 122 is connected to rotatably mounted housing 124 using gear 126 . The gearbox 122 also turns ball screw 128 which drives housing 130 axially in opposed directions. Arms 132 and 134 link the housing 130 to the cutters 136 . As arms 132 and 134 get closer to each other the cutters 136 extend radially. Reversing the rotational direction of cutter motor 120 retracts the cutters 136 .
When the proper depth is reached and the anchor assemblies 116 get a firm grip on the tubular 118 to resist torque from cutting, the motor 120 is started to slowly extend the cutters 136 while the housing 124 is being driven by gear 126 . When the cutters 136 engage the tubular 118 the cutting action begins. As the housing 124 rotates to cut the blades are slowly advanced radially into the tubular 118 to increase the depth of the cut. Controls can be added to regulate the cutting action. They controls can be as simple as providing fixed speeds for the housing 124 rotation and the cutter 136 extension so that the radial force on the cutter 136 will not stall the motor 120 . Knowing the thickness of the tubular 118 the control package 104 can trigger the motor 120 to reverse when the cutters 136 have radially extended enough to cut through the tubular wall 118 . Alternatively, the amount of axial movement of the housing 130 can be measured or the number of turns of the ball screw 128 can be measured by the control package 104 to detect when the tubular 118 should be cut all the way through. Other options can involve a sensor on the cutter 136 that can optically determine that the tubular 118 has been cut clean through. Reversing rotation on motors 108 and 120 will allow the cutters 136 to retract and the anchors 116 to retract for a fast trip out of the well using the slickline 102 .
FIG. 6 illustrates a scraper tool 200 run on slickline 202 connected to a control package 204 that can in the same way as the package 104 discussed with regard to the FIG. 5 embodiment, selectively turn on the scraper 200 when the proper depth is reached. A battery pack 206 selectively powers the motor 208 . Motor shaft 210 is linked to drum 212 for tandem rotation. A gear assembly 214 drives drum 216 in the opposite direction as drum 212 . Each of the drums 212 and 216 have an array of flexible connectors 218 that each preferably have a ball 220 made of a hardened material such as carbide. There is a clearance around the extended balls 220 to the inner wall of the tubular 222 so that rotation can take place with side to side motion of the scraper 200 resulting in wall impacts on tubular 222 for the scraping action. There will be a minimal net torque force on the tool and it will not need to be anchored because the drums 212 and 216 rotate in opposite directions. In the alternative, there can be but a single drum 212 as shown in FIG. 7 . In that case the tool 200 needs to be stabilized against the torque from the scraping action. One way to anchor the tool is to use selectively extendable bow springs 224 that are preferably retracted for run in with slickline 202 so that the tool can progress rapidly to the location that needs to be scraped. Other types of driven extendable anchors could also be used and powered to extend and retract with the battery pack 206 . The scraper devices 220 can be made in a variety of shapes and include diamonds or other materials for the scraping action.
FIG. 9 shows using a slickline 400 conveyed motor to set a mechanical packer 403 . The tool 400 includes a disconnect 30 , a battery 34 , a control unit 401 and a motor unit 402 . The motor unit can be a linear motor, a motor with a power screw or any other similar arrangements. When motor is actuated, the center piston or power screw 408 which is connected to the packer mandrel 410 moves respectively to the housing 409 against which it is braced to set the packer 403 .
In another arrangement, as illustrated in FIG. 10 , a tool such as a packer or a bridge plug is set by a slickline conveyed setting tool 430 . The tool 430 also includes a disconnect 30 , a battery 34 , a control unit 401 and a motor unit 402 . The motor unit 402 also can be a linear motor, a motor with a power screw or other similar arrangements. The center piston or power screw 411 is connected to a piston 404 which seals off using seals 405 a series of ports 412 at run in position. When the motor is actuated, the center piston or power screw 411 moves and allow the ports 412 to be connected to chamber 413 . Hydrostatic pressure enters the chamber 413 , working against atmosphere chamber 414 , pushing down the setting piston 413 and moving an actuating rod 406 . A tool 407 thus is set.
FIG. 11 illustrates a deviated wellbore 500 and a slickline 502 supporting a bottom hole assembly that can include logging tools or other tools 504 . When the assembly 504 hits the deviation 506 , forward progress stops and the cable goes slack as a signal on the surface that there is a problem downhole. When this happens, different steps have been taken to reduce friction such as adding external rollers or other bearings or adding viscosity reducers into the well. These systems have had limited success especially when the deviation is severe limiting the usefulness of the weight of the bottom hole assembly to further advance downhole.
FIG. 12 schematically illustrates the slickline 502 and the bottom hole assembly 504 but this time there is a tractor 508 that is connected to the bottom hole assembly (BHA) by a hinge or swivel joint or another connection 510 . The tractor assembly 508 has onboard power that can drive wheels or tracks 512 selectively when the slickline 502 has a detected slack condition. Although the preferred location of the tractor assembly is ahead or downhole from the BHA 504 and on an end opposite from the slickline 502 placement of the tractor assembly 508 can also be on the uphole side of the BHA 504 . At that time the drive system schematically represented by the tracks 512 starts up and drives the BHA 504 to the desired destination or until the deviation becomes slight enough to allow the slack to leave the slickline 502 . If that happens the drive system 512 will shut down to conserve the power supply, which in the preferred embodiment will be onboard batteries. The connection 510 is articulated and is short enough to avoid binding in sharp turns but at the same time is flexible enough to allow the BHA 504 and the tractor 508 to go into different planes and to go over internal irregularities in the wellbore. It can be a plurality of ball and socket joints that can exhibit column strength in compression, which can occur when driving the BHA out of the wellbore as an assist to tension in the slickline. When coming out of the hole in the deviated section, the assembly 508 can be triggered to start so as to reduce the stress in the slickline 502 but to maintain a predetermined stress level to avoid overrunning the surface equipment and creating slack in the cable that can cause the cable 502 to ball up around the BHA 504 . Ideally, a slight tension in the slickline 502 is desired when coming out of the hole. The mechanism that actually does the driving can be retractable to give the assembly 508 a smooth exterior profile where the well is not substantially deviated so that maximum advantage of the available gravitational force can be taken when tripping in the hole and to minimize the chances to getting stuck when tripping out. Apart from wheels 512 or a track system other driving alternatives are envisioned such a spiral on the exterior of a drum whose center axis is aligned with the assembly 508 . Alternatively the tractor assembly can have a surrounding seal with an onboard pump that can pump fluid from one side of the seal to the opposite side of the seal and in so doing propel the assembly 508 in the desired direction. The drum can be solid or it can have articulated components to allow it to have a smaller diameter than the outer housing of the BHA 504 for when the driving is not required and a larger diameter to extend beyond the BHA 504 housing when it is required to drive the assembly 508 . The drum can be driven in opposed direction depending on whether the BHA 504 is being tripped into and out of the well. The assembly 510 could have some column strength so that when tripping out of the well it can be in compression to provide a push force to the BHA 504 uphole such as to try to break it free if it gets stuck on the trip out of the hole. This objective can be addressed with a series of articulated links with limited degree of freedom to allow for some column strength and yet enough flexibility to flex to allow the assembly 508 to be in a different plane than the BHA 504 . Such planes can intersect at up to 90 degrees. Different devices can be a part of the BHA 504 as discussed above. It should also be noted that relative rotation can be permitted between the assembly 508 and the BHA 504 which is permitted by the connector 510 . This feature allows the assembly to negotiate a change of plane with a change in the deviation in the wellbore more easily in a deviated portion where the assembly 508 is operational.
The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below:
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A wellbore cleanup tool is run on slickline. It has an onboard power supply and circulation pump. Inlet flow is at the lower end into an inlet pipe that keeps up fluid velocity. The inlet pipe opens to a surrounding annular volume for sand containment and the fluid continues through a screen and into the pump for eventual exhaust back into the water in the wellbore. A modular structure is envisioned to add debris carrying capacity. Various ways to energize the device are possible. Other tools run on slickline are described such as a cutter, a scraper and a shifting tool.
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This is a continuation of application Ser. No. 06/735,149 filed May 17 1985, now abandoned which was a continuation-in-part of application Ser. No. 06/619,583 filed 11 June 1984, also now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Citrate esters are useful as plasticizers for polyvinyl chloride (PVC) resins as certain of these esters provide a low order of toxicity when compared to phthalate esters which have been conventionally used. Other advantages have been noted using certain citrate esters as plasticizers in PVC compositions and articles, including improved resistance to soapy water extraction and low temperature and transport properties.
The preparation of the citrate esters has been found to be significantly enhanced by the utilization of certain organic titanate catalysts which allow the excess alcohol to be removed after the esterification step.
2. Description of the Prior Art and Objectives of the Invention
Citrate esters commercially produced using citric acid have long been available and have been used as plasticizers for PVC resins. However, the performance of articles produced from the PVC resin compositions whether utilizing citrate esters known to date or conventional phthalate plasticizers have had many inherent disadvantages. For example, medical-grade PVC compositions are used to form blood bags, tubing and a variety of health-related articles and in recent years toxicity has been a major concern for manufactures of such articles. Recent reports have identified di-2-ethylhexyl phthalate (DEHP) or (DOP) and di-2-ethyl-hexyl adipate (DEHA) as hepatocarcinogens in rodents. While certain of the phthalates have excellent plasticizing qualities, their suspected carcinogenic nature renders them doubtful candidates for future medical-grade uses. As an alternative, known citric acid esters such as acetyltri-n-butyl and tri-n-butyl citrate were tried as PVC plasticizers in medical-grade applications but it was determined that these compounds were not entirely satisfactory due to their high soapy water extraction percentages and would therefore not be useful in many medical area applications. Also, it has been found that new production techniques had to be devised for the newer citric acid esters which were determined to have suitable toxicity and physical characteristics when used as PVC plasticizers.
It is therefore an objective of the present invention to provide PVC plasticizers which provide superior toxicity test results in biological studies.
It is also an objective of the present invention to provide plasticizers for PVC compositions which can be processed without difficulty using conventional extrusion, calendering, or plastisol techniques.
It is yet another objective of the present invention to provide new citric acid esters namely: acetyltri-n-hexyl citrate, n-butyryltri-n-hexyl citrate, acetyltri-n-(hexyl/octyl/decyl)citrate, and acetyltri-n-(octyl/decyl)citrate which can be used as plasticizers having desirable physical characteristics when imparted into PVC compositions.
It is still another objective of the present invention to provide PVC compositions and formed articles therefrom having superior results in toxicology studies concerning dermal toxicity, oral toxicity and genetic assays.
It is also an objective of the present invention to provide a new process for the low temperature manufacture of the four new citric acid esters utilizing organic titanates to provide economical and efficient production methods. be demonstrated to those skilled in the art as set forth in detail below.
SUMMARY OF THE INVENTION
Citrate esters of the formula: ##STR1## where R 1 , R 2 , and R 3 =CH 3 to C 18 H 37
R 4 =CH 3 to C 7 H 15
and more specifically acetyltri-n-hexyl citrate, n-butyryltri-n-hexyl citrate, acetyltri-n-(hexyl/octyl/decyl)citrate, and acetyltri-n-(octyl/decyl)citrate are produced utilizing an organic titanate catalyst and such esters have been found useful as medical-grade plasticizers in PVC compositions. The plasticizers have a low order to toxicity and inpart to PVC the proper balance of physical properties needed in health care and medical-grade uses. The production steps for the citric acid esters include low temperature esterification at 140° C. or below, removal of any excess alcohol and thereafter, alkoxylation. Conventional neutralization and finishing steps are then carried out. The alkoxylation step is carried out at a temperature less than approximately 110° C.
A PVC resin can be combined with one of the above-mentioned citric acid esters, along with suitable stabilizers and lubricants, to form a plasticized PVC which can be extruded, calendered or otherwise processed into suitable articles of manufacture including blood bags, tubing and other products. Articles so made have a low order of toxicity and provide superior extraction properties, particularly in soapy water extraction tests. The soapy water extraction test is a standard test, the results of which closely resemble the results obtained with body fluids such as human blood.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The four preferred forms of the citrate esters are as follows: ##STR2##
The preferred method of manufacture of the above-identified citrate esters comprises low temperature esterification below 150° C. and preferably at a temperature range of from 125° C. to 130° C. of the proper alcohol (such as n-hexyl alcohol for acetyltri-n-hexyl citrate) with citric acid in the presence of the organic titanate, tetra-n-butyl titanate, removal of any excess n-hexyl alcohol, and then alkoxylation of the esters produced with an acid anhydride. At esterification temperatures above 150° C. citrates undergo rapid degradation resulting in numerous products of decomposition. At temperatures somewhat below 150° C. the major decomposition product is an aconitate ester. The alkoxylation takes place at a temperature of below approximately 110° C. Tetra-n-butyl titanate is preferred since the ester interchange which takes place between the titanate alkyl groups and citrate alkyl groups does not result in the introduction of alkyl groups not normally present in the citrate esters.
The preferred PVC composition comprises blending and milling a medium molecular weight PVC resin with one of the above citrate esters on a two to one ratio, resin to plasticizer, along with stabilizers, lubricants and extenders as required. Articles manufactured from the preferred PVC compositions include blood bags, tubing and other articles for the medical and health care fields.
DETAILED DESCRIPTION OF THE INVENTION
Certain citrate esters, namely acetyltri-n-hexyl citrate, n-butyryltri-n-hexyl citrate, acetyltri-n-(hexyl/octyl/decyl)citrate and acetyltri-n-(octyl/decyl)citrate have been found to be particularly useful in medical applications when compounded with PVC resins through conventional plastisol, calendering or extrusion techniques. Such plasticized PVC exhibits good clarity, good low temperature properties, low volatility and low extractability into various media. Also, a low order of acute toxicity has been shown and complete compatibility with medium molecular weight PVC resins make the four named esters unique and valuable. Studies have shown that the four citrate esters are not toxic substances, primary skin irritants or ocular irritants to unrinsed eyes and oral administration has produced no signs of systemic toxicity and has shown no mortality in fasted mice or rats. Genetic toxicology assays for detecting mutagenic activity at the gene or chromosomal level have shown that these esters do not induce gene mutation in either microbial cells or in mammalian cells in vitro or chromosomal mutation in vivo or in vitro. Studies have also shown that under in vivo conditions, these citrate esters hydrolyze rapidly and completely in concentrations at expected realistic levels of human exposure.
Preparation of the citrate esters are as follows:
Example 1
Preparation of acetyltri-n-hexyl citrate
330 lbs. of n-hexyl alcohol, 180 lbs. of citric acid and 1.54 lbs. of tetra-n-butyl titanate and 15 gallons of heptane are charged to a vessel equipped with agitator, thermometer, vapor column, condenser and a decanter set to allow removal of water formed during the reaction while refluxing heptane. The esterification is effected at 140° C. to maintain the aconitate (THA) level below 0.5% for general production. As shown in FIG. 1 the aconitate level can be kept well below the 0.2% range by longer reaction times at lower temperatures with the optimum time, and aconitate levels reached by temperatures of from approximately 125° C. to 130° C. As shown, at a temperature of approximately 130° C. a unique result is achieved in that the aconitate formation levels out to provide a citrate ester having excellent purity. During esterification water is periodically removed from the decanter in order to maintain proper temperature and reaction rates. The esterification is continued until the esterification mixture tests 0.5% maximum acidity calculated as citric acid although lower temperature esterification and acidity percentage may be used for higher purity products as mentioned above. Next, the vessel is cooled to 120° C. and any water is removed from the separator and any heptane therein is also removed for future use. The reflux line of the vessel is closed and pressure on the system is reduced slowly. The kettle is heated to 130°-140° C. and steam is introduced to help remove any residual alcohol. This vacuum stream stripping is continued until alcohol cannot be detected by conventional laboratory tests. When no more alcohol can be found, the steam is discontinued and the temperature is reduced to 100° C. and the vacuum is broken with nitrogen gas.
Next, 0.4 lb. concentrated sulfuric acid (H 2 SO 4 ) is charged into the vessel after which it is sealed and approximately 107 lbs. of acetic anhydride (in a determined molar amount) are added at a slow rate so that the temperature does not exceed 110° C. When all the anhydride has been added, agitation of the mix continues for approximately one hour until the acetylation reaction has been completed.
Next, a full vacuum is put on the system and enough heat is added for distillation to proceed at a suitable rate. This step continues until acetic acid is shown to be 5% or less by conventional lab tests whereupon the mixture is cooled to 75° C. for neutralization.
The remaining steps of neutralization, bleaching, washing, etc. are carried out as in conventional esterification processes.
Example 2
Preparation of n-butyryltri-n-hexyl citrate
The vessel used in example 1 is again charged with 330 lbs. of n-hexyl alcohol, 180 lbs. of citric acid and 1.54 lbs. of tetra-n-butyl titanate. Esterification is carried out as in example 1 as is the heptane-alcohol strip. Butyrylization is thereafter done with the addition of 0.4 lbs. of concentrated sulfuric acid and 166 lbs. of n-butyric anhydride as shown above in the acetylation process. The butyric acid may be removed as shown above or by neutralization.
Examples 1 and 2 produce esters with the following characteristics:
______________________________________ANALYTICAL DATA Acetyltri-n-hexyl n-Butyryltri-n-hexylProperty Citrate Citrate______________________________________Purity wt % 99 99Color APHA 50 max. 50 maxNeut. No. mg KOH/g 0.2 max. 0.2 max.Moisture K.F. 0.25 max. 0.25 max.S.G. @ 25/25° C. 1.0045-1.0055 0.991-0.995R.I. @ 25/25° C. 1.445-1.447 1.444-1.448Viscosity @ 25° C. cps 25-35 25-35Odor @ 25° C. Little or none Little or noneHeat Stability(2 Hrs. @ 150° C.)Color APHA 50-60 50-60Neut. No. mg KOH/g 0.2 max. 0.2 max.Odor @ 25° C. Mild Mild______________________________________
It has been determined that a citrate ester yield can be achieved of 99+% purity with a minimum of aconitate formation and unaceylated esters by lowering the esterification temperatures to 130° C. or below with a preferable temperature range of 125° C. to 130° C. Table A and FIG. 1 demonstrate the percentage of tri-n-hexyl aconitate (THA) formed during the production of acetyltri-n-hexyl citrate whereby the reaction is terminated at approximately 0.2% acidity, as citric acid. As shown in Table A and FIG. 1 below, the aconitate levels range from approximately 0.14 to 0.19 with a reaction time of from 25 to 19 hours at temperatures of from 125° C. to 130° C. It has been determined that by lowering the temperature from 140° C. to 130° C. an additional reaction time of only 90 minutes is required with the aconitate level dropping from 0.35 to 0.19%, a decrease of approximately 45%. As shown, the aconitate level can be tremendously decreased by lowering the temperature approximately 10 degrees from 140° C. to 130° C. without substantially increasing the reaction time based on 0.2% acidity (citric acid) as the reaction completion indicator. As shown in FIG. 1 a stabilization of the aconitate formation occurs during esterification at a critical temperature of approximately 130° C. providing a technique for the manufacture of high purity esters having low aconitate levels. Lower aconitate percentages and other impurities provide the high quality plasticizer needed for medical-grade products.
TABLE A______________________________________Reaction Time and AconitateFormation Rates at Various TemperaturesEsterification Reaction Final THA % Acidity AsTemperature (°C.) Time (Hrs.) Content (%) Citric Acid______________________________________120 241/4 0.07 0.17125 25 0.14 0.17130 19 0.19 0.17140 171/2 0.41 0.16150 13 0.59 0.19______________________________________
It is believed that acids such as citric acid with low pK values exhibit a synergistic effect with titanate catalysts at low temperatures in the 150° C. or lower range. Phthalic acid which has a high pk value will not undergo esterification with the titanate catalysts at these low temperatures.
Also, other organic titanate catalysts can be used to produce the four (4) esters of this invention such as tetrakis-2-ethylhexyl titanate although superior results have been demonstrated using tetra-n-butyl titanate.
______________________________________PREPARATION AND TESTING OF PVC COMPOSITIONS PARTS BYFORMULATION WEIGHT______________________________________Resin (Medium Molecular Weight PVC) 100Plasticizer 50Stabilizer (Calcium/Zinc) 2.5Lubricant (stearic acid) 0.25______________________________________
The above formulation was blended and milled for 5-10 minutes at 325° to 340° F. The milled stock was pressed (3 min. at 340°-360° F. and 32,000 psi) to 40- and 70-mil sheets, and aged for 48 hours at room temperature for evaluation. All tests were made with samples cut from 70-mil pressed stock except for extraction tests which were obtained on 40-mil samples. The performance data was obtained by accepted ASTM methods with modifications as detailed below in Table B.
______________________________________Tensile Strength Determined with Instron TT, 1100Ultimate Elongation series (2 in./min.) using aModulus (100% elongation) dumbbell-shaped specimen. Test(ASTM D638) carried out at 70° ± 5° F.Hardness Determined with Shore Durometer A(ASTM D676) (10 sec.) at 75° ± 5° F.Torsional Flex (T.sub.4 and T.sub.f) Determined with Torsion Flex(ASTM D1043) Tester suspended Clash and Berg design. T.sub.4 is the temperature at which the Modulus of Rigidity is 10,000 psi; T.sub.f is the temperature at which the Modulus of Rigidity is 100,000 psi.Brittle Point Determined by impact method using(ASTM D746) Scott Tester, Model EVolatile Loss (A/C) Determined on specimens 2 inches in(ASTM D1203) diameter heated in activated carbon at 70° C. for 24 hours. Results are expressed as percent of plasticizer lost.Water extraction (Tap) Determined on specimens 2 inches inSoapy Water Extraction diameter suspender in appropriate(1% Ivory Flakes) liquid at 60° C. for 24 hours.Oil Extraction Results are expressed as percent(ASTM NO. 3) of plasticizer lost.Migration Loss (silica) Determined on specimens 2 inches in diameter heated in silica (100 mesh), at 70° C. for 24 hours. Results are expressed as percent or plasticizer lost.Volatile Loss (air) Determined by Oven Method (24 hr. at 100° C.) on specimens 2 inches in diameter. Results are expressed as percent of plasticizer lost.______________________________________
TABLE B__________________________________________________________________________(PLASTICIZER PERFORMANCE DATA)PLASTICIZER DEHP DEHA #1 #2 #3 #4 #5__________________________________________________________________________HARDNESS, 79 78 78 81 81 87 87Durometer A, 10 Sec.TENSILE, psi 2748 1797 2862 2978 2924 2743 2789ULTIMATE 395 414 400 390 427 364 374ELONGATION, %100% MODULUS, psi 1368 1092 1348 1574 1362 1656 1704T.sub.4 (10,000 psi), -8.4 -30.8 -7.6 -9.1 -11.9 -6.9 -4.0°C.T.sub.f (100,000 psi), -38.8 -66.5 -35.6 -41.6 -48.7 -53.1 -59.7°C.BRITTLE POINT, °C. -24.5 -56.5 -18.5 -26.0 -33.5 -36.8 -37.8VOLATILE LOSS, (air), % 4.8 7.1 12.1 2.6 1.7 .3 .1VOLATILE LOSS, (A/C), % 3.4 7.6 7.0 1.7 1.4 2.8 4.5WATER EXTRACTION, % .7 1.5 1.2 1.9 1.7 1.5 3.3SOAPY WATER 2.7 11.0 9.5 5.4 2.2 3.4 2.4EXTRACTION, %OIL EXTRACTION, % 11.4 34.7 10.9 13.8 15.7 15.2 19.3SILICA GEL MIGRATION, % 12.2 23.0 17.0 4.4 3.6 4.8 7.4__________________________________________________________________________ #1 acetyltrin-butyl citrate #2 acetyltrin-hexyl citrate #3 nbutyryltri-n-hexyl citrate #4 acetyltrin-(hexyl/octyl/decyl) citrate #5 acetyltrin-(octyl/decyl) citrate
The plasticizer performance data in Table C demonstrates the results of tests with citric esters/expoxidized soybean oil (ESO) blends. ESO is commonly used in conjunction with DEHP at levels in the range of 1-5% based on DEHP as an aid in stabilization. The ratio of 2.5/97.5 ESO/citrate was used as a base point in the studies. Test results on this combination are shown in column 1. A significant improvement in properties, particularly soapy water extraction is noted.
TABLE C__________________________________________________________________________(PLASTICIZER PERFORMANCE DATA)PLASTICIZER 2.5 ESO 20 ESO 40 ESO 40 ESO 40 ESOPERCENTAGES: 97.5 #2 80 #2 60 #2 60 #3 60 #5__________________________________________________________________________HARDNESS, 81 80 80 81 85Durometer A, 10 Sec.TENSILE, psi 2907 3010 3079 3165 3097ULTIMATE 422 424 420 428 395ELONGATION, %100% MODULUS, psi 1415 1429 1491 1514 1779T.sub.4 (10,000 psi) -9.5 -7.8 -7.7 -8.2 -5.4°C.T.sub.4 (100,000 psi) -41.8 -41.3 -39.3 -41.8 -50.3°C.BRITTLE POINT, °C. -26.5 -25.5 -20.5 -24.5 -26.5VOLATILE LOSS, (Air), % 2.4 2.1 1.5 .8 .5VOLATILE LOSS, (A/C), % 1.3 1.6 1.4 .9 1.1WATER EXTRACTION, % 1.3 .9 .6 .8 1.0SOAPY WATER 2.9 2.9 6.4 4.8 3.8EXTRACTlON, %OIL EXTRACTION, % 13.0 11.6 10.1 10.0 12.9SILICA GEL MIGRATION, % 5.7 5.3 4.7 4.0 2.5__________________________________________________________________________ ESO Ester/epoxidized Soybean Oil #2 acetyltrin-hexyl citrate #3 nbutyryltri-n-hexyl citrate #5 acetyltrin-(octyl/decyl) citrate
Since ESO is less expensive than citrates, a reduction in plasticizer cost results if ESO can be substituted for part of the citrates. Results of tests with higher ESO/citrate ratios as shown in columns 2-5 of Table C and a significant improvement in properties up to and perhaps beyond the ratio of 20/80 ESO/citrate ratio as shown.
Various other PCV compositions can be formulated and the examples and illustrations shown herein are for illustrative purposes and are not intended to limit the scope of the invention.
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Citrate esters are formed utilizing organic titanates as a catalyst allowing excess alcohol to be removed. Four citrate esters have been found which provide advantageous plasticizing properties to PVC compositions which include superior toxicity test results and superior soapy water extraction test results. The four citrate esters are: acetyltri-n-hexyl citrate, n-butyryltri-n-hexyl citrate, acetyltri-n-(hexyl/octyl/decyl) citrate, and acetyltri-n-(octyl/decyl) citrate. Articles formed from the PVC plasticized mixtures are extremely useful in the medical or health care field as they demonstrate a low order of toxicity.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 12/572,558, filed on Oct. 2, 2009, which claims the benefit of U.S. Provisional Patent Application No. 61/102,338 filed Oct. 2, 2008 whose contents are incorporated herein for all purposes.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to lighting sources and more particularly to a light source with flashlight, e.g. for projecting a beam of light, and lantern function, e.g. for a 360 degree light source.
[0004] 2. Description of the Prior Art
[0005] Portable lighting is typically designed with the task in mind. Accordingly, flashlights are designed to focus a beam of light for peering into dark corners or cast light longer distances. In contrast, lanterns are designed for general lighting to cast light short distances but in all directions.
[0006] Conventional flashlights are designed to be powered by batteries installed within a barrel of the flashlight rearwardly of the light source. Because of this placement of the batteries with respect to the light source, it is generally impossible for the flashlight to also be tasked to provide lantern-like lighting in a full circle. Instead, and because the battery placement would block at least some of the light from the light source, such devices are designed to provide general task lighting at an obtuse angle rather than one that is greater than 180 degrees much less a full 360 degrees.
[0007] Accordingly, the need exists for a combination lighting device that fulfills both a flashlight function and a lantern function to maximize illumination.
SUMMARY OF THE INVENTION
[0008] In various representative aspects, the present invention describes a multipurpose lighting device.
[0009] A multipurpose lighting device comprising a flashlight end, a lantern end including a barrel through which light may pass, and a module mounted between the flashlight end and lantern end. The module includes a first light source configured to direct light out the flashlight end, and a second light source configured to direct light out the lantern end. The second light source is disposed on an opposite end of the module from the first light source. The module further includes a power source configured to energize the first light source and second light source, wherein the second light source is oppositely disposed on the module from the first light source.
[0010] A module housing encloses the module and including a housing button located on the outside of the housing that aligns with the button coupled to the module. Actuating the housing button also serves to actuate the module button so that the multipurpose lighting device is operated. Furthermore, the second light source may emit a colored light. Also, successive actuations of the button may operate the device to operate the first light source only, the second light source only, or the second light source in a repeating flash mode.
[0011] The foregoing and other objects, features and advantages of the invention will become more readily apparent from the following detailed description of a preferred embodiment of the invention that proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a front perspective view of a lighting device implemented according to a preferred embodiment of the invention.
[0013] FIG. 2 is a rear perspective view of the lighting device of FIG. 1 implemented according to a preferred embodiment of the invention.
[0014] FIG. 3 is a partial exploded front perspective view of the lighting device of FIG. 1 .
[0015] FIG. 4 is a side-elevation view of the lighting device of FIG. 1 .
[0016] FIG. 5 is a side-section view of the lighting device of FIG. 1 .
[0017] FIG. 6 is a fully exploded view of the lighting device of FIG. 1 .
[0018] FIGS. 7-15 illustrate various views of an alternate form factor from the embodiment of FIGS. 1-6 implementing a two-sided lighting module per the teachings of the invention and also including a trapdoor feature.
DETAILED DESCRIPTION
[0019] FIGS. 1 , 2 , and 4 illustrate a multipurpose lighting device 10 according to a preferred embodiment of the invention. Device 10 is comprised of a device body having a front housing comprising an opaque module housing 12 and end cap 16 defining a flashlight end, and a rear housing in a lantern end of the device 10 defining a transparent or translucent barrel 14 through which light is capable of passing along a substantial length of the barrel 14 . The barrel 14 is releasably affixed to the module housing 12 as by threading the barrel 14 into housing 12 (as shown in FIG. 6 ) or via hooks on the barrel 14 that engage with housing 12 when inserted and rotated a quarter turn.
[0020] A button 18 is defined on a surface of the module housing 12 and interfaces with a button on a lighting module 20 ( FIG. 3 ) as will be described further below. The lantern housing 14 includes multiple ribs 22 running along the length of and spaced circumferentially about the barrel 14 . The ribs 22 act to provide a non-slip grippable surface and further assist in dispersing light emitted from a rearwardly directed second light source 36 ( FIG. 3 ) that passes through the transparent or translucent sidewalls of the lantern portion of the device 10 . A flange 24 is fixed at an end of the module housing 12 and couples with a detachable wrist strap (not shown).
[0021] As illustrated in FIG. 3 , the module housing 12 defines a hollow interior 28 into which the lighting module 20 is installed. Female threads ( FIG. 5 ) formed on the inside walls of the end cap 16 mate with male threads ( FIG. 3 ) formed on the end of the module housing 12 , thereby enclosing the interior 28 and fixing the lighting module 20 within the lighting device 10 .
[0022] The lighting module includes two opposable light sources, shown by flashlight LED 34 and lantern LED 36 . Both light sources 34 , 36 are actuated by a button 38 formed on the lighting module that, itself, is aligned with an actuated by the button 18 formed on the module housing 12 .
[0023] FIG. 3 shows the end cap 16 removed from the end of the module housing 12 . As will be appreciated, the multipurpose lighting device 10 includes a flashlight function, and a lantern function where the power source (e.g. batteries 56 a , 56 b , 56 c [ FIG. 6 ]) does not interfere with the lantern light source so that it is capable of casting light in all radial directions out the lantern end of the device. The device thus provides a useful multipurpose tool for emergencies or just general use.
[0024] Turning to FIGS. 5 and 6 , the lighting module 20 is shown installed within the module housing 12 of the device 10 . Module 20 may include a rounded lower end terminating in elongate ridges running the length of the module. Complementary molded portions may be formed on inside walls of the cavity 28 that are slidingly engaged with the ridges when the lighting module 20 is installed. The cavity 28 of the module housing 12 is thus shaped by the molded portions 50 a , 50 b and by the dimensions of the cavity to locate the lighting module at a specific point so that (a) the lighting module button 38 is aligned with the button 18 formed on the outside of the module housing 12 , and (b) the flashlight LED 34 inserts properly within a shaped reflector 52 so that the light may be focused and projected outward through a forward-facing lens or transparent front 54 located within cap 16 . A power source, such as batteries 56 a , 56 b , and 56 c , is installed within the lighting module 20 to power the LEDs 34 , 36 and electronics necessary to selectively actuate the lights according to the table below.
[0025] As shown in FIG. 5 , button 18 includes an elastomeric top portion that resiliently deforms under downward pressure to force a hard contact against the aligned button 38 of the lighting module 20 . Multiple clicks on the button 38 operate control electronics within the module to function progressively as shown in Table 1 below, namely:
[0000] TABLE 1 Button Operation of the Device Button Press Operation 1 flashlight LED 34 turned ON (lantern LED 36 remains OFF) 2 lantern LED 36 turned ON (flashlight LED 34 remains ON) 3 flashlight LED 34 turned OFF (lantern LED 36 remains ON) 4 lantern LED 36 FLASHED intermittently as emergency light (flashlight LED 34 remains OFF) 5 lantern LED 36 turned OFF (flashlight LED 34 remains OFF) 6 cycle back to operation for button press 1 . . .
The above operations are examples of use and not all are required to fulfill the spirit of the invention or required for implementation.
[0026] Turning lastly to the lantern operation, and as shown best in FIG. 5 , lantern LED 36 illuminates within the elongate chamber 58 formed within the lantern housing 14 . It is preferred that the chamber 58 be hollow and removable from module housing 12 so that it may be used as an illuminated storage chamber. Light emitted from the LED 36 is internally reflected within the elongate lantern chamber 58 and scatters out the sidewalls of the housing 14 to form a fairly even glow along its length. That is, the lantern LED 36 is directed along a long axis of the barrel 14 and radiates radially from the barrel along its periphery to result in a lantern that radiates in 360 degrees from along the long axis. Alternately, the lantern LED 36 is configured to emit light omni-directionally into the hollow elongate chamber 58 and out the sidewalls of the barrel 14 . The whole, with ribs 22 , operates to better diffuse the illumination along the entire length of the lantern housing 14 . In this way, the housing may or may not include the hollow interior 58 , and may or may not include a solid core (not shown) of a diffusive and/or light scattering material.
[0027] In a preferred embodiment, LED 36 gives off a colored light (e.g. red or blue). Alternately, LED 36 can emit a white light and the lantern housing 14 can be formed of a colored translucent or transparent plastic material. As shown best in FIG. 6 , lantern housing 14 includes an O-ring 60 on an outside wall that bears against the inside wall of module housing 12 when the two housings are screw-fitted together. The O-ring 60 helps to prevent water from seeping into the hollow interior 28 of the module housing 12 and thereby adversely affecting the lighting module.
[0028] The multipurpose lighting device is useful in that it uses, in its preferred implementation, a single power source and actuator (e.g. button 18 ) to alternately operate a flashlight and lantern. In special emergencies, therefore, a single device can thus project light a far distance (flashlight), provide general lighting (lantern), or flash colored light in all directions. The multipurpose lighting device is further useful in that it may include a hollow storage chamber 58 for holding items such as keys, first aid materials, etc. and that such items may be illuminated by the lantern LED 36 when actuated by button 18 . Access to the hollow storage chamber 58 within the lantern end 14 of the lighting device 10 may be by disengaging the lantern end 14 from the module housing 12 of the device. In the embodiment shown in FIG. 6 , threads 32 formed on an outside of the barrel 14 engage with complementary threads 30 on the inside of the housing 12 . In alternate embodiments, hooks (not shown) formed on the barrel engage with complementary structures within the module housing when the barrel is inserted and then turned within the housing 12 .
[0029] FIGS. 7-12 illustrate perspective, rear, top and side elevations of a spotlight form factor 110 implementing the teachings of the invention. The outer shell of the spotlight device 110 includes similar general features as that described above with respect to flashlight 10 . A module housing 112 and end cap 116 define the flashlight (front) end of the housing. The translucent lantern end 114 of the housing encloses a hollow chamber 128 ( FIG. 15 ) accessible by a trapdoor 170 hingedly attached to the rear portion of the lantern end 114 of the device housing.
[0030] FIG. 7 is a perspective view of spotlight 110 . The flashlight end of the housing 112 has a general circular shape and retains (as shown in the exploded view of FIG. 13 ) the lighting module 120 , reflectors 152 , and transparent lens 158 configured to project one or more beams of light forwardly of the device 110 . The lantern (rear) portion of the device 110 has a generally square cross-section and includes a handle 162 and wrist strap 164 . The outer shell of the lantern end 114 is made of a translucent material so that light shown into the interior cavity 128 of the rear portion is transmitted through the exterior surfaces of the shell.
[0031] FIG. 13 is an exploded view showing assembly of the components of the spotlight device 110 . A lighting module 120 , installed within the module housing 112 of the device 100 , includes among other elements a forward-facing bank of LEDs 134 , batteries 156 , and a rear-facing bank of LEDs 136 . Each of the LEDs within the forward-facing bank of LEDs 134 are received within respective reflector portions of reflector 152 so that each are individually focused forwardly. A rubber O-ring 160 is received around the threads 132 of the housing 112 so that the seal between the cap 116 and housing 112 is watertight when the cap and housing are screw-fitted together. An elastomeric button 118 and complementary parts interfaces with a button 138 on lighting module 120 for operating the lights of the module. The button may be coupled to a timer circuit that maintains the LEDs in an on position for only a preset amount of time after which point the LEDs turn off in order to save power should the button be inadvertently activated and left as may take place in a retail environment where a customer tries the light but forgets to turn it off. Finally, a trapdoor 170 is attached via hinge 172 to the back end of lantern end 114 so that it pivots up out of the way for access to an interior cavity within the end 114 . The trapdoor 170 is releasably retained in a closed position via clasp 174 , buckle, key, or other contemplated device. One or more O-rings 176 are captured between the trapdoor 170 and rear face of the opening to effect a water-tight seal.
[0032] FIG. 14 is a perspective view showing the spotlight device 110 with the trapdoor 170 opened and two clasps 174 a , 174 b released.
[0033] FIG. 15 shows a sectioned view of the spotlight device 110 of FIG. 14 . The trapdoor 170 pivots out of the way to access the interior storage compartment 128 of the spotlight 110 . This compartment 128 may be further illuminated by the rear-facing bank of LEDs 136 .
[0034] Having described and illustrated the principles of the invention in a preferred embodiment thereof, it should be apparent that the invention can be modified in arrangement and detail without departing from such principles. We claim all modifications and variation coming within the spirit and scope of the invention.
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A multipurpose lighting device comprising a flashlight end, a lantern end including a barrel through which light may pass, and a module mounted between the flashlight end and lantern end. The module includes a first light source configured to direct light out the flashlight end, and a second light source configured to direct light out the lantern end. The second light source is disposed on an opposite end of the module from the first light source. The module further includes a power source configured to energize the first light source and second light source, wherein the second light source is oppositely disposed on the module from the first light source.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. Ser. No. 11/444,837, filed Jun. 1, 2006, which application is a continuation of U.S. Ser. No. 10/948,827, filed Sep. 23, 2004, which application is a continuation of U.S. Ser. No. 10/731,825, filed Dec. 9, 2003, which application is a continuation of U.S. Ser. No. 10/057,597, filed Jan. 25, 2002, which claims priority to U.S. Ser. No. 60/281,344, filed Apr. 4, 2001, and German Patent Application No. 101 06 970.7 filed Feb. 15, 2001, each of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to the hydrochloride of 4-[4-(2-pyrrolylcarbonyl)-1-piperazinyl]-3-trifluoromethylbenzoylguanidine, processes for preparing it and its use in preparing a pharmaceutical composition.
BACKGROUND OF THE INVENTION
[0003] A number of benzoylguanidine derivatives are known in the art. Thus, for example, International Patent Application WO 00/17176 discloses benzoylguanidine derivatives which are characterized by valuable pharmacological properties. These compounds are effective against arrhythmias which occur in hypoxia, for example. They may also be used for complaints connected with ischaemia (such as cardiac, cerebral, gastrointestinal (such as mesenteric thrombosis/embolism), pulmonary or renal ischaemia, ischaemia of the liver, and ischaemia of the skeletal muscles). Corresponding indications include, for example, coronary heart disease, cardiac infarct, angina pectoris, stable angina pectoris, ventricular arrhythmia, subventricular arrhythmias, cardiac insufficiency, and also for assisting bypass operations, for assisting open heart surgery, for assisting operations which require an interruption to the blood supply to the heart and to assist in heart transplants, embolism in the pulmonary circulation, acute or chronic kidney failure, chronic renal insufficiency, cerebral infarct, reperfusion damage in the restoration of blood supply to areas of the brain after the break-up of vascular occlusions, and acute and chronic circulatory disorders of the brain. The abovementioned compounds may also be used in such cases in conjunction with thrombolytic agents such as t-PA, streptokinase, and urokinase.
[0004] During reperfusion of the ischemic heart (e.g., after an attack of angina pectoris or a cardiac infarct) irreversible damage may occur to cardiomyocytes in the affected region. In such cases the compounds have a cardioprotective effect, inter alia.
[0005] The category of ischaemia should also include the prevention of damage to transplants (e.g., as protection for the transplanted organ, such as, for example, liver, kidney, heart, or lung, before, during, and after implantation and during the storage of the transplant organs), which may occur in connection with transplantation. The compounds disclosed in WO 00/17176 are also pharmaceutical compositions with a protective effect in carrying out angioplastic surgical interventions on the heart and on peripheral blood vessels.
[0006] In essential hypertension and diabetic nephropathy the cellular sodium-proton exchange is increased. The compounds are therefore suitable as inhibitors of this exchange for the preventive treatment of these diseases.
[0007] The compounds are further characterized by a powerful inhibiting effect on the proliferation of cells. Therefore, the compounds are useful as medicaments in diseases where cell proliferation plays a primary or secondary part and may be used as agents against cancers, benign tumors or, for example, prostatic hypertrophy, atherosclerosis, organ hypertrophy and hyperplasia, fibrotic diseases, and late complications of diabetes.
[0008] The abovementioned pharmacologically valuable properties of the benzoylguanidine derivatives disclosed in the prior art are the main prerequisite for effective use of a compound as a pharmaceutical composition. An active substance, however, has to satisfy still more requirements in order to be allowed to be used as a medicament. These parameters are largely connected to the physico-chemical nature of the active substance.
[0009] Without being restricted thereto, examples of these parameters are the stability of effect of the starting substance under different ambient conditions, stability during the production of the pharmaceutical formulation, and stability in the finished compositions of the medicament. The pharmaceutical active substance used to prepare the pharmaceutical compositions should therefore have high stability which must also be guaranteed even under different ambient conditions. This is absolutely necessary to prevent the use of pharmaceutical compositions which contain breakdown products of the active substance, for example, in addition to the active substance itself. In such a case, the content of active substance present in pharmaceutical formulations may be lower than specified.
[0010] The absorption of moisture reduces the content of pharmaceutical active substance because of the increase in weight due to the uptake of water. Pharmaceutical compositions with a tendency to absorb moisture have to be protected from moisture during storage, for example, by the addition of suitable drying agents or by storing the pharmaceutical composition in an environment which is protected from damp. Moreover, the uptake of moisture may reduce the content of pharmaceutical active substance during manufacture if the pharmaceutical composition is exposed to the environment without any protection from moisture whatsoever. Preferably, therefore, a pharmaceutical active substance should be only slightly hygroscopic.
[0011] As the crystal modification of an active substance can influence the activity of a pharmaceutical composition, it is necessary to clarify any existing polymorphism of an active substance present in crystalline form as much as possible. If there are different polymorphic modifications of an active substance, care must be taken to ensure that the crystalline modification of the substance does not change in the subsequent pharmaceutical preparation. Otherwise, this could have a detrimental effect on the reproducible activity of the medicament. In this context, active substances which are characterized by limited polymorphism are preferred.
[0012] Another criterion which may be of exceptional importance in certain circumstances, depending on the choice of formulation or on the choice of the method of production of the formulation, is the solubility of the active substance. If, for example, pharmaceutical solutions are prepared (for example for infusions), it is essential that the active substance is sufficiently soluble in physiologically acceptable solvents. A sufficiently soluble active substance is also very important for pharmaceutical compositions administered orally.
[0013] The underlying aim of the present invention is to prepare a pharmaceutical active substance which is not only characterized by a potent pharmacological activity but also satisfies as far as possible the physico-chemical requirements referred to above.
DETAILED DESCRIPTION OF THE INVENTION
[0014] It has been found that the abovementioned aim is achieved by means of the compound 4-[4-(2-pyrrolylcarbonyl)-1-piperazinyl]-3-trifluoromethylbenzoylguanidine hydrochloride 1
[0015] The compound of formula 1 is not hygroscopic and dissolves readily in physiologically acceptable solvents. It is also characterized by a high degree of stability.
[0016] The methanesulfonate of formula 1′ disclosed in WO 00/17176
unlike the compound of formula 1, does not meet the requirements set out hereinbefore, however.
[0017] Accordingly, in one aspect, the present invention relates to the compound of formula 1 as such. In another aspect, the present invention relates to the compound of formula 1 in the form of its hydrates, preferably in the form of its monohydrate or hemihydrate.
[0018] In another aspect, the present invention relates to the use of the compound of formula 1 as a medicament. The present invention further relates to the use of the compound of formula 1, optionally in the form of its hydrates, for preparing a pharmaceutical composition for treating diseases in which inhibitors of the cellular Na + /H + exchange may develop a therapeutic benefit.
[0019] The present invention further relates to the use of the compound of formula 1 to prepare a pharmaceutical composition for treating cardiovascular diseases.
[0020] The present invention further relates to the use of the compound of formula 1 to prepare a pharmaceutical composition for treating arrhythmia such as occurs in hypoxia, for example. The present invention further relates to the use of the compound of formula 1 to prepare a pharmaceutical composition for treating complaints connected with ischaemia (such as: cardiac, cerebral, gastrointestinal (such as mesenteric thrombosis/embolism), pulmonary, renal ischaemia, ischaemia of the liver, and ischaemia of the skeletal muscles. The present invention further relates to the use of the compound of formula 1 to prepare a pharmaceutical composition for treating diseases selected from the group consisting of coronary heart disease, cardiac infarct, angina pectoris, stable angina pectoris, ventricular arrhythmia, subventricular arrhythmias, cardiac insufficiency, and also for assisting bypass operations, for assisting open heart surgery, for assisting operations which require an interruption to the blood supply to the heart and to assist in heart transplants, embolism in the pulmonary circulation, acute or chronic kidney failure, chronic renal insufficiency, cerebral infarct, reperfusion damage in the restoration of blood supply to areas of the brain after the dissolving of vascular occlusions and acute, and chronic circulatory disorders of the brain. The present invention further relates to the use of the compound of formula 1 to prepare a pharmaceutical composition for treating diseases in which the use of cardioprotective active substances may be of therapeutic benefit. The present invention further relates to the use of the compound of formula 1 to prepare a pharmaceutical composition for treating cancers, benign tumors or, for example, prostatic hypertrophy, atherosclerosis, organ hypertrophy and hyperplasia, fibrotic diseases, and late complications of diabetes.
[0021] The compound of formula 1 may be used as an aqueous injectable solution (e.g., for intravenous, intramuscular, or subcutaneous administration), as a tablet, as a suppository, as an ointment, as a plaster for transdermal administration, as an aerosol for inhalation into the lungs or as a nasal spray.
[0022] The content of active substance in a tablet or a suppository is between 5 mg and 200 mg, preferably between 10 mg and 50 mg. For inhalation, the single dose is between 0.05 mg and 20 mg, preferably between 0.2 mg and 5 mg. For parenteral injection, the single dose is between 0.1 mg and 50 mg, preferably between 0.5 mg and 20 mg. The doses specified above may be given several times a day if necessary.
[0023] The following are some examples of pharmaceutical preparations containing the active substance:
TABLETS Component Amount (mg) Compound of formula 1 18.0 magnesium stearate 1.2 maize starch 60.0 lactose 90.0 polyvinylpyrrolidone 1.5
[0024] SOLUTION FOR INJECTION Component Amount Compound of formula 1 0.3 g sodium chloride 0.9 g water for injections ad 100 mL
This solution can be sterilized using standard methods.
[0025] WO 00/17176 discloses possible methods of production which can be used to synthesize the free base 4-[4-(2-pyrrolylcarbonyl)-1-piperazinyl]-3-trifluoromethylbenzoylguanidine. Starting from this compound, the following possible methods of synthesizing the compound of formula 1 are illustrated by way of example.
EXAMPLE 1
4-[4-(2-pyrrolylcarbonyl)-1-piperazinyl]-3-trifluoromethylbenzoylguanidine hydrochloride
[0026] 15.1 g of 4-[4-(2-pyrrolylcarbonyl)-1-piperazinyl]-3-trifluoromethylbenzoylguanidine is taken up in 151 mL of methanol and the resulting suspension is cooled to about 10° C. 16 mL of a saturated ethereal HCl solution are added to this suspension which is thus acidified to a pH of between 1 and 2. Stirring is continued, while cooling with ice, until crystallization is complete. The crystals are suction filtered, washed with cold methanol, and then with cold diethyl ether. Yield: 16.19 g; melting point: 223° C. (uncorrected).
EXAMPLE 2
4-[4-(2-pyrrolylcarbonyl)-1-piperazinyl]-3-trifluoromethylbenzoylguanidine hydrochloride hemihydrate
[0027] 15.0 kg of 4-[4-(2-pyrrolylcarbonyl)-1-piperazinyl]-3-trifluoromethylbenzoylguanidine is taken and combined with 120 L of ethyl acetate. The suspension is heated to about 45° C. and combined with 30 L of water. The resulting mixture is stirred for about 15 minutes and the aqueous phase is then separated off. A solution of 3.62 kg of concentrated hydrochloric acid in 20 L of water is added to the organic phase at a constant temperature. Within about 1 to 2 hours, the mixture is cooled to 25° C. to 20° C. The hydrochloride obtained is separated off, washed with 50 L of ethyl acetate, and dried in vacuo at about 60° C. Yield: 78%; melting point: 225° C.±5° C. (DSC at a heating rate of 10 K/min).
EXAMPLE 3
4-[4-(2-pyrrolylcarbonyl)-1-piperazinyl]-3-trifluoromethylbenzoylguanidine hydrochloride monohydrate
[0028] 109.4 g of 4-[4-(2-pyrrolylcarbonyl)-1-piperazinyl]-3-trifluoromethylbenzoylguanidine is suspended in 1.5 L of water and heated to about 50° C. 26.1 mL of concentrated aqueous hydrochloric acid is diluted with 300 mL of water and added dropwise to the preheated suspension within about 20 minutes. The mixture is stirred for about 15 minutes at constant temperature. Then the temperature is lowered to about 35° C. with stirring over a period of about 1.5 hours. It is then cooled to 5° C. to 10° C. and stirred for another hour at this temperature. The crystals obtained are separated off, washed with a little water, and dried in vacuo at about 50° C. Yield: 116.5 g; melting point: 180° C.±5° C. (DSC at a heating rate of 10 K/min).
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4-[4-(2-pyrrolylcarbonyl)-1-piperazinyl]-3-trifluoromethylbenzoylguanidine hydrochloride and its hydrates, processes for preparing this benzoylguanidine salt and its hydrates, pharmaceutical compositions containing this benzoylguanidine salt and its hydrates, and its use in treating diseases, particularly those in which inhibition of the cellular Na + /H + exchange is of therapeutic benefit.
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This is a division of copending application Ser. No. 07/634,905 filed on Dec. 27, 1990.
TECHNICAL FIELD
The invention relates to high temperature gas turbines and in particular to cooling of the first to second stage turbine seal area.
BACKGROUND OF THE INVENTION
The turbines of gas turbine engines operate with gas temperatures on the order of 1650° C. Such elevated temperature limits the allowable stress of various turbine parts, and produces deterioration which reduces the time between maintenance and replacement. The area between the first and second turbine rotor stages experiences high temperatures and is vulnerable By recognizing the temperature limits of the rotating structure we are able to maintain that temperature. Hot gas tends to bypass the stationary vanes adjacent to the first and second rotor disks. Labyrinth seals are used to restrict this leakage. Cooling air is frequently injected into this area to further deter gas path flow from contacting highly stressed parts. U.S. Pat. No. 4,869,640 shows such apparatus and further includes a restricted flow area between the main gas flowpath and the inlet ahead of the labyrinth seal.
Also requiring cooling airflow are the second stage vanes and the second stage turbine outer air seals around the periphery of the turbine. The cooling air is obtained from a compressor stage of high enough pressure to produce the necessary flow. Selection of a higher than necessary stage increases parasitic power loss because of the increased compression. It further supplies hotter air because of this compression.
The maximum need for cooling air is at maximum power which is equivalent to the maximum rotor speed. With the percentage airflow established for this condition, excess air flows at lower operating speeds and temperatures including cruise condition. All of the bypassing cooling air leads to reduced engine and turbine component efficiency. Excess cooling air beyond that required is therefore not desirable since it increases the thrust specific fuel consumption.
It is generally not sufficient to supply only an amount of cooling air to protect the 1-2 seal area with new seals. Additional air must be supplied to handle a worn seal condition. While this flow is only required at high power when the seals are worn, once the design is established this air flow exists at all times.
Of the three cooling air flows discussed above the cooling air to the labyrinth seal area is exposed to the highest gas pressure. Therefore, the differential pressure between the supply chamber and the injection point is less here than it is for the other cooling air flow. Accordingly, introduction of the cooling air into the labyrinth seal area is sensitive to achieve the efficacy of operation.
In the seal area between the first and second rotor stages a seal runner is secured to the turbine disks. This seal runner tends to operate hotter than the disks and therefore places a stress on the disk because of the differential expansion. In the transient from idle to takeoff power the runner heats faster than the disk and therefore the stress level peaks. This leads to low cycle fatigue damage.
SUMMARY OF THE INVENTION
It is an object of the invention to provide adequate cooling to the area between the first and second rotor stages as required while promoting engine efficiency when full cooling is not required.
It is a further object to maintain safe operating conditions in the event of failure of the temperature control.
It is a further object to decrease the off peak load cooling air flow to the second vane and to the second stage turbine air seals.
It is a further object to maintain low cycle fatigue life of the turbine disks and seal runner.
Cooling air for the area between the first and second turbine stage is taken from a plenum supplied from a compressor stage. A plurality of conduits deliver air to this plenum with a fixed resistance in one of the conduits and a variable operating valve in the other conduits.
The temperature at the 1-2 seal area is measured and the cooling air modulated in response to this measurement. This also reduces the cooling air to the second stage vane and to the second stage turbine air seal, where these receive air from the same plenum.
Dual thermocouples are used and valve position is checked. At appropriate times temperature is compared to an acceptable range. Warnings are established, maintenance messages are recorded, and a fail safe condition is established. Operating conditions are established in response to various failure modes.
At low mach air speed, generally corresponding to low engine speed, excess cooling air is supplied to overcool the interstage seal runner. During a subsequent power excursion, such as takeoff or thrust reversing on landing, the excess temperature of the seal runner is reduced, thereby maintaining low cycle fatigue life.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a compressor and turbine;
FIG. 2 is a section through the 1-2 turbine stage area showing cooling air injection;
FIG. 3 is a section through the 1-2 stage area showing the thermocouple installation;
FIG. 4 is a section through the thermocouple installation showing the dual thermocouples;
FIG. 5 is a curve showing the percent cooling air at various engine speeds;
FIG. 6 is a logic diagram showing the handling of faults; and
FIG. 7 is a curve showing the acceptable low power temperature window for the health check.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic of a gas turbine engine showing compressor 10 and gas turbine 12. The air passes through the combustors 14 producing the hot gas for entrance to the turbine.
The conduit network 16 includes an orificed conduit 18 and a plurality of conduits 20 each containing a modulatable control valve 22. This conduit network is connected to a compressor stage delivering air to plenum 24. Thermocouple assembly 26 measures a temperature described hereinafter and sends a temperature measurement signal to the engine controller 28. This controller includes the logic described hereinafter, and also includes the conventional information such as engine speed, ambient temperature, etc. Air speed sensor 30 also sends a control signal to the engine controller.
Control valve actuator 32 receives a control signal through line 34 and returns a position signal through line 36.
Referring to FIG. 2, a first rotor stage 38 includes a rotor disk 40 and a plurality of turbine blades 42. The second bladed rotor stage 44 includes a disk 46 and a plurality of blades 48. A vaned stator assembly 50 includes a plurality of hollow vanes 52 and a surrounding seal shroud 54.
An annular flow of hot working fluid 56 passes sequentially through blades 42, vanes 52 and blades 48.
Seal shroud 54 includes around its outer periphery an abradable honeycomb material 58. Seal runner 60 is sealingly connected to rotor stage 38 and rotor stage 44. This runner includes a plurality of knife edges 62 closely spaced from the seal shroud 54. This flow resistant labyrinth seal formed of knife edges 62 and shroud 54 forms a labyrinth flow passage 64. An upstream plenum 66 is in restricted fluid communication with the annular flow 56 through the convoluted passageway 68. Downstream plenum 70 is in restricted fluid communication with annular flow 56 through a restricted passageway 72.
Within hollow vanes 52 there is a perforated plate 74 closely spaced from the interior wall of the vane. Cooling air from plenum 24 passes through this perforated plate impinging on the inner surface of the vane. The cooling air exits through opening 76 at the downstream edge of the vanes. This is a conventional approach to cooling the vanes.
A further portion of the airflow from plenum 24 passes through the vane and through inlets 78 producing injection cooling airflow 80 into plenum 66 The purpose of this injected coolant 80 is to deter ingestion of hot gas through the passage 68 and to mix with this gas providing a lower temperature mixture. The maximum temperature desired in downstream plenum 70 is 650° C. At 11 000 turbine RPM the gas temperature entering the vanes is 1230° C. With an airflow 80 of 0.3 percent of the total engine airflow, the temperature in plenum 66 is 560° C. Work energy put into the airflow as it passes through the labyrinth seal causes increased heating with the temperature of approximately 650° C. in downstream plenum 70. With further heating as it exits through the restricted passage 72 it returns to the gas flow path at a temperature of 665° C.
In the described embodiment, injection passage 78 is located only on alternate vanes. All vanes include the vane cooling with perforated plate 74. FIG. 3 illustrates the installation of thermocouple assembly 26 through a vane which is not carrying the airflow to plenum 66. Cap 79 supports the thermocouple assembly and has two thermocouple outputs 83 and 81. The thermocouple assembly is straight and is therefore easily assembled and may be readily maintained in place. It passes into an opening 82 in shroud 54 for the purpose of sensing the gas temperature at the intermediate point 84 of the labyrinth flow passageway 64. The temperature at this location of 592° C. corresponds to the temperature of 650° C. in plenum 70. A bypass opening 86 through seal shroud 54 is in fluid communication with location 84 and also with the downstream plenum 70. A portion of the gas passes through this bypass opening since it is in parallel flow relationship with the remaining portion of the labyrinth flow passage. The thermocouple assembly 26 includes two thermocouples 88 and 89 (A and B) located within the flow passage. This provides a local high velocity at the thermocouple tips and permits the thermocouples to be located away from interference with the labyrinth seal interface.
A third cooling flowpath from plenum 24 passes as flow 90 through the plenum wall and cools the second stage turbine outer air seals 92. This flow thereafter passes into the main gas stream.
In response to the temperature sensed by thermocouple assembly 26 control system 28 sends a signal to actuator 32 of the modulatable valve 22 to vary the cooling airflow. The set point temperature for the temperature at 84 is substantially constant, being selected to keep the temperature in plenum 70 at an acceptable constant value. A higher temperature in plenum 70 would degrade the material beyond the amount designed to be acceptable. Too low a temperature, on the other hand, represents excess parasitic cooling airflow. The valves therefore are modulated to maintain this desired temperature.
During modulation the valves are open at intermediate and at high engine ratings, since at lower engine ratings the target temperature is not reached even with the valves fully closed. The unvalved conduit with a flow restriction provides some flow at all times even with the valves closed. This satisfies the need for some cooling flow in the three flowpaths.
It can be appreciated therefore that even with the valves modulating in a attempt to hold the temperature, there is a portion of the operating range where these valves will be fully closed in such an attempt. At such time the temperature is acceptable and the parasitic airflow is decreased.
FIG. 5 illustrates the percentage cooling air used at various engine speeds. Curve 102 illustrates the airflow injected into plenum 66 with the valves full open. Curve 104 illustrates the airflow to the second vane plus the second stage air seal with the valves fully open while curve 106 illustrates the total airflow to both of these.
With the valves fully closed, the corresponding flows are shown by curve 112 for the air to plenum 66 and curve 114 for the other airflow resulting in the total valve closed airflow of curve 116. At an engine speed of approximately 10,750 RPM the preselected temperature limit is reached and the valves begin modulation. This results in the increased airflow with increasing RPM shown by curve segments 122, 124 and 126, respectively. At the cruise rating of about 10,600 RPM this results in a total parasitic airflow reduction from 3.2 percent to 1.2 percent. Accordingly, engine efficiency is increased at this long term operating condition.
It is furthermore noted that since the valves are deeply modulated for the long term flight conditions and opened only insofar as they are needed at higher conditions, oversizing of the conduit network is not detrimental to the engine operation. It follows that with no penalty, the increased size may be used to provide sufficient cooling air even in the event of a severely deteriorated labyrinth seal.
Sizing of the cooling flow lines is done in the design stage, and must therefore be sufficient for a worst case leakage production engine. In the absence of this modulate to temperature invention, all production engines would suffer the performance penalty, even though the particular engine did not have high leakage.
Table 1 is a calculation where the total airflow is 3.60 percent with values full open and 1.90 percent with the values modulated.
TABLE 1______________________________________% Cooling FlowOPEN MODULATED % OF OPEN FLOW______________________________________Labyrinth 1.47 0.22 14.9Seal Area2nd Vane 1.09 0.80 73.42nd Outer 1.04 0.78 75.0Air SealTotal 3.60 1.90 52.8______________________________________
While the overall flow modulated is 52.8 percent of the full open flow, the 1-2 stage injection is only 14.9 percent of the full open flow. The sensitivity of this injection flow compared to the second vane flow and the second outer seal flow can be seen.
Low cycle fatigue damage to the turbine rotor disks can also be maintained by this system. Referring to FIG. 2 is it noted that the seal runner 60 is secured to disks 40 and 46. The seal runner 60 normally operates at a temperature higher than that of the disks and accordingly this circumferential seal places the loading on the disks. During idle conditions both are at relatively low temperature, but on takeoff the sudden increase of power causes the air and gas temperatures to rapidly increase. In this case the seal runner 60 increases its temperature at a more rapid rate than the disks 40 and 46. The temperature difference during this transient is greater than the temperature difference either before the transient before idle or after the transient for steady state operation at high power. This causes an exceptionally high stress during the transient leading to low cycle fatigue stress damage of the rotor.
Accordingly, when operating at low power conditions and expecting a power increase, valves 22 may be opened even through there is no disk cooling need for plenums 66 and 70. This reduces the temperature of the seal runner from 300° C. to 210° C. When takeoff power is applied, the seal runner starting at a lower temperature does not run as far ahead of the turbine disks as it would otherwise. The particular desire for such operation is at idle on the ground in preparation for takeoff, and during landing in preparation for thrust reversal operation. In either case the low power operation is a situation where engine efficiency and thrust are not required, and accordingly there is no significant penalty for use of the excess cooling air.
While various parameters could be used to detect the low power mode in anticipation of a power increase, the measurement of airspeed has been selected as best meeting the low cycle fatigue concern. During takeoff the cooling air is maintained independent of the turbine speed. Reverse thrust on landing is anticipated. Any other very low engine speed flight will usually be followed by a power excursion.
Referring to the logic diagram of FIG. 6 following start engine command 202 there is an open valve command 204. In logic box 206 valve positions are checked to see if the valves are fully open. If they are, the logic passes to logic box 208 which checks to see if thermocouple A equals thermocouple B. If the temperatures match within 22°, they are considered to be equal and the average of the two is used.
The logic passes to logic box 210 where the temperature (the average of the two) is checked to see if the measurement is within the health band. This band is substantially a predicted temperature range for the low power condition as a function of the ambient temperature along with a tolerance, and is described later with respect to FIG. 7. If the temperature is within the limits, the logic passes to logic box 212 for a check of aircraft speed. If the speed is below mach 0.375 the logic returns to the open valve box 204 and the series of logical comparisons are repeated.
Upon exceeding mach 0.375 the logic passes to instruction box 214 which starts the temperature control and modulates the valves. During this operation logic box 216 continues to check that both thermocouples are working and logic box 218 check to measure temperature against an extreme overtemperature condition.
Where the overtemperature is not found, logic passes to box 220 where a check is made to see if the valves are closed plus engine speed is greater than 1,000 RPM plus also the temperature is less than 590° C. Such a combination would suggest a thermocouple error. In the absence of that problem, logic passes to box 222 to see whether aircraft speed has dropped below mach 0.325. In the absence of such an airspeed decrease, operation continues in the modulated valve loop.
The pattern of operation in the event of an unsuccessful check in the logic falls into two groups. In instruction box 224 a fault warning is signaled to the pilot indicating the nature of the deficiency. A maintenance message is also sent to the aircraft computer for later review on the ground. If the aircraft has not been dispatched, dispatch is prohibited and if in flight the valves are either held open or continued attempts are made to open them.
Logic box 226 indicates the instructions on a less serious fault. There is no immediate warning, but a maintenance message is stored in the aircraft computer. Dispatch of the aircraft is permitted, but the valves are held open for the entire flight. Therefore no modulation is permitted and the performance benefit is lost while the fault exists.
Going back to the beginning of the logic loop, in logic box 206 if the valves are not full open, instruction box 224 is followed.
In logic box 208 if the thermocouples do not match, instruction box 226 is used.
The health band check in box 210 has two results depending upon whether the temperature is high or low compared to the band. If high, instruction box 224 is used, while if low, instruction box 226 is used.
During the modulated valves mode, a mismatch of temperatures in logic box 216 results in instruction box 226 action. A high temperature in logic box 218 directs the instructions in box 224. The potential thermocouple error identified in logic box 220 causes the action of instruction box 226 to take place.
In either case, instruction box 224 and 226 are both followed by an end of logic operations 228 since the valves will be held open and no further modulation will be considered.
FIG. 7 shows the temperatures in the 1-2 turbine seal stage as a function of the engine speed. Curve 302 shows the expected nominal temperature on a 20° C. day. Curve 304 represents the expected temperature on a -50° C. day while curve 306 represents this temperature on a 55° C. day. Illustrated with respect to the 20° C. day is a high target limit 308 which is 35° above the nominal temperature and low target limit 310 which is 35° C. below the nominal temperature. These curves 308 and 310 establishing the high target and low target define the health check area 311 used during low speed operation to confirm that the thermocouples are properly operating. It is noted that this is established with the valves full open and that the box moves depending upon the ambient temperature. The target area 311 stops at 10,500 RPM. Above this engine speed the logic assumes any temperature to be within the health check box, since a check has already been made at lower turbine speed.
Also shown is curve 312 which (on the left side) represents the temperature at the 1-2 stage with the valves fully closed. A constant temperature portion 314 of the curve represents modulated valves holding a temperature of 602° C. Curve extension 316 represents on a 20° C. day, the temperature with valves full open. The difference between the temperatures of curve 314 and that of 316 is accomplished by the modulating of the valves. It is noted that as illustrated even at the maximum design speed 318 of 11,800 RPM the valves are not yet fully open. This provides tolerance for operation on a hotter day as well as tolerance for increased flow should it be needed for seal wear.
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Cooling air to the 1-2 turbine stage seal is supplied in parallel with air to the second vane from a plenum. A modulatable valve in the supply line to the plenum regulates air flow in response to a sensed temperature in the 1-2 seal area at high sensed speeds. Valve and thermocouples are checked for proper operation. Immediate alerts and maintenance messages are established along with fail safe operating conditions upon fault detection. Over cooling of the seal area during low power operation, in anticipation of a power increase, is used to improve low cycle fatigue life of the turbine disk and seal runner.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2007-250423, filed on Sep. 27, 2007, the entire contents of which are incorporated herein by reference.
BACKGROUND
[0002] A general color image sensor has a structure in which every single pixel has a color filter disposed thereon that allows the pixel to detect only one color, that is, only a wavelength range corresponding to one color in operation of the color image sensor. Specifically, in each of many color image sensors, RGB (red, green and blue) color filters are regularly arrayed so that one color filter corresponds to each pixel. Each pixel with a red color filter detects red light, and green light and blue light are also detected in similar manners.
[0003] Thus, in reproducing an image, the color image sensor reproduces green and blue signal in each pixel with a red color filter by calculating intensities of the green and blue colors through signal processing based on information on the adjacent pixel with a green color filter and on the adjacent pixel with a blue color filter. At the same time, red and blue signal in each green pixel, and red and green signal in each blue pixel are also reproduced by using signal processing in similar manners.
[0004] As described above, a conventional color image sensor processes an image by allotting one color to each pixel. As a result, the color image sensor has poor reproducibility characteristics for an object showing a significant spatial color variation or an object containing similar colors. For example, from such an object, the color image sensor is likely to reproduce a more unclear image as to look out of focus than the original object. In addition, the conventional technique has a problem that, in a color image sensor having a large number of pixels, each pixel inevitably has such a small structure that its element for detecting light, such as a photodiode, cannot receive a light beam with a sufficient intensity for its detecting operation.
[0005] Note that an imaging device with a multilayer interferometric filter has already been known (refer to Japanese Patent Application Publication No. 2005-308871). Meanwhile, a technique of employing interferometric films in a reflective color display device has been also known (refer to Japanese Patent Application Publications No. 2005-77718 and No. 2006-20778).
SUMMARY
[0006] Aspects of the invention relate to an improved color filter and color image sensor.
[0007] In one aspect of the present invention, a color filter capable of controlling wavelengths of light to be transmitted therethrough may include a pair of interferometric films which are substantially parallel to each other and which transmit the light;
[0008] and a drive member which drives at least one film of the pair of the interferometric films to change a distance of a gap between the interferometric films.
[0009] In another aspect of the invention, a color image sensor, may include a color filter including at least one pair of interferometric films which are substantially parallel to each other and which transmit light; a plurality of photoelectric converters which are arrayed two-dimensionally to receive the respective light transmitted through the color filter and to output electrical signals; and a drive member which changes the wavelengths of the light transmitted through the corresponding pair of the interferometric films by moving at least one film of the pair of the interferometric films to change a distance of a gap between the interferometric films.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0010] A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.
[0011] FIG. 1A is a schematic cross-sectional view showing the color image sensor of the first embodiment. FIG. 1B is a schematic plan view of the color image sensor shown in FIG. 1A . FIG. 1C is a schematic cross-sectional view in which cross-sectional views as viewed from the respective directions of the arrow A-A and the arrow B-B of FIG. 1B overlap on each other.
[0012] FIGS. 2A to 2F are schematic cross-sectional views showing the manufacturing process of the color image sensor.
[0013] FIG. 3A is a schematic cross-sectional view showing the color image sensor of the second embodiment.
[0014] FIG. 3B is a schematic plan view of the color image sensor shown in FIG. 3A . FIG. 3C is a schematic plan view showing a part, corresponding to one pixel, of the color image sensor shown in FIG. 3B .
[0015] FIG. 4A is a cross-sectional view as viewed from the direction of the arrow IVa-IVa of FIG. 3C . FIG. 4B is a cross-sectional view as viewed from the direction of the arrow IVb-IVb of FIG. 3C .
DETAILED DESCRIPTION
[0016] Various connections between elements are hereinafter described. It is noted that these connections are illustrated in general and, unless specified otherwise, may be direct or indirect and that this specification is not intended to be limiting in this respect.
[0017] Embodiments of the present invention will be explained with reference to the drawings as next described, wherein like reference numerals designate identical or corresponding parts throughout the several views.
First Embodiment
[0018] Firstly, with reference to FIGS. 1A to 1C , description will be given of a configuration of a first embodiment of a color image sensor according to the present invention. FIG. 1A is a schematic cross-sectional view showing the color image sensor of the first embodiment. FIG. 1B is a schematic plan view of the color image sensor shown in FIG. 1A . FIG. 1C is a schematic cross-sectional view in which cross-sectional views as viewed from the respective directions of the arrow A-A and the arrow B-B of FIG. 1B overlap on each other.
[0019] In the color image sensor, multiple photodiode regions 5 , each of which serves as a photoelectric converter corresponding to a pixel, are arranged in horizontal and vertical lines on a substrate 6 , and an interlayer insulating film 4 is formed thereon. In the interlayer insulating film 4 , an unillustrated wiring layer is formed. A color filter 20 is disposed on the interlayer insulating film 4 , and multiple microlenses 2 are arranged at positions corresponding to the respective photodiode regions 5 . Though pixels are arranged in 3 horizontal and 3 vertical lines in the example shown in FIGS. 1A to 1C , the number of pixels may typically be far larger than this. For example, several million pixels may be arranged in a matrix in a plane.
[0020] In this embodiment, an arrangement is employed in which the single color filter 20 covers the entire matrix of the multiple photodiode regions 5 . The color filter 20 has a lower interferometric film 1 a directly disposed on the interlayer insulating film 4 and an upper interferometric film 1 b disposed parallel to the lower interferometric film (interference film) 1 a . Each of the lower and upper interferometric films 1 a and 1 b is formed of a stable film made, for example, of amorphous silicon. Between the lower and upper interferometric films 1 a and 1 b , support structures 8 are interposed in a peripheral region outside an optical path, and thus a gap 21 is formed between the lower and upper interferometric films 1 a and 1 b.
[0021] Lower motion control electrodes 7 a are attached on the lower surface of the lower interferometric film 1 a , and upper motion control electrodes 7 b are attached on the upper surface of the upper interferometric film 1 b . The lower and upper motion control electrodes 7 a and 7 b are disposed in the peripheral region outside the optical path so as to face each other in the direction of the optical path. The color image sensor is configured such that a potential difference caused between the lower and upper motion control electrodes 7 a and 7 b can change the gap distance between the lower and upper interferometric films 1 a and 1 b . Specifically, if such a potential difference is caused between the two electrodes, an electrostatic force is applied between the two electrodes to deform the support structures 8 , and thereby moves the upper interferometric film 1 b up and down to change the gap distance. This change in the gap distance between the lower and upper interferometric films 1 a and 1 b changes the wavelength of interfered light beams. In this way, the wavelength of the light beams transmitted through this color filter is made variable.
[0022] As shown in FIGS. 1A and 1C , the light-shielding metal layers 3 are formed in the interlayer insulating film 4 to prevent light beams transmitted through each adjacent microlenses 2 from interfering with one another.
[0023] In addition, a distance meter 40 for measuring a distance between the lower and upper interferometric films 1 a and 1 b is also disposed as shown in FIG. 1C .
[0024] In the color image sensor with the above configuration, light beams incident from the respective microlenses 2 are caused to have a certain limited wavelength by the color filter 20 when the light beams is being transmitted therethrough, and then reach the photodiode regions 5 . Thereafter, the light beams are photoelectrically converted in the respective photodiode regions 5 to be detected as electrical image data signals.
[0025] Then by detecting electrical image data signals as described above after the distance between the lower and upper interferometric films 1 a and 1 b is changed, the color image sensor can obtain a data set representing a different color. In this way, the color image sensor can obtain data sets representing the respective RGB colors after, for example, three rounds of such data detection. Finally, by overlapping these color data sets, the color image sensor can reproduce a color image.
[0026] As described above, the color image sensor produces an image by imaging, that is, detecting colors of, an object with all the pixels one color by one color till all the colors desired to be detected are obtained and then by overlapping these obtained colors by using signal processing. In general, a microelectromechanical system (MEMS) is supposed to have an operation speed on the order of several ten μsec. Accordingly, the color image sensor can be used in high-speed imaging by enhancing performance of peripheral elements such as an analog-to-digital converter (ADC), photodiodes and the like.
[0027] Note that this embodiment is applicable to both types of a charge coupled device (CCD) image sensor and a complementary metal oxide semiconductor (CMOS) image sensor.
[0028] In the image sensor of this embodiment, the gap distance between the lower and upper interferometric films 1 a and 1 b can be continuously changed by utilizing a potential difference. This enables the image sensor to reproduce not only the RGB colors but basically all the colors. Accordingly, the image sensor of this embodiment is capable of detecting colors other than the RGB colors, and thus has improved color reproducibility characteristics.
[0029] Here, though the gap distance between the lower and upper interferometric films 1 a and 1 b may be controlled within a predetermined range every time before a certain color is detected, an alternative operation is also possible. In the alternative operation, the color filter 20 is continuously or periodically moved during an imaging session while the distance meter 40 keeps monitoring the height of the color filter 20 , and the image sensor reads image signals when the color filter 20 has the height providing the color desired to be obtained. This operational mode eliminates the need to precisely control the movement of the color filter 20 , and the precision of the color to be obtained in this operational mode depends on the precision of the height detection instead. Accordingly, employment of this operational mode can simplify the MEMS structure of this image sensor even more.
[0030] Next, with reference to FIGS. 1D and 2A to 2 F, description will be given of a manufacturing process of the color image sensor of this first embodiment. FIG. 1D is a schematic cross-sectional view showing a finished form of the manufacturing process of the color image sensor of this first embodiment. FIGS. 2A to 2F are schematic cross-sectional views showing the manufacturing process of the color image sensor. FIG. 1D is basically the same as FIG. 1C except that the upper motion control electrodes 7 b and the support structures 8 in FIG. 1C are integrally formed in FIG. 1D .
[0031] Firstly, as shown in FIG. 2A , multiple photodiode regions 5 , each of which corresponds to a pixel, are arranged in horizontal and vertical lines on a substrate 6 , and then an interlayer insulating film 4 and light-shielding metal layers 3 are formed thereon. Specifically, the light-shielding metal layers 3 are formed in the interlayer insulating film 4 . Thereafter, a lower interferometric film la is formed on the interlayer insulating film 4 . The steps so far are no different than in conventional techniques. Then, as shown in FIG. 2B , lower motion control electrodes 7 a are formed on the lower interferometric film 1 a . Then, as shown in FIG. 2C , a sacrificial layer 30 is deposited on the lower interferometric film 1 a and the lower motion control electrodes 7 a and thereafter patterned.
[0032] Then, as shown in FIG. 2D , an upper interferometric film 1 b is deposited on the sacrificial layer 30 and thereafter patterned. Subsequently, as shown in FIG. 2E , upper motion control electrodes 7 b and a metal layer including support structures 8 are deposited on the upper interferometric film 1 b and thereafter patterned. Then, as shown in FIG. 2F , microlenses 2 are formed on the upper interferometric film 1 b . Lastly, the sacrificial layer 30 is removed off, and, as a result, the form shown in FIG. 1D is obtained.
[0033] Note that as the modification of the above procedure, the upper interferometric film 1 b may be formed after the upper motion control electrodes 7 b is formed. Still alternatively, the lower motion control electrodes 7 a may be formed concurrently with the interlayer insulating film 4 including the wiring layers to position under the lower interferometric film 1 a.
[0034] According to this first embodiment, each pixel can detect multiple colors at different timings, respectively. This enables the image sensor to obtain fine image data without increasing the number of pixels therein.
[0035] Moreover, since the color image sensor of this embodiment has a structure in which the distance between the interferometric films can be continuously changed, each pixel therein is capable of detecting any wavelength. This enables the image sensor to detect not only the RGB colors but also the other colors, and thus to have improved color reproducibility characteristics. Furthermore, the capability of each pixel of detecting all the colors necessary to reproduce an image not only eliminates the need for conventionally-required color correction of the pixel but also allows the color image sensor to obtain an increased number of signals and thus to have improved image reproducibility characteristics. In addition, since the interferometric films, the support structures and the like can be implemented with reliable materials, the reliability of the color image sensor is not decreased unlike the problematic case in which a color image sensor with a conventional color filter formed of an organic film has a seriously decreased reliability.
[0036] Moreover, this structure can be implemented using the interferometric films 1 a and 1 b each formed of a stable film made of a material such as amorphous silicon, and the support structures 8 can be formed of insulating films. Accordingly, an appropriate selection of materials for these films can provide an even higher reliability with the color image sensor.
[0037] Especially, the MEMS color filter of this embodiment integrally formed for all the pixels has a simple structure since the motion control electrodes 7 a and 7 b and the support structures 8 need not be formed in the pixels, and thus can be manufactured by a simple process.
Second Embodiment
[0038] Secondly, with reference to FIGS. 3A to 4B , description will be given of a second embodiment of a color image sensor according to the present invention. Note, however, that the same or similar components as in the first embodiment are denoted by the same reference numerals and the redundant description thereof will be omitted. FIG. 3A is a schematic cross-sectional view showing the color image sensor of the second embodiment. FIG. 3B is a schematic plan view of the color image sensor shown in FIG. 3A . FIG. 3C is a schematic plan view showing a part, corresponding to one pixel, of the color image sensor shown in FIG. 3B . FIG. 4A is a cross-sectional view as viewed from the direction of the arrow IVa-IVa of FIG. 3C . FIG. 4B is a cross-sectional view as viewed from the direction of the arrow IVb-IVb of FIG. 3C .
[0039] In this embodiment, the upper interferometric film 1 b is separated into portions corresponding to the respective pixels. In addition, the MEMS movement units, that is, the lower motion control electrode 7 a , the upper motion control electrodes 7 b and the support structures 8 , are provided for each pixel so as to individually change the gap distance between the lower and upper interferometric films 1 a and 1 b in the pixel. Here, in the pixel, the pair of the lower motion control electrodes 7 a , the pair of the upper motion control electrodes 7 b and the pair of the support structures 8 are each diagonally disposed with respect to the microlens 2 , so as not to obstruct a gapless arrangement of the microlenses 2 . With this arrangement, the microlenses 2 can be arranged in an array with no gap between one another.
[0040] The MEMS color filter of this embodiment is implemented to have a structure allowing an MEMS operation on the one-pixel basis. Thus, if an object image includes a part showing a significant color variation or a part containing similar colors, the color image sensor of this embodiment can detect, from the part, colors critical for image reproduction on the one-pixel basis after detecting basic colors such as the RGB colors from the entire object image. Here, the color image sensor calculates such colors critical for image reproduction by using signal processing. For example, the color image sensor can minutely detect colors around the target wavelengths from the part containing similar colors and can additionally detect colors only in the part showing a significant color variation.
[0041] Embodiments of the invention have been described with reference to the examples. However, the invention is not limited thereto.
[0042] Other embodiments of the present invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and example embodiments be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following.
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In one aspect of the present invention, a color filter capable of controlling wavelengths of light to be transmitted therethrough may include a pair of interferometric films which are substantially parallel to each other and which transmit the light; and a drive member which drives at least one film of the pair of the interferometric films to change a distance of a gap between the interferometric films.
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This is a continuation of application Ser. No. 08/098,444 filed on Jul. 23, 1993, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a cordless telephone.
In the ETSI Committee in Europe, specifications called CT-2 are under investigation as standards for digital cordless telephone.
In the CT-2 system, there are provided 40 channels in an 800 MHz band. For example, while talking over the telephone, a parent telephone and a child telephone are connected by a channel and the channel is used for transmission and reception by being time shared in the transmission frame T and the reception frame R as shown in FIG. 7. All the prepared 40 channels are talking channels with control data transmitted and received as attached data to the speech data. Hence, there exists no independent control channel.
In the CT-2 system, telephones can be used versatilely than with ordinary cordless telephones by having them previously registered. More specifically, for example as shown in FIG. 8, if a plurality of child telephones 11 to 1j are previously registered with a parent telephone 21, the parent telephone 21 can manage both an outgoing call and an incoming call through a line wire for any of the child telephones 11 to 1j. Further, if a child telephone 11 is previously registered with a plurality of parent telephones 21 to 2i, the child telephone 11 can send a call to and receive a call from a line wire through any of the parent telephones 21 to 2i.
The cordless telephone on the CT-2 system individually has a narrower service area than that of the cordless telephone on the general cellular system but is simpler in system structure and economical in terms of the telephone charges. Hence, if it is used within an office block or the like, it can provide means for simple communications despite up the narrowness in service area.
When an outside call comes in to the above described CT-2 system, it is unknown to the child telephone which parent telephone (of those, with which the child telephone is registered) will request the child telephone to receive the call and which channel the parent telephone will use. Therefore, the child telephone on standby must repeat sequential receiving of all of the 40 channels to get ready for a request from a parent telephone for receiving an incoming call.
Then, however, the battery power supply to the child telephone is greatly consumed. Hence, the usable period of time of a once charged battery becomes considerably short.
Therefore, a method which alternately performs a scan mode and a sleep mode is considered. The scan mode scans all of the channels sequentially only once. The sleep mode stops, for a fixed period of time, the operations of all of the circuits except the system controller. By using this method, the battery can be suppressed from being consumed because even the system controller consumes little power during the period in the sleep mode.
In such case, however, any appreciable effect cannot be obtained unless the period in the sleep mode is set sufficiently long as compared with the period in the scan mode. Further, since as many as 40 channels are sequentially received in the scan mode, the time required for the scan mode becomes relatively long.
Thus, in order to effectively suppress the power consumption of the battery, the cycle of the scan mode plus the sleep mode becomes considerably long. Then, when a request for receiving an incoming call is transmitted from a parent telephone, a long time elapses before the child telephone accepts the request for receiving a call, and therefore this method has little practicability.
Furthermore, since there are as many as 40 usable channels for talking, the degree of freedom in selecting a channel becomes high for both the child telephone and the parent telephone. Accordingly, it is difficult, conversely, to select one channel out of them. Hence, a long time is taken, for example, in receiving an incoming call as described above.
SUMMARY OF THE INVENTION
The present invention was made to overcome the above mentioned difficulties.
In order to achieve the above object, it is arranged in the present invention, taking the case where there are channels in number as described above as an example, such that the 40 channels are divided for example into four groups, each with 10 channels, as shown in FIG. 10 at step 701.
For example, the division is made such that:
the first group has the first to tenth channels,
the second group has the 11th to 20th channels,
the third group has the 21st to 30th channels, and
the fourth group has the 31st to 40th channels. This is shown in FIG. 10 at step 701.
Further, it is arranged such that one parent telephone is assigned one group, or one parent telephone uses one group such that:
the first parent telephone 21 is assigned the first group,
the second parent telephone 22 is assigned the second group,
the third parent telephone 23 is assigned the first group, and
the fourth parent telephone 24 is assigned the third group. This is shown in FIG. 10 at step 702.
When a parent telephone is connected with a child telephone, the connection between the parent telephone and the child telephone is achieved using a channel belonging to the group assigned to the parent telephone. The relationships between parent telephones and child telephones are as shown in FIG. 8.
When the child telephone is on standby, the child telephone sequentially receives all of a plurality of channels belonging to the group assigned to the parent telephone with which the child telephone is registered (scan mode). The child telephone then goes into a power saving mode (herein sometimes called sleep mode) for a predetermined period of time if there is no detected request for connection from the parent telephone during the scan mode. The child telephone repeats the foregoing operations until a request for connection from the parent telephone is detected. The child telephone responds to the request for connection when it is detected using the channel over which the request was detected.
More specifically, using reference numerals of parts corresponding to those used in the later described embodiment, there is provided a cordless telephone system, in which one channel is selected out of 40 channels and the selected channel is used in a time-sharing manner for transmission and reception. In this cordless telephone system, speech data is transmitted and received between a parent telephone 2 and a child telephone 1. This cordless telephone system includes the step of dividing the 40 channels into 4 groups. This cordless telephone system further includes the step of assigning one of the groups to the parent telephone 2. This cordless telephone system further includes the step of connecting the parent telephone 2 and the child telephone 1, when the parent telephone 2 is to be connected with the child telephone 1, using a channel belonging to the group assigned to the parent telephone 2. This cordless telephone system further includes the step of causing the child telephone 1, while it is on standby, to alternately repeat a mode sequentially receiving a plurality of channels of the group assigned to the parent telephone 2 with which the child telephone 1 is registered and a mode to stop operations for a predetermined period of predetermined period of time. This cordless telephone system further includes the step of causing
the child telephone 1, when there is transmitted a request for connection from the parent telephone 2 during the course of the repetition, to respond to the request for connection using the channel over which the request has been transmitted.
In short, the parent telephone 2 and the child telephone 1 connect with each other using a channel selected from the channels belonging only to one group as one of the divisions into which 40 channels are divided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system diagram showing an example of a child telephone in the present invention;
FIG. 2 is a system diagram showing an example of a parent telephone in the present invention;
FIG. 3 is a flow chart showing a portion of an example of a registration routine in the present invention;
FIG. 4 is a flow chart showing a portion following the portion shown in FIG. 3;
FIG. 5 is a flow chart showing a portion following the portion shown in FIG. 4;
FIG. 6 is a flow chart showing an example of an incoming call receiving routine in the present invention;
FIG. 7 is a diagram showing a relationship between transmission and reception;
FIG. 8 is a diagram showing relationships between parent telephones and child telephones;
FIG. 9 is a diagram showing an example of relationships between parent telephones, child telephones, and channels in the present invention;
FIG. 10 is a flow chart showing a method of facilitating connections between parent telephones and child telephones; and
FIG. 11 is a flow chaff showing a method of facilitating connections between parent telephones and child telephones invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 and FIG. 2, reference numeral 1 denotes a child telephone, 2 denotes a parent telephone, and 3 denotes a telephone line (line wire). In this case, the child telephone 1 represents an arbitrary set chosen out of the child telephones 11 to in shown in FIG. 8 and the parent telephone 2 represents an arbitrary set chosen out of the parent telephones 21 to 2m shown in FIG. 8.
In the child telephone 1, 110 denotes its transmission circuit and 120 denotes its reception circuit. The transmission line 110 is such that transmits a speech signal St and a control signal (control data) CTRL, which are converted to an FM signal Su during the period of the transmission frame T. Reference numeral 111 denotes a telephone transmitter.
The reception circuit 120 receives an FM signal Sd from the parent telephone 2 during the period of the reception frame R and demodulates therefrom a speech signal Sr and a control signal CTRL. The reception circuit 120 also acquires a detection signal RSSI indicating presence or absence of an FM signal Sd transmitted from the parent telephone 2 by detecting for example an intermediate signal. Reference numeral 129 denotes a telephone receiver.
Further, in the child telephone 1, 100 denotes a transmit/receive antenna and 119 denotes an antenna switch circuit for switching connection of the antenna 100 to the transmission circuit 110 and the reception circuit 120 at the beginning of the transmission frame T and the reception frame R, respectively.
Reference numerals 131a to 131n denote various operator keys such as the dial keys and talk key, 138 denotes a ringer, and 140 denotes a microcomputer for system control. In the microcomputer 140, while the command signal CTRL transmitted from the transmission circuit 110 is generated, judgment is made as to the command signal CTRL and the detection signal RSSI acquired from the reception circuit 120. Further, permission/prohibition of transmission/reception by the transmission circuit 110 and the reception circuit 120 and channel selection are performed by the microcomputer 140.
Reference numeral 141 denotes a ROM, in which identification code CPPID for identifying this child telephone 1 from other child telephones and, for example, processing routines 300 and 500 as shown in FIG. 3 to FIG. 6 are stored. Further, reference numeral 142 denotes a nonvolatile memory constituted of a RAM backed up by a battery in this example. The RAM 142 stores channel data PSM indicative of the channels which the child telephone 1 monitors for reception while it is in its standby state. The child telephone 1 is driven by a battery.
The parent telephone 2 has similar circuits to the circuits 100 to 142 in the child telephone 1. Having the circuits corresponding to the circuits 100 to 142 denoted by reference numerals 200 to 242 instead of the reference numerals 100 to 142, detailed description of the same will be omitted.
In the parent telephone 2, however, there is provided an NCU (network control unit) 239 instead of the telephone transmitter 111 and the telephone receiver 129 of the child telephone 1. The NCU 239 is connected with a transmission circuit 210, a reception circuit 220, and the telephone line 3. A ringer signal from the line wire 3 is detected and, thereby, an incoming call is detected by the NCU 239 and the detection output is supplied to the microcomputer 240. In the present embodiment, the parent telephone 2 has nothing corresponding to the telephone transmitter 111, the telephone receiver 129, and the ringer 138.
The ROM 241 stores identification code CFPID for identifying this parent telephone 2 from other parent telephones and, for example, processing routines 400 and 600 as shown in FIG. 3 to FIG. 6.
Between the child telephone 1 and the parent telephone 2, the following processes are executed and various modes are realized.
[Talking]
The speech signal St from the telephone transmitter 111 is supplied to the transmission circuit 110 and converted to the FM signal Su being alive during the transmission frame T. This signal Su is supplied to the antenna 100 through the switch circuit 119 so as to be transmitted to the parent telephone 2. At this time, the control signal CTRL from the microcomputer 140 is supplied to the transmission circuit 110 so as to be transmitted together with the speech signal during the transmission frame T.
In the parent telephone 2, the signal Su is received by the antenna 200, and the signal Su is supplied to the reception circuit 220 through the switch circuit 219 and the original speech signal St and control signal CTRL are extracted from the same. The speech signal St is transmitted over the telephone line 3 through the NCU 239 and the control signal CTRL is supplied to the microcomputer 240.
On the other hand, the speech signal Sr from the line 3 is supplied to the transmission circuit 210 through the NCU 239 so as to be converted to the FM signal Sd being alive during the reception frame R. This signal Sd is supplied to the antenna 200 through the switch circuit 219 and transmitted to the child telephone 1. At this time, a control signal CTRL from the microcomputer 240 is supplied to the reception circuit 210 and transmitted together with the speech signal during the reception frame R.
In the child telephone 1, the signal Sd is received by the antenna 100 and this signal Sd is supplied to the reception circuit 120 through the switch circuit 119 and the original speech signal Sr and control signal CTRL are extracted therefrom. The speech signal Sr is supplied to the telephone receiver 129 and the control signal CTRL is supplied to the microcomputer 140.
Thus, it is made possible to talk with the other party using the transmitter/receiver 111, 129. During the talking or before or after the talking, necessary commands and data are transmitted and received between the child telephone 1 and the parent telephone 2 using the control signal CTRL.
[Registration of Child Telephone with Parent Telephone]
This is the case where an arbitrary child telephone 1j is registered with an arbitrary parent telephone 2i, as shown in FIG. 10 at step 703. The registration is achieved by the microcomputer 140 executing the routine 300 and the microcomputer 240 executing the routine 400. Note that routine 300 and routine 400 are shown as flowcharts in FIGS. 3-5. Through this process, data of the group used by the parent telephone 2i is registered in the registered child telephone 1j.
In step 401 of the routine 400 for the parent telephone 2, one channel is selected at random out of the first to fortieth channels. In the following step 402, it is determined whether or not a transmit signal Su from the child telephone 1 is transmitted over the channel selected in step 401 through checking the signal RSSI. If it is transmitted, it is checked in the following step 403 whether or not a registration key out of the keys 231a to 231n of the parent telephone 2 is depressed. When it is depressed, in the following step 404, the frame is synchronized with the transmitted signal Su.
When the synchronization for the frame is achieved, the control signal CTRL is extracted from the synchronized signal Su in the following step 405. Then, in the following step 406, it is checked whether or not the identification code CPPID included in the extracted control signal CTRL is the identification code of a child telephone which can be registered with its own telephone. When the identification code is not that of the child telephone which can be registered with its own telephone, the processing of the microcomputer 240 is returned to step 401.
Also when any signal Su is not transmitted in step 402, the processing is returned to step 401. Further, if the requested processing is that effected by another key than the registration key in step 403, the processing of the microcomputer 240 is advanced to step 409, and in this step 409, the process corresponding to the request for processing is executed and the processing is then returned to step 401.
Thus, steps 401 to 406 are repeated while signal reception for the child telephone 1 is on standby.
When, in step 406, the identification code CPPID included in the extracted control signal CTRL is the identification code of a child telephone which can be registered with its own telephone, then in step 411, setting is made to confirm the child telephone 1 at the other end every one second until the present routine 400 is ended. In the following step 412, data indicative of the capability of the parent telephone 2 executing the present routine 400 is transmitted. Then, in the following step 413, the parent telephone 2 waits for arrival of data indicative of the capability of the child telephone 1 to which the parent telephone 2 is currently responding.
On the other hand, the routine 300 for the child telephone 1 has corresponding steps 301 to 309 to steps 401 to 409 for the parent telephone 2. These steps 301 to 309 are executed by the microcomputer 140.
However, in step 302, it is determined whether or not a transmit signal Sd from the parent telephone 2 is transmitted over the channel selected in step 301, and when it is not transmitted, the processing is advanced to step 303. When it is transmitted, the processing is returned to step 301 through a sleep mode in step 307.
In step 303, it is adapted such that, when the registration key of the child telephone 1 is operated simultaneously with or within a predetermined period of the operation of the registration key of the parent telephone 2 in its step 403, the processing is advanced to step 304. Further, in step 306, it is checked whether or not the identification code CFPID included in the extracted control signal CTRL is the identification code of the parent telephone with which its own telephone can be connected.
In step 307, the child telephone 1 is put in a sleep mode for a predetermined period of time, for example 2 seconds.
When, in step 306, the identification code CFPID is the identification code of the parent telephone with which its own telephone can be connected, then, in step 311, setting is made to confirm the parent telephone 2 at the other end every one second until the present routine 300 is ended. Then, in the following step 312, the child telephone 1 waits for the data indicative of the capability of the parent telephone 2 transmitted in step 412.
When, in step 312, the data transmitted from the parent telephone is received, then in step 313, data indicative of the capability of the child telephone 1 executing the present routine 300 is transmitted.
Then, this data is received by the parent telephone in step 413. After it has been received, it is checked in the following step 414 whether or not the capability of the child telephone 1 from which the data was received is in conformity with the capability of the parent telephone 2 executing the present routine 400. When it is in conformity, the processing is advanced to step 421.
In step 314 for the child telephone 1, it is checked whether or not the capability of the parent telephone 2 received in step 312 (transmitted in step 412) is in conformity with the capability of the child telephone 1 executing the present routine 300. When it is in conformity, the processing is advanced to step 321.
In step 321, a control signal CTRL requesting for registration of its own telephone with the parent telephone 2 is transmitted, which is received in step 421. When it has been received, in the following step 422, a control signal CTRL as a reply to the request made in step 321 is transmitted, which is received in step 322. When it has been received, in the following step 323, an identification code CFPID of the parent telephone 2 with which the registration is requested transmitted in step 424 is received, and in the following step 324, the identification code CFPID is written into the RAM 142.
Also on the side of the parent telephone 2, the identification code CPPID of the child telephone 1 requesting for registration is written into the RAM 242 in the step 423 following the step 422. Thereafter, in step 424, the completion of the registration with the parent telephone 2 is transmitted.
In the following step 431, it is checked whether or not a sleep mode is included in the capability of the child telephone 1 received in step 413 (transmitted in step 313). If it is included, in the following step 432, data is transmitted indicative as to which group, of the groups into which the 40 channels are divided, is being used by the parent telephone 2, as shown in FIG. 10 at step 704.
Although there are various ways of dividing the 40 channels into groups, here, for simplicity, the way wherein every 10 channels is assigned to one group as described above will be considered.
When it becomes necessary for the parent telephone 2 to newly select a group out of the four groups or to change the selected group from one to another, the selection or change is achieved by having a predetermined key of the keys 231a to 231n operated. Or, when the steps 401 to 406 are repeated many times, a list of used channels is made out and, according to which, a group having the greatest number of empty channels, for example, is selected.
On the side of the child telephone 1, it is checked in step 331 whether or not there is included a sleep mode in the capability of the child telephone 1 transmitted in step 313, and when it is included therein, the data indicative of the group transmitted in step 432 is received in the following step 332. Then, in the following step 333, the data of group received in step 332 and the identification code CFPID of the parent telephone 2 are written into the RAM 142. In the following step 334, a control signal CTRL indicative of confirmation is transmitted and then, in step 335, the transmission and reception are cut off and the channel between it and the parent telephone 2 is released.
On the side of the parent telephone 2, in step 433 following step 432, the control signal CTRL as the reply transmitted in step 334 is received. In the following step 434, the data of group transmitted in step 432 and the identification code CPPID of the child telephone 1 are written into the RAM 242. Then, in step 435, the transmission and reception are cut off and the channel between it and the child telephone 1 is released.
When, as the result of the checking as to whether or not the capability of the child telephone 1 is in conformity with the capability of the parent telephone 2 in step 414, it is not in conformity, steps 421 to 434 are skipped over in the parent telephone and steps 321 and 334 are skipped over in the child telephone. When a sleep mode is not included in the capability of the child telephone 1 in step 431, steps 432 to 434 are skipped over in the parent telephone and steps 332 to 334 are skipped over in the child telephone.
In the manner as described above, the child telephone 1 is registered with the parent telephone 2 and at the same time the group of channels being used by the parent telephone 2 is registered in the child telephone 1.
The left-hand column and the center column of FIG. 9 show an example of registration of the child telephones 11 to in with the parent telephones 21 to 2m, in which the child telephone 11 is registered with the parent telephones 21, 22, and 23, the child telephone 12 is registered only with the parent telephone 21, the child telephone 13 is registered with the parent telephones 21 and 23, and so on.
If the groups of channels assigned to (used by) the parent telephones 21 to 2m are as described above, the groups and channels which the child telephones 11 to in can use are as shown in the right-hand column of FIG. 9. For example, while the child telephone 11 is registered with three parent telephones 21, 22, and 23, the child telephone 11 can use 20 channels of 2 groups since the parent telephone 21 and the parent telephone 23 are using the same group.
[Standby State]
This is a state where the child telephone 1 and the parent telephone 2 are in a standby state for an incoming call. This state is brought about by the microcomputer 140 executing a routine 500 (shown in FIG. 6).
When the registration key of the child telephone 1 is not depressed, then in step 309 of the processing routine 300 for the microcomputer 140, another process is executed. As a portion of the step 309, the routine 500 is executed. Likewise, as a portion of the step 409 of routine 400 in the parent telephone, the routine 600 is executed.
On the side of the child telephone 1, in step 501 of the routine 500, the data indicating the group written in the RAM 142 is read. In the following step 502, k=1 is set as the variable k specifying the channel in the read group.
Then, in step 503, the child telephone 1 is put in a sleep mode for a predetermined period of time, for example 2 seconds. In the following step 504, the data specifying the k-th channel of the group read in step 501 is supplied to the transmission circuit 110 and the reception circuit 120 so that the transmitting and receiving channel is set to the k-th channel.
In the following step 505, it is judged whether or not a signal Sd is being received through the channel set up in step 504 by checking the signal RSSI. When it is not received, the variable k is incremented in step 506 and then the processing is returned to step 503. However, when k becomes k=11 as the result of increment in step 506, it is initialized to k=1.
Thus, the child telephone 1 repeats the mode of checking of presence or absence of a signal Sd from the parent telephone 2 in the channels of the group assigned to the parent telephone 2 and the child telephone 1 and the sleep mode until the signal Sd from the parent telephone 2 is received. This is the state of the child telephone 1 being on standby.
The state of the parent telephone 2 being on standby is similar to that in the conventional cordless telephone, i.e., by monitoring presence or absence of a ringer signal from the wire line, the parent telephone 2 stands by for an incoming call.
[Incoming Call]
If a call comes in from the wire line while the parent telephone 2 and the child telephone 1 are in their standby states, the ringer signal indicating the incoming call is detected by the NCU 239 and the microcomputer 240 is notified of the incoming call. Then, the processing of the microcomputer 240 is shifted to the routine 600. In step 601 of the routine 600, the data indicating the group written in the RAM 242 is read, and in the following step 602, the variable k specifying the channel in the read group is set to k=1.
In the following step 604, the data specifying the k-th channel of the group read in step 601 is supplied to the transmission circuit 210 and the reception circuit 220 and the transmitting and receiving channels are set to the k-th channel.
In the following step 605, it is judged whether or not the channel set in step 604 is being used by checking the signal RSSI. When it is used, the variable k is incremented in step 606 and the processing is returned to step 604. However, when k becomes k=11 as a result of increment in step 606, k is initialized to k=1.
If, in step 605, a channel corresponding to the variable k is not used, the processing advances to step 611.
Thus, the parent telephone 2, when there is an incoming call, selects an empty channel in the group assigned to the parent telephone 2.
In step 611, the parent telephone 2 calls the child telephone 1. This call is detected by the child telephone 1 in its standby state in step 505 and then the processing is advanced to step 511. Then, a predetermined protocol is executed between the child telephone 1 and the parent telephone 2 and they are connected by a line. Thereafter, the party at the other end of the line wire can talk with the user of the child telephone 1.
[Other Processes]
Outgoing call from the child telephone 1, termination of a call by the child telephone 1, and other processes are performed in the same manner as in the ordinary cordless telephone or in accordance with the basic protocol in the CT-2 system.
Although the case where 40 channels are sequentially divided into the first to fourth groups each having 10 channels was described in the foregoing, each group can alternatively be assigned channels (channel numbers) for example in accordance with the following expression:
C=S+I·k
where C: the channel number of a channel belonging to the I-th group
S: initial value, any value of S=1 to 31
I: channel interval, any value of I=1 to 4
k: variable, any integer of k=1to 9
FIG. 11 shows the alternative method of dividing channels into groups which is explained directly above. Note that FIG. 11 corresponds to FIG. 10, except that the channels are divided into groups according to the expression C=S+I·k at step 801. In this case, by arranging such that the values of S and I are transmitted and received when data of the group is transmitted and received in steps 432 and 332 and written into the RAMs 142 and 242, the channel number can be reconstructed.
Although an embodiment adapted to the CT-2 system has been described above, the present invention can also be applied to other systems than the CT-2 system provided that the system has a plurality of channels (four channels or above) and the channels can be divided into a plurality of groups each having two channels or above.
From the invention the following meritorious effects can be obtained.
Since the child telephone 1 can be put into a sleep mode while it is on standby, the battery for power supply can be suppressed from being consumed.
Since, in that case, the child telephone 1 scans only a portion of a plurality of channels, it becomes possible to make the period of sleep mode sufficiently longer than the period for the scan mode and, hence, a great power saving effect during the period of the sleep mode can be obtained. Further, since the cycle of the scan mode plus the sleep mode can be made shorter, the interval between the instant of sending request for receiving a call from the parent telephone and the instant of responding by the child telephone to the request for receiving an incoming call can accordingly be shortened.
Further, since the parent telephone 2 is only required to control channels of one group and also the child telephone 1 is only required to control a number of channels corresponding to the parent telephone 2 with which the child telephone 1 is registered, such operations as channel selection can be made faster.
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A method for facilitating communication between parent telephones and child telephones in a cordless telephone system. The method includes steps of dividing a plurality of channels into groups and assigning each parent telephone to one of the groups. When a child telephone is registered with one of the parent telephones, the child telephone may scan only the channels in the group assigned to the parent telephone with which the child telephone is registered, rather than the entire plurality of channels in the cordless telephone system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 61/593,368 filed Feb. 1, 2012, entitled “Exercise Adapter System,” the contents of which are incorporated herein by reference in their entirety.
BACKGROUND
[0002] The present disclosure relates generally to exercise equipment, and particularly to multiple-function fitness equipment for home or individual use. Some example multiple function exercise equipment includes bodyweight support bars for performing exercises such as pull-ups and push-ups. Some other examples of exercise equipment may include those which maintain a user's proper skeletomuscular alignment, or provide instability in limited directions to both engage the core of a user, such as exercise bars with variable or sliding grip separation.
[0003] The apparatus in this disclosure solves the problem of providing a sliding push-up bar and pull-up bar in the same device. Prior art products act as push-up stands or pull-up bars alone, or provide only a static frame without sliding handles. Existing push-up stands may consist of two handles elevated from the ground, or as a single bar placed on the floor or against a wall. Prior art combined pull-up/push-up bars do not provide a sliding function. Currently, U.S. Pat. No. 7,892,158 is provided only as a push-up stand with sliding handles, and includes three feet that sit on the ground and hold up the bar system containing the sliding handles. The apparatus in current disclosure provides horizontally sliding and rotating handles, in a push-up bar and pull-up bar combination.
SUMMARY
[0004] A fitness apparatus has an elongated main body, comprised of two bar sections connected rigidly in-line by opposite arms of a T-connector. Each bar section includes a sliding handle between a pair of retaining collars near each end of each tube section. The diameter constricts or tapers at each end of each bar section, the end generally the section from the retaining collar to the end of the bar. A radius elbow having a foot locks to the end of each bar section.
[0005] A first adapter for a first pull-up setting includes a crossbar affixed to an elbow tube slidably locked to the perpendicular leg of the T-connector. The apparatus may be mounted above a door frame to provide a horizontal bar for exercises such as sliding grip pull ups. The slidable lock between the T-connector and elbow tube allows the fitness apparatus to accommodate walls of various widths.
[0006] A second adapter for a second push-up setting includes a third foot fitted to a perpendicular leg of the T-connector. The apparatus may be set on a horizontal surface for sliding grip push-ups.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several embodiments in accordance with the disclosure and are, therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.
[0008] In the drawings:
[0009] FIG. 1 is a front plan view of an exemplary fitness apparatus in accordance with the disclosure;
[0010] FIG. 2 is a back plan view of the exemplary fitness apparatus of FIG. 1 ;
[0011] FIG. 3 is a perspective view of the exemplary fitness apparatus of FIG. 1 ;
[0012] FIG. 4 is a perspective view of an exemplary tube section of the fitness apparatus of FIG. 1 ;
[0013] FIG. 5 is a perspective view of an exemplary door frame adapter;
[0014] FIG. 6 is a perspective view of an exemplary T-connector;
[0015] FIG. 7 is a perspective view of an exemplary elbow tube, cross bar and T-connector;
[0016] FIG. 8 is an exemplary fitness apparatus in a first setting; FIG. 8( a ) shows the mounting side; FIG. 8( b ) shows the front side; and
[0017] FIG. 9 is an exemplary fitness apparatus in a second setting; FIG. 9( a ) shows an exemplary floor adapter foot; and FIG. 9( b ) shows perspective view of an exemplary fitness apparatus in a second setting.
DETAILED DESCRIPTION
[0018] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be used, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the Figures, may be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and make part of this disclosure.
[0019] Methods, systems, devices, and/or apparatus related to fitness equipment are described. Some example embodiments according to the present disclosure may pertain to adjustable exercise bars with multiple settings, for developing upper-body and core strength.
[0020] Referring to FIGS. 1-3 , perspective views of an exemplary embodiment of the fitness apparatus 100 are shown. FIG. 1 is a front plan view of apparatus 100 , as a user may approach apparatus 100 for use. FIG. 2 is a back plan view of apparatus 100 from the mounted side of a wall. FIG. 3 is a perspective view of apparatus 100 , to discern lateral aspects of apparatus 100 .
[0021] Apparatus 100 may be comprised of two generally identical elongated bars, 102 a and 102 b , which may be referred to as a single reference numeral 102 for simplicity. Each bar 102 a and 102 b includes two retaining collars 103 a and 103 b ; and 103 c and 103 d respectively, located near the end of each bar 102 . A T-connector 602 is rigidly disposed between bars 102 a and 102 b at the proximal end of each bar 102 , and connecting bars 102 a and 102 b in a generally straight line.
[0022] A radius elbow 108 may be attached to each bar 102 at the distal end of bar 102 beyond retaining collar 103 . Radius elbow 108 bends at approximately a 90 degree angle, and each radius elbow 108 includes a foot 110 . Each foot 110 may be flat on the bottom side, and canted on the top side from the center to the edges, to form a stable base and distribute a pressure exerted on bar 102 . Foot 110 is offset from bar 102 by a vertical leg of the radius elbow 108 , and any longer side of foot 110 may be substantially perpendicular to the bar 102 .
[0023] A handle 112 may be disposed on each bar 102 . Each handle 112 slides freely along bar 102 , between retaining collars 103 , which prevent handles 112 from sliding off bars 102 . Retaining collars 103 may be formed of metal or rubber. Handle 112 may be metal, and covered with a grip such as rubber, silicone, plastic, cork, foam, wood. Handle 112 may slide along bar 102 with a sliding mechanism, such as, but not limited to, ball bearings.
[0024] FIG. 3 shows elbow tube 104 , slidably attached to T-connector 602 . Relative to T-connector 602 , elbow tube 104 may have lateral extension 104 a and vertical extension 104 b . A crossbar 106 may be attached to an elbow tube 104 b by bolt 114 ( FIG. 2 ), and may be generally parallel to bar 102 . Slot 107 may allow elevation adjustments of apparatus 100 .
[0025] FIG. 4 is a view of an individual bar 102 . Bar 102 is disengaged from T-connector 602 to reveal the ends 402 of bar 102 . Ends 402 may be of a smaller diameter than body of bar 102 to allow uniform diameter across apparatus 100 when bars 102 are fitted into a connection tube. For example, the inner diameter of the connection tube may approximate the outer diameter of bar end 402 . Ends 402 may include rounded, spring-loaded pins 404 . Spring-loaded pins 404 may depress upon the application of pressure, and spring back upon the removal of pressure. For example, pins 404 may be pushed into the interior of bar 102 by T-connector 602 barrel 702 (shown in FIG. 7 ), and spring-lock into T-connector 602 hole 608 . In alternate embodiments, other connecting and locking mechanisms may be in place, such as a threaded, or a twist lock connection.
[0026] FIG. 5 shows an elevated view of a first adapter 500 , to mount apparatus 100 in a pull-up setting. Elbow tube 104 may include a proximal end 104 a and a distal end 104 b which meet at approximately a 90 degree angle. Elbow tube 104 may include end cap 406 . Elbow tube 104 b may connect to a crossbar 106 . Crossbar 106 may be a hollow or solid rectangular prism, and may include a thin, compressible strip 508 such as felt, on its wall facing side when apparatus 100 is mounted ( FIG. 8 ). In an exemplary embodiment, crossbar 106 may be plastic for weight savings, and reduce wall damage. Bolt 504 and corresponding threaded locking knob 502 extend through a diameter of elbow tube 104 a . Locking knob 502 allows a user to loosen or tighten knob 502 against bolt 504 without tools.
[0027] FIG. 6 is a perspective view of T-connector 602 with arm 604 and perpendicular leg 606 , and pin receiving holes 608 in both arm 604 and leg 606 . Perpendicular leg 606 includes an elongated track or slot 610 through its diameter. Slot 610 extends a partial length of leg 606 , may be rounded at the ends, and may be a width sized to fit a threaded portion of bolt 504 .
[0028] FIG. 7 shows adapter 500 attached to T-connector 602 . Elbow tube 104 may be slidably attached to T-tube 602 , and may lock into a position along slot 610 . Elbow tube 104 may be fitted over T-connector 602 , secured together by bolt 504 and knob 502 inserted through elbow tube 104 and slot 606 . Elbow tube 104 a may telescope along T-connector 602 by sliding bolt 504 along slot 610 . At a desired lateral extension, knob 502 may be tightened to bolt 504 to secure the length. Crossbar 106 may be attached to the interior side of elbow tube 104 b with bolt 114 , which extends through elbow tube 104 b into the interior of crossbar 106 .
[0029] Knob 502 may be loosened to allow elbow tube 104 a to slide along T-connector 602 . Knob 502 may be completely unscrewed and removed from bolt 504 , to allow separation of elbow tube 104 from T-connector 602 , such as for changing between a pull-up and a push-up setting of apparatus 100 .
[0030] In a first setting of an exemplary embodiment, FIG. 8A and FIG. 8B show apparatus 100 mounted over a door frame 802 on a wall 800 . Apparatus 100 may be mounted by placing the crossbar 106 over a ledge of the door frame 802 on a first side of a wall 800 , resting the feet against the second side of the wall 800 . Elbow tube 104 may be telescoped along T-connector 602 to an appropriate length, and tightening the bolt 504 and threaded knob 502 .
[0031] FIG. 8A shows crossbar 106 on a ledge of a doorframe against a first side of wall 800 , while bar 102 and handles 112 are on a second side of wall 800 . Crossbar 106 opposes a downward force, and a rotational force of apparatus 100 . Apparatus 100 may be adjusted for various wall 800 thickness by sliding elbow tube 104 along T-connector 602 in the steps described above.
[0032] FIG. 8B shows apparatus 100 mounted to a wall 800 as it would be approached for pull-ups. Feet 110 transfer a rotational force of bar 102 into wall 800 . Because crossbar 106 and feet 112 transfer opposing forces into wall 800 , apparatus 100 remains stable over the door frame 802 . Handles 112 freely slide along bar 102 as a user performs pull-ups.
[0033] FIG. 9 is a second, push-up, setting of an exemplary embodiment of apparatus 100 . FIG. 9A shows adapter 900 , including foot 912 as it may be connected to T-connector 602 with tube 914 . As shown in FIG. 9B , adapter 900 and feet 112 elevate bar 102 above a horizontal surface. Handle 112 may freely slide along bar 102 . For increased stability, any longer length of each foot 112 and 912 may be rotated to lie perpendicular to bar 102 .
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A multi-purpose, adjustable fitness apparatus is provided for performing exercises; in particular, sliding pull-ups and push-ups. Two in-line metal bars are interposed by a T-connector. A sliding handle grip may be disposed on each bar between a pair of retaining collars. A radius elbow including a foot is attached to each bar. A first adapter for a first setting includes a crossbar and elbow tube is slidably locked to the perpendicular leg of the T-connector. The apparatus may be mounted over a doorframe; the elbow tube and T-connector provides adjustability to fit frames of various widths. A second adapter for a second setting includes a third foot fitted to the T-connector, and provides stability on a horizontal surface.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to engine control devices, and particularly relates to mechanisms designed to remotely control the throttle, shift and emergency stop functions of marine engines.
2. Description of the Prior Art
A number of remote control units for marine engines have been developed in the prior art. The most widely used of these control units include a remote housing and a single control handle. The control handle is connected to the throttle and shift mechanisms of the engine by throttle and shift cables. The control unit also may include electrical switches which are connected to the electrical system of the engine. These remote control units permit operation of only the shift mechanism (forward or reverse) during the first portion of rotation of the control handle and then, during the last portion of rotation, permit control of only the throttle mechanism. Such arrangements are disclosed in the following U.S. Pat. Nos.: 3,301,084 to Boda; 3,309,938 to Pervier; and 4,027,555 to Rauchle, et al.
The United States patents to Pervier and Rauchle, et al, also describe a "warm up" or "throttle only" button positioned at the base of the control handle. This button disengages the shift mechanism and permits operation of only the throttle mechanism upon rotation of the handle. One disadvantage of such "throttle only" mechanisms is that they utilize a driving key which moves axially to engage or disengage a shift mechanism. This requires an elongated slot which is difficult and costly to manufacture.
One known prior control also includes a neutral lock mechanism. The neutral lock mechanism locks the control handle in a neutral position. Included in the neutral lock mechanism is a release lever or trigger to unlock the control handle. When unlocked, the control handle can be rotated to operate the shift and throttle mechanisms. The problem with this known prior control is that the trigger is on the lower surface of a T-shaped control handle. This position of the trigger is difficult to operate with a natural closing of the hand over the T-shaped control handle. This prior known control also was limited to a vertical handle position for neutral.
Marine engines have also used a safety stop switch as a separate accessory. A safety stop switch is used to stop the engine in an emergency. One suitable prior safety stop switch used a spring loaded push switch which when depressed permits the engine to operate. A cap is normally positioned on the switch to permit the engine to operate. The cap is connected to the operator so that if the operator is thrown from the control station the lanyard pulls the cap free of the switch causing the engine to stop. The safety stop switch must be continually depressed to allow a passenger to restart and run the engine in order to rescue the operator.
U.S. Pat. Nos. 2,588,650; 2,729,984; 2,826,283; 2,919,772; 2,975,653; 3,023,869; 3,165,941; 3,208,300; 2,702,615; 2,737,822; 2,884,109; 2,960,199; 2,986,044; 3,043,159; 3,202,125; 3,143,994; 2,705,485; 2,762,606; 2,907,421; 2,966,969; 2,987,152; 3,127,785; 3,204,732; and 3,160,027 describe prior remote control units for marine engines. These patents describe one method for absorbing unwanted throttle movement during shifting. This is accomplished by a spring attached to a control cable anchor point. When the control handle is moved for shifting, the spring maintains the idle throttle position until the shift motion is completed. Although satisfactory, it is not suitable for a compact design.
SUMMARY OF THE INVENTION
The present invention contemplates a safety stop switch for an engine, and more particularly a marine engine, for use with a remote control unit for the marine engine. Included is a control unit housing, and a normally closed toggle switch mounted on the housing and having a switch arm extending away from the housing to permit operation of the switch between closed and open positions. The switch is electrically connected to the engine to interrupt engine operation when switched to the open position. A key is included which encircles the switch arm, and means are provided for restricting removal of the key from the switch arm while the switch is in the closed position. Additional means, such as a lanyard, are coupled to the key to exert a force through the key against the switch arm to thereby operate the switch to the open position.
In a preferred embodiment, the restricting means preventing removal of the key while the switch arm is in the closed position comprises a hood having a lip at the extremity thereof which is spaced from the switch arm while in the closed position a dimension less than the thickness of the key. Preferably, the switch arm is mounted so as to move in a vertical plane, the hood further including a pair of slanted wing walls which extend away from the periphery of the control unit housing to the peripheral lip. The hood, including the lip and the wing wall portions thus form a partial enclosure about the switch, to maintain the key on the switch arm, until a sufficient force exerted along the length of the lanyard causes the key to pull the switch arm downward to interrupt operation of the engine.
The safety stop switch of the present invention permits the interruption of the engine operation during emergency conditions. Typical emergency conditions of this type may occur when the operator of the boat falls overboard. The lanyard attached to the operator thus draws the key downward, interrupting engine operation, until the switch arm is moved back into the normally closed position, which may be accomplished without using the key and without continuously holding the switch arm in the normally closed position.
THE DRAWING
FIG. 1 is a front elevation of the control unit incorporating the features of the present invention.
FIG. 2 is a cross sectional side elevation of the unit of FIG. 1, taken along the line 2--2.
FIG. 3 is a cross sectional top view of the unit of FIGS. 1 and 2, taken along the line 3--3 in FIG. 2.
FIG. 4 is a cross sectional top view of an internal portion of the unit of FIG. 1, taken along the line 4--4.
FIG. 5 is a back view of the unit shown in FIG. 1.
FIG. 6 is another back view of the unit of FIG. 1, with a portion of the structure shown in FIG. 5 removed, to more clearly illustrate the bias arrangement provided between the throttle arm and throttle lever.
FIG. 7 is a sectional view of another portion of the unit of FIG. 1, detailing the safety stop switch arrangement.
FIG. 8 is a cross sectional elevation illustrating an alternate embodiment of the "throttle only" control arrangement for the unit of FIGS. 1-7.
FIG. 9 illustrates details associated with the control handle lock mechanism for the unit shown in FIGS. 1-4.
DETAILED DESCRIPTION
Referring to FIGS. 1, 2 and 4, the control unit 10 includes a cover 12 having an internal cast housing 14. A control handle 16 is connected to a control shaft 18 extending through a central hole 20 in the housing 14. A bushing 22 surrounds the control shaft 18 in the central shaft hole 20. A "throttle only" or "warm up" button 24 is positioned at the bottom of the control handle 16, and is attached to a "throttle only" shaft 26. The shaft 26 is biased in an outward direction, as will be described below.
Referring to FIGS. 1, 2 and 3, the control handle 16 includes a hollow tube of generally rectangular cross-section having a crossed hand grip 28 at the top. A trigger 30 is positioned in the forward face of the grip 28, and is pivotally attached at pivot 32. In the operation of the trigger 30, it pivots at 32 to contact a stop 34, formed as an internal surface in the control handle 16.
The trigger 30 includes an aperture 36 and is forced outward by a spring 38 against a stop 40 formed within the grip 28.
As illustrated in FIGS. 2 and 3, the control unit 10 further includes a lock rod 42 having a bent upper end portion 44 retained within the aperture 36 of the trigger 30. As shown at the bottom of FIG. 2 and in detail in FIG. 9, the housing 14 includes a plurality of blind holes 46 positioned in a circular fashion about the central shaft hole 20. A lock ring 48 includes a pair of pins 49 for matching engagement with the holes 46 and slots 50 which engages the lower end of the lock rod 42. The lower end 52 of the lock rod 42 has a compound bend to engage one of the slots 50. The holes 46 in the housing 14 are spaced at equal angular distances about the central shaft hole 20 in the housing 14. In the preferred embodiment the holes 46 are about 30 degrees apart and the slots 50 in the lock ring 48 are offset about 15 degrees with respect to the radial line of the opposing slot. This permits the user to select a preferred neutral control handle position from a group of possible neutral positions. This is accomplished by alternately selecting one or the other slot and rotating the lock ring 48 to different positions with respect to the pins 49 and the holes 46.
Referring again to FIGS. 1, 2 and 3, the disengagement of the lower end 52 of the lock rod 42 can be accomplished by squeezing the trigger 30. This causes rotation of the upper end 44 which also causes the entire length of the lock rod 42 to rotate and disengage the lower end 52 from the slot 50. This causes the control handle 16 to be unlocked from the corresponding neutral position.
As shown in FIGS. 1 and 2, the control handle 16 is provided with a pair of push button switches 60 and 62 which are used to control the tilt of the marine engine in a conventional manner. These switches are surrounded by a lip 64 to prevent accidental operation. Electrical wires 66 extend through the control handle 16 and are connected with associated electrical wires 68 by a non-conductive encasement 70 which is hinged to lock corresponding male and female electrical connections associated with the wires 66 and 68 together. The control unit 10 is further provided with an ignition switch 72 which is operable with an associated key 74. The choke function is operated by axial movement of the key 74 into the switch 72. The key 74 is also encased in a plastic housing 76 having a collar 78. This facilitates movement of the key 74 toward the ignition switch 72.
In FIGS. 4 and 5, a shift gear 80 has a central opening therein surrounding the control shaft 18 to permit the shift gear 80 to rotate about that shaft. The shift gear 80 further includes a radial slot 84 and a conventional rotation limiting groove 86 on the opposing side from the slot 84, with a conventional limit pin 88 extending within the groove 86. A limited number of gear teeth 90 mesh with associated gear teeth 92 on the outer periphery of a shift pinion 94, which in turn is mounted on an associated throttle shaft 96. A shift lever 97 is fixed to the shift pinion 94 and is connected at one end to the shift cable 98. The entire assembly is supported in the housing 12 by a bearing plate 99. As will be described in greater detail below, the shift and throttle linkages are connected with the shaft 96 and associated hardware to control the shift and throttle cable linkages 98 and 100, respectively.
The warm up shaft 26 includes a tongue 102 at the inner end with the tongue having a ramp 104 along its outer periphery. A ball 106 is positioned within the depression formed by the ramp 104 and bears against a latch pin 108 extending through the slot 84 in the shift gear 80. The pin 108 is under compression by a ball 110 loaded with a spring 112. The tongue 102 is surrounded by a cylindrical member 114 which permits the tongue to slide axially through the housing 14. The cylindrical member 114 has a hole 115 adapted to receive the ball 106.
To warm up the marine engine, the throttle only button 24 (with the control handle 16 in the neutral position) is first depressed to move the shaft 26 axially toward the back of the housing 14. This forces the ball 106 upward into a hole in the control shaft which forces the latch pin 108 out of engagement with the hole in the control shaft. With the latch pin 108 disengaged from the control shaft 18, the control shaft 18 is free to rotate without engagement of the shift mechanism. Then the trigger 30 must be depressed to permit movement of the handle. Moving the handle will then only operate the throttle.
Upon warm up of the engine, combined throttle and shift is again obtained by moving the control handle back to the neutral position. This causes the lock rod 42 to engage the lock ring 48, and further causes the ball 106 to drop into the forward edge of the ramp 104. Then the load of the spring 112 against the ball 110 and the latch pin 108 causes further movement of the ball 106 downward across the surface of the ramp 104 to cam the throttle only shaft 26 outward thereby returning the warm up button 24 to the original position. As the pin 108 returns to its original position it is latched with the control shaft 18, thereafter causing the shift gear 80 to rotate with the control shaft 18 until such time as the throttle only button 24 is again depressed. The warm up construction described above permits manufacture of component parts at a low cost. The known prior throttle only components are very time consuming to manufacture at a reasonable cost. The warm up construction described above only requires the drilling of one hole in the control shaft 18 (the hole which engages the pin 108) and the forming of the slot 84 during the casting of the shift gear 80. Thus, the use of the radial motion shown in FIG. 4 provides a highly reliable, relatively inexpensive method for providing the throttle only feature of the control unit 10.
An alternate arrangement for providing the throttle only control is shown in FIG. 8 with like reference numerals employed with respect to the same elements which are shown in FIGS. 1 through 7.
In FIG. 8 the throttle only control comprises a knob 120 extending through the control shaft 18 and having a key 122 extending axially therefrom toward the rear of the control unit. The key 122 includes a ramp 124 similar to the ramp 104 of FIG. 4 but being ramped in the opposing direction. A detent groove 126 is positioned at the inner end of the key 122. A ball 106 is positioned in a corresponding hole in the control shaft 18 and engages the latch pin 108 which in turn is pushed inward by another ball 110 and a spring 128. In the arrangement of FIG. 8, the throttle only mechanism is activated by pulling the knob 120 outwardly causing the ball 106 to be cammed up the ramp 124 and coming to rest in the detent 126. This movement forces the latch pin 108 upward and out of contact with the control shaft 18. As a result the shift gear 80 (with which the latch pin 108 is engaged by a slot 84 like the slot of FIG. 4), is disengaged from the control shaft 18. This disengages the shift mechanism thereby permitting the control handle to provide throttle only for engine warm up.
Upon engine warm up the shift mechanism is engaged by moving the control handle 16 to the neutral position and pushing the throttle only knob 120 inward. This causes the ball 106 to initially be driven upward against the latch pin 108, ball 110 and spring 128. After the ball passes out of the detent 126 it is cammed downward over the ramp 124 coming to rest in a position which permits the pin 108 to again engage the control shaft 18 to thereafter rotate the shift gear 80 with the control shaft. The throttle only feature shown in FIG. 8 requires a manual return of the throttle only knob 120 while the throttle only feature shown in FIG. 4 automatically returns the control to a combined throttle and shift operation.
Referring to FIGS. 5 and 6, the throttle mechanism includes a detent plate 129 and a crank arm 130 which are connected for rotation with the control shaft 18, and a link 132 connecting the crank arm 130 and a throttle lever 134. The throttle lever 134 is connected to a throttle arm 136 which in turn is attached to the throttle control cable 100. Rotation between the throttle lever 134 and the throttle arm 136 is limited by a pin 138 fixed to the throttle lever 134 and extending into a slot in the throttle arm 136. The purpose of this limited rotation between the throttle lever 134 and the throttle arm 136 is to absorb the motion of the crank arm 130 as it moves 30 degrees either way from dead center during operation of the shift mechanism.
To prevent the throttle control cable 100 from being moved during the 30 degrees of rotation of the handle 16 during operation of the shift mechanism, a spring 142 is inserted between the throttle lever 134 and the throttle arm 136 to keep the throttle arm tight against the idle stop while the throttle lever is moving. The spring 142 is mounted on corresponding tabs 144 and 146 on the throttle lever 134 and throttle arm 136. The throttle arm 136 is double ended so that the throttle control cable 100 can be attached to either end and be pulled or pushed to increase engine speed in the desired manner. This makes the control unit 10 useable for a variety of different engine throttle linkages. To permit a right hand or left hand control for installation on either side of the boat, the crank arm 130, throttle lever 134 and throttle arm 136 are all symmetrical so that the connecting link and spring can be assembled on either side of the throttle lever and arm.
Referring to FIGS. 1, 4, 5 and 7, a safety stop switch assembly is mounted on the rearward face of the housing 14. The safety stop switch comprises a conventional single pole single throw toggle switch having a switch arm 154 extending outward from the periphery of the cover 12. The throw of the switch is maintained in a vertical direction. The switch 152 is connected to the electrical system of the engine to turn the engine off when the switch arm 154 is in the down position. (Note electrical connection shown in FIG. 5). The switch arm 154 is partially surrounded by a switch hood 156, the edge of the hood having a lip which is positioned close to the outward end of the switch arm 154 when the switch is in the "up" position (Note FIG. 7). Slanted wing portions extend between the periphery of the cover 12 and the lip.
The safety stop switch 152 is also provided wih a key 158 which comprises a closed loop which can be positioned under the hood 156 to encircle the switch arm 154 (Note FIGS. 1, 4 and 7). The thickness of the key 158 is dimensioned so that it cannot pass between the switch arm 154 and the hood 156 while the switch arm 154 is in the "up" position. The key 158 further includes a hole at the bottom for receiving a lanyard 160 which can be attached to the operator of the boat.
In use, if the operator of the boat accidently falls overboard, the lanyard 160 pulls the key 158, causing the switch arm 152 to be pulled to the down (and off) position, thereby interrupting operation of the engine. The engine may be restarted and operated by reaching under the hood 156 and forcing the switch arm 154 into the up or "run" position. This permits the engine to be started and then run without continuous manual operation of the safety stop switch 152. This is useful in emergencies to permit a passenger to operate the boat without using the key 158.
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A safety stop switch for a marine engine includes a control unit housing, and a normally closed, single throw toggle switch mounted on the housing and including a switch arm extending away from the housing to permit operation of the switch between closed and open positions. The switch is electrically connected to the engine to interrupt engine operation when switched to the open position. A hood extends from the periphery of the housing and covers the switch arm when in the closed position, and has a peripheral lip which is spaced from the switch arm a dimension which is less than the thickness of a key which encircles the switch arm. A lanyard is connected to the key and to the boat operator, and upon the exertion of a force on the lanyard, the key pulls the switch arm down into the open position, thereby interrupting operation of the marine engine.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to method for producing a garland or decorative arrangement using Spanish moss and, more particularly, for making a decorative arrangement using such moss to create a spooky appearance for Halloween.
[0002] Spanish moss ( Tillandsia usneoides ) is a flowering plant that grows upon larger trees, commonly the Southern Live Oak or Bald Cypress throughout the southeastern United States and also in Mexico and in Hawaii. The plant has slender stems with thin, curved or curly, heavily scaled leaves that range between 0.5 and 2.5 inches in length and are about 0.04 inches in width so that they appear as string-like cords of a grayish green color when live. The leaves and stems grow in chain-like fashion to form hanging structures up to 20 feet in length. The individual leaves and stems tend to be fragile and break away in fragments that blow on the wind and stick to other trees and limbs where they grow into new hanging structures. Birds have also been known to collect Spanish moss to create nests which further spreads the moss into new locations.
[0003] The elongate stems and leaves of Spanish moss tend to intertwine and create a structure that is often home for a number of creatures, including rat snakes, bats and insects. Spiders are common in moss structures as are redbugs, or chiggers, the latter being a source of an unpleasant, itching rash on the skin if the plants are handled. Spanish-moss was harvested for years as a stuffing material in automobile seats, furniture, and mattresses. The plants were dried and cured before being used.
[0004] It is known to use Spanish moss to create a spooky mood by hanging such moss so as to simulate the appearance of spider webs and other items that often collect in deserted houses or other buildings and in outdoor areas. However, because Spanish moss is a live parasite that is often the home for other insects, such as spiders and chiggers, the moss must be treated before use. Another problem with using Spanish moss for decoration is that the moss rapidly begins to die and deteriorate when taken from its host, such as oak trees. As the Spanish moss dies, it begins to break into small pieces in response to any disturbance thus creating a messy environment. However, it is desirable to dry and cure the moss before use to eliminate the insects in the moss thus enhancing the detrimental breakage of the moss stems and leaves.
SUMMARY OF THE INVENTION
[0005] The present invention provides a method for treating Spanish moss and for creating a decorative arrangement that overcomes the disadvantages discussed above. Spanish moss that is collected from its natural environment can be treated, if necessary, with a pesticide to destroy any live insects that may be found in the moss. The moss is then dried so that it is no longer living. The dried moss is then separated into strands and draped over a cord that has been pre-treated with an adhesive binder. The adhesive binder causes the strands to adhere to the cord and creates a continuous layer of moss over the length of the cord. The strands are then sprayed with another adhesive that covers the strands and provides a binder that supports the strands and prevents the dead moss from further deterioration. The layers of moss are then allowed to dry for a further period so that the adhesive binder sets and is no longer tacky to the touch. Predetermined lengths of the layers of moss are then packaged for retail sale.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] For a better understanding of the present invention, reference is made to the following detailed description taken in conjunction with the accompanying drawings in which:
[0007] FIG. 1 is a view of a decorative arrangement or garland of Spanish moss in a form in which it would be applied for use as a decoration; and
[0008] FIG. 2 is a block diagram illustrating a preferred method of producing the garland of FIG. 1 .
DETAILED DESCRIPTION
[0009] Referring to FIG. 1 , there is shown a decorative arrangement 10 of Spanish moss produced in accordance with the teaching of the present invention. As shown in this figure, the moss has been separated into strands 12 and a plurality (or a group) of such strands are draped over a support, preferrably a cord or string 14 of either natural or man-made fibers having flexibility so that the decoration can be rolled for packaging and storage and easily unpacked for decorating by draping across an opening such as a window or doorway. The strands 12 are created by pulling the moss stems and leaves apart to separate the intertwined bunches into smaller segments typically about five inches in width and about three to four feet in length. Such strands are about one to two inches in thickness and can either be laid flat or hung over a support for drying. The cord 14 has extended ends to allow the decorative arrangement to be affixed at each end using tacks or tape or other fasteners. During the manufacturing process, the arrangement 10 is supported on a pole 16 as will be described hereinafter.
[0010] Turning now to FIG. 2 , there is shown a preferred process in block diagram form for creating the decorative arrangement of FIG. 1 . The first step, after obtaining a supply of Spanish moss, is to dry the moss, block 20 , until all of the green tinge has disappeared so that there is no live portion of the moss remaining. The drying process is necessary to prevent growth of algae on the moss if the moisture content is not sufficiently reduced and to avoid “rotting” of the moss when packaged. Applicants have found that drying the moss in a kiln at about 160 degrees Fahrenheit for about eight hours is sufficient to remove moisture and to eliminate any pests habitant in the moss. It is also possible to sun dry the moss if protected from rain but such process can take up to 18 days or more depending on relative humidity. Sun drying may not kill any insects in the moss and may require use of an insecticide treatment. Further, for sun drying, the moss must be spread onto a protective supporting sheet such as a plastic or fabric tarpaulin and therefore requires a large outdoor, unobstructed area. Once the moss has dried, it can be colored using a dye spray or submersion if desired but then requires additional drying time for the dye liquid to dry.
[0011] After drying the moss, it is now ready to be separated into long strands that can be draped over the cord 14 , block 21 . The preferred method of separation of the moss into strands is to manually pull the moss apart. As discussed above, Spanish moss grows with a stem from which a leaf structure extends. Both the stem and leaf structure are structurally weak. Typically, the plant consists of a slender stem bearing alternate thin, curved or curly, heavily scaled leaves 2-6 cm long and 1 mm broad that grow in chain-like fashion (pendant) to form hanging structures up to 6 m in length. The moss stem is not much larger in cross section than the leaves. Leaves from adjacent stems tend to intertwine and cause the moss to hang from trees in globular masses. The process of separating the moss into strands involves manually pulling the masses apart until a reasonable size segment or strand of moss results.
[0012] In block 22 , the cord 14 is prepared by applying an adhesive binder to the cord. The preferred method is to pass the cord through a container containing the adhesive. Applicants use a 3-ply jute twine for the cord 14 and a latex adhesive such as a Hycar brand binder available under their model number 26349. One method for coating the cord with the adhesive is to partially fill a container with the adhesive, submerge a metal rod or other retainer in the adhesive, and then pass the end of the cord into the container and under the retainer so that as the cord is pulled through the container, it becomes saturated with the adhesive. The cord 14 is then cut to a desired length using any conventional cutting mechanism and then stretched across an elongate support, block 24 .
[0013] The support may be any type of pole such as bamboo rod 16 to which the cord 14 can be attached. In a preferred form, a single pole is be used for each cord 14 with the cord attached to the pole at opposite ends. A hook, screw or other feature may be fastened adjacent ends of the pole to provide an easy connection point for the ends of the cord. The advantage of using the single pole is that each of the decorative arrangements can be individually handled rather than having a plurality of the arrangements 10 that must be processed together. For example, since each arrangement must be individually created by draping the separated strands 12 of moss over the cord 14 , block 26 , having a separate pole for each arrangement allows a worker to position the pole in a convenient position for placing the moss on the cord. As stated in block 26 , the worker separates the dried moss into long strands and then hangs or drapes the strands over the adhesive soaked cord 14 in adjacent positions to create the arrangement as shown in FIG. 1 . It will be appreciated that the moss strands are placed on the cord 14 before the adhesive has dried so that the moss will bond to the cord via the adhesive. It is desirable to press the moss into the adhesive to assure sufficient bonding of the moss to the cord 14 . With the single pole method described above, once the cord has been covered with the moss, the pole can then be placed on a support rack, not shown, awaiting the next step in the process.
[0014] As previously discussed, one problem with handling of Spanish moss is its brittleness that causes constant breakage of small pieces of moss, particularly after the moss is no longer alive and has been dried to a low moisture content. In order to overcome this problem, the decorative arrangements 10 are next processed by applying a spray coating of an adhesive binder to the arrangements, block 28 . The binder may be applied in a conventional type of spray or paint booth or, if the weather permits, in an outdoor environment. In a preferred embodiment, the decorative arrangements 10 are processed through a spray booth that assures relatively even coating of the moss with the adhesive binder. In the spray booth, not shown, a pair of pneumatic spray guns direct a diluted adhesive onto both sides of each arrangement 10 . The adhesive may be the same adhesive identified above for coating of the cord 14 but diluted enough to be applied via the spray guns. If necessary to assure even coating, additional spray guns may be used in the booth with all of the spray guns being fixed in position and remotely actuated. Alternatively, a mechanical sensor or an electronic sensor may be used to sense the presence of an arrangement 10 in the spray booth and actuate the spray guns. The decorative arrangements 10 may be advanced through the spray booth using any conventional type of mechanism common to automated spray booths. Such a mechanism allows a series of arrangements or garlands to be sequentially passed through the spray booth for production purposes.
[0015] In the present invention, the decorative arrangement or garland 10 is hung from overhead hooks or hangers (not shown) using the pole 16 . The overhead hangers are part of a conventional mechanism such as a circulating chain conveyer that advances the hangers into and through the spray booth. The aforementioned spray guns are coupled to a pressurized tank of Hycar adhesive and are actuated by detection of a leading edge of a garland 10 entering the spray booth. After the garland is sprayed with the adhesive, the conveyer advances it out of the spray booth where it is removed from the overhead hangers and placed on a drying rack, block 30 . It has been found that the adhesive covering the moss is sufficiently dry within about 24 hours to allow the garland 10 to be removed from the pole 16 and prepared for packaging, block 30 .
[0016] It is desirable to package the garland 10 , block 32 , in a minimum size package in order to reduce shelf space requirements in a retail outlet. However, it has been found that simply rolling up or folding the garland results in the overlapping strands becoming entangled with each other and causes undue breakage when separated by a user. In order to prevent such entangling, applicant lays out the garland on a surface and covers the garland with tissue paper. The garland can then be rolled with the tissue paper separating the overlapping layers. The rolled garland can then be inserted into a bag. It has been found that use of the tissue paper also reduces breakage of the individual stems and leaves of the moss. Preferably, the bag is a conventional type of plastic package that can be heat sealed for moisture protection. Various methods are known in the art for inserting the rolled garland into the bag and applicant has found that the use of a simple chute is effective for this purpose.
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A method is disclosed for treating Spanish moss and for creating a decorative arrangement of the moss. Spanish moss is collected, treated with a pesticide, if necessary, and dried to remove substantially all moisture. The dried moss is separated into strands and draped over a cord that has been pre-treated with an adhesive binder to cause the strands of moss to adhere to the cord and create a continuous layer of moss over the length of the cord. The strands are then sprayed with adhesive that covers the strands and provides a binder that supports the strands and prevents the dried moss from deterioration. The adhesive covered layer of moss is then dried until the adhesive binder has set and is no longer tacky to the touch. Predetermined lengths of the layers of moss are then packaged for retail sale.
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BACKGROUND OF THE INVENTION
The invention relates to a cabinet hinge having a wall-related part in the form of an elongated arm of substantially channel-like cross section which is coupled pivotingly by a linkage to the door-related part. The door is mounted for adjustment in at least two coordinate directions on a mounting plate which can be fastened to the wall of a cabinet, while the flanges of the channel at least partially straddle the mounting plate. The web portion of the arm, at its end remote from the hinge link, has a longitudinal slot with an open end or an enlarged pass-through opening through which passes the shank of a holding screw threaded into the mounting plate. The web is also provided at a distance from the slot with a tap through which a threaded spindle is driven so as to thrust against the mounting plate. In an inside surface of the arm facing the mounting plate there is provided an abutment which projects toward the hinge-link end of the arm, and in the area of the mounting plate opposite this abutment a projecting resilient catch is provided. The catch on the mounting-plate is adapted to engage the abutment on the arm when the arm is displaced lengthwise parallel to the wall on the mounting plate, just as the shank of the screw driven into the mounting plate enters into the rearward area of transition between the longitudinal slot and the pass-through opening or open end of the slot.
Cabinet hinges of this kind (U.S. Pat. No. 4,517,706) have overcome the disadvantage of older hinges which consists in the danger of the separation of the arm from the mounting plate and thus the dropping of a door attached to a cabinet with such hinges as long as the screws holding the arm on the mounting plate are not tightened, because, for example, a precise adjustment of the depth or of the overlap of the door relative to the cabinet is yet to be performed. By means of the catch on the mounting plate and its abutment on the arm, which engage one another when the arm is pushed onto the mounting plate, the assurance is provided that accidental separation is no longer possible. At the same time the possibility of the adjustment of the arm on the mounting plate and thus of the door relative to the cabinet is made no more difficult than it was in the case of the older hinges. The known hinges have proven practical and are widely used.
To release the safety catch in these hinges when a door is to be removed from the cabinet for furniture moving purposes, it is necessary only to back out the screw holding the arm on the mounting plate by such an additional amount that the arm can be raised at right angles to the wall such that the abutment on the arm can be disengaged from the catch on the mounting plate. In the raised position the arm can then be withdrawn from the mounting plate. The deliberate backing off of the screws for this purpose does not involve much work, but it has the disadvantage that the safety-catching of the arm on the mounting plate is not assured when the door is later reinstalled on the cabinet if one has forgotten to turn the screw back into the mounting plate by the necessary amount.
Accordingly, the invention is addressed to the problem of improving the known hinges such that the safety catch securing the arm on the mounting plate can be more easily and quickly disengaged in case of need without loss of effectiveness and security, and can be automatically restored upon subsequent reassembly without the need for special measures or manipulations.
SUMMARY OF THE INVENTION
Setting out from a cabinet hinge of the kind mentioned in the beginning, this problem is solved according to the invention in that the resilient catch is in the form of a leaf spring which is disposed in the hollow interior of the mounting plate with its end remote from the hinge linkage affixed to the corresponding end of the mounting plate, and which extends toward the hinge linkage in substantially parallel contact with the underside of the mounting plate bridge spanning its hollow interior; in that the free end of the leaf spring has a portion bent toward the arm through a cutout in the bridge of the mounting plate and forming a catch, and in that the holding screw driven into the mounting plate passes freely through an oversize bore in the mounting plate bridge, and is screwed into a complementary threaded eye provided in the leaf spring underneath the oversize bore. Therefore, unlike the state of the art, the threaded portion of the holding screw is not driven into the mounting plate but into the threaded eye in the leaf spring through the oversize bore in the mounting plate. By backing the holding screw out of the threaded eye, the arm previously clamped against the mounting plate can be loosened and drawn out until the abutment on the arm and the catch on the leaf spring engage one another, i.e., to a point just before the arm becomes separated from the mounting plate. For the final release, however, the free end of the leaf spring must be deflected toward the cabinet wall until the catch and its abutment are free and clear of one another. This is accomplished simply by pressing the loosened holding screw downward, i.e., toward the cabinet wall. The leaf spring is thereby deflected downwardly, and its free end bearing the catch goes back into the cutout in the bridge of the mounting plate, thereby disengaging the safety catch and releasing the arm. The head of the holding screw, therefore, serves not only for engagement by a screwdriver to fasten or unfasten the arm on the mounting plate, but it also constitutes a pushbutton for the release of the safety catch. Since the holding screw is much closer to the fixed end of the leaf spring than to the free end bearing the catch, the releasing movement performed on the leaf spring with the holding screw loosened will be proportional to the lever arms measured between the threaded eye and fixed end on the one hand and between the catch and the fixed end on the other. In other words, the holding screw needs only to be backed out from the threaded eye in the leaf spring by a small amount in order to produce the greater movement required for the release of the arm at the location of the catch and its cooperating abutment.
The catch abutment on the arm can be formed by creating an indentation in the web of the arm, and the hinge-linkage end of the depression surrounding the longitudinal slot in the arm is available for this purpose.
In the hollow of the mounting plate underneath the cutout in its bridge, there is provided, in an advantageous further development of the invention, an abutment for the arris at the free end of the leaf spring, this abutment being disposed at such a distance below the cutout that, when the free end of the leaf spring is pushed downwardly, the edge of the catch will disappear just below the surface of the bridge. The releasing movement of the catch is thus limited to what is necessary, assuring that, even if the holding screw is backed out more than is needed, the leaf spring can still be depressed no more than the small amount necessary for the release of the catch. Any accidental excessive flexing of the leaf spring that might result in permanent deformation so that the catch and its abutment might fail to engage one another is thus prevented.
The leaf spring is best riveted at its end remote from the hinge link to the underside of the bridge of the mounting plate.
To provide the leaf spring with the necessary strength, and at the same time to give it sufficient resilience, it is recommendable to provide it with a cutout in the area between its threaded eye and its fixed end, thus reducing its resistance to flexure in the area beside the cutout in comparison to the other areas of the spring.
To form the catch, it is expedient to provide a cutout also in the free end area of the leaf spring, giving it such a shape that a tongue projecting towards the fixed end of the spring will be created. Then the free end of the spring is bent downwardly along a transverse line so that the free end of the tongue will project upwardly through the cutout in the bridge of the mounting plate. The downwardly bent free end of the leaf spring then cooperates with the above-mentioned abutment in the hollow of the mounting plate.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be further explained in the following description of an embodiment in conjunction with the drawing, wherein:
FIG. 1 is a longitudinal cross section through the center of the cabinet-wall-related part of a hinge according to the invention, which is held on its mounting plate,
FIG. 2 is a plan view of the mounting plate, as seen in the direction of arrow 2 in FIG. 1,
FIG. 3 is a longitudinal cross section through the leaf spring provided in the hollow of the mounting plate, showing its catch, and
FIG. 4 is a plan view of the leaf spring, as seen in the direction of the arrow 4 in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, only the parts of a hinge, generally indicated at 10, which are to be fastened to a cabinet are shown, namely the cantilever arm 12 and its mounting plate 14, which is to be screwed to the wall of the cabinet, and on which the arm 12 is mounted so as to be adjustable and, in its configuration according to the invention, secured against accidental separation when the fasteners holding it thereon are loosened. Let it be assumed that the door-related part in the form of a cup mortised in the back of the door is coupled by a linkage mechanism, not shown, to the left end of the arm 12 as shown in FIG. 1. The linkage mechanism may be, for example, a common four-joint mechanism formed by two hinge links whose ends are journaled in a conventional manner in the cup at one end and on the arm 12 on the other. The bores 16a and 16b shown at the left end of the arm in FIG. 1 serve to accommodate pivots for the hinge links mentioned above.
As stated, the arm 12 can be fastened adjustably on the mounting plate 14 which, in the present case, is an adjustable-height, so-called "wing plate." The height adjustment is provided by means of a known two-part construction of the mounting plate 14 having a bottom part 14a that can be screwed directly to the cabinet wall, and an upper part 14b which is adjustable on this bottom part 14a in the direction of the height of a door that is to be hung by means of the hinge according to the invention, i.e., in FIG. 2, showing the mounting plate alone in plan, in a vertical direction. The height adjustment and the manner in which it is achieved is not, however, part of the present invention and therefore is not further described, inasmuch as the securing of the arm 12 against unintentional separation from the mounting plate, which is striven for in the invention, can be achieved in the same manner even in one-piece mounting plates which are not adjustable in height. The mounting plate 14 has a bridge 18 from which flat, wing-like projections 20 extend, each having a through-bore 22 for fastening. It is these wing-like projections 20 that give such mounting plates their name of "wing plates." For the invention, however, it is immaterial whether the mounting plate is configured as a wing plate in this manner, or is in the otherwise common oblong configuration.
The arm 12, which is made by stamping from sheet metal, is substantially channel-shaped, with flanges 24 joined along their upper margins by a web 26. In the end portion situated on the left in FIG. 1, the previously mentioned bores 16a and 16b are provided in the flanges 24 for the pivot pins of the hinge links.
In the substantially flat, sunken end portion 32 of the web 26, which is on the right in FIG. 1, i.e., the side opposite the hinge linkage, there is provided a longitudinal slot 34, open at the end of the arm, which serves to accommodate the threaded shaft of a screw 36 by which the arm 12 is fastened at its end remote from the hinge linkage to the mounting plate 14. The underside of the sunken end portion 32 is best provided with transverse serrations.
At a distance from the sunken end portion 32, a tap 38 is provided centrally in the web 26, into which a threaded spindle 40 is driven, to whose inner end between the flanges 24, a holding head 40b of enlarged diameter is connected by a constricted neck section 40a. Between the threaded portion of the spindle 40 and the holding head a circumferential groove is thus formed. The sunken portion 32 forms at its front end facing the hinge linkages, between the flanges 24, an abutment 44, which will be further explained below.
The bridge 18 of the mounting plate 14, which is higher than the wing-like projections 20, has a width in its upper portion corresponding approximately to the free width between the inside faces of the flanges 24 of the arm 12, so that the arm 12 can therefore be slid onto the mounting plate such that the flanges 24 straddle the bridge 18. In the right end portion of mounting plate 14 as seen in FIG. 1, there is provided a surface for fastening 46, with transverse serrations corresponding to the above-mentioned transverse serrations in the end portion of the arm 12. A bore 46a is provided in about the middle of the fastening surface 46 through which the shaft of the screw 36 is fitted with clearance. At its front end, the bridge 18 is provided with a longitudinal groove 48 which is open at its left end and is narrower at its upper side where it is wide enough to permit the neck section 40a between the holding head 40b and the threaded portion of the spindle 40 to be fitted into it. The mounting of the arm 12 on the mounting plate 14 is performed by sliding the arm with its longitudinal slot 34 under the head of the screw 36 which is held in the space under the bridge 18 in a thread provided underneath the bore 46a, and has been loosened, and at the same time the neck section 40a is slipped into the narrowed longitudinal groove 48. It can be seen that the arm 12 can be fastened at selectable positions on the mounting plate 14 along the slot 34, and that the holding of the arm against longitudinal displacement is then accomplished by tightening the screw 36 to draw the transverse serrations on the underside of the end portion 32 against the transverse serrations of the fastening surface 46. It can also be seen that the distance between the front (left) end of the arm 12 and the mounting plate bottom formed by the underside of the wing projections 20 can be varied on an associated cabinet wall by changing the depth of the threaded spindle 40 in the tap 38. The arm 12 is therefore adjustable in two coordinate directions, namely in the lengthwise direction and at right angles thereto, i.e., approximately perpendicularly to the cabinet wall surface, in addition to the adjustability in height that is provided in the mounting plate.
As it can be seen especially in FIG. 1, a catch in the form of the leaf spring 50 shown separately in FIGS. 3 and 4 is disposed in the hollow space under the bridge 18. This substantially planar leaf spring 50 has a hole 52 punched in its right end, by means of which it is riveted at 54 against the underside of the bridge 18. In alignment with the bore 46a in the fastening surface 46 on the bridge 18, the leaf spring 50 has a threaded eye 56 whose thread matches the thread on the shaft of the screw 36. When screw 36 is tightened, therefore, its threaded portion is driven through the threaded eye 56 until its head is pressing sufficiently tightly on the margins of the recess 32 which define the sides of the longitudinal slot 34, and thus the serrations in the bottom of the recess 32 and those in the upper side of the fastening surface 46 are pressed against one another. At the same time the leaf spring 50 is pressed in firm engagement with the underside of the bridge 18. The end of the leaf spring 50 that is on the left in FIG. 1 extends beneath a cutout 58 in the bridge 18 and is provided with the double bend 60, which will be described in conjunction with FIGS. 3 and 4. Owing to the double bend 60, this end portion of the leaf spring enters into the cutout 58, and the edge 64 of a tongue 62 stamped out of the leaf spring 50 projects above the top of the bridge 18. It is evident that the catch 62 permits the arm 12 to slide over the edge 64 in the direction of withdrawal from the mounting plate with screw 36 loosened, but only until it comes in contact with the abutment 44 provided on the arm 12. It is assumed that this contact will occur just as the shaft of the screw 36 enters into the open end of the slot 34 and the holding head 40b enters into the mouth of the longitudinal groove 48, i.e., the catch formed by tongue 62 with the abutment 44 restricts the adjustability of the arm on the mounting plate to a range in which there is still no danger of accidental release. Adjustment in the opposite direction, however, i.e., in the direction of the cabinet interior, is not prevented, so that the arm is therefore mounted on the mounting plate so as to be adjustable to the usual extent, but is secured against accidental separation from the mounting plate.
There are two ways of removing the arm 12 completely from the mounting plate 14. Either the screw 36 is backed out by a certain, relatively small amount, so that its head can assume, for example, the position represented in broken lines in FIG. 1. Then, when the tip of the screwdriver, also indicated in broken lines is pressed against the head of the screw 36, the leaf spring 50 will flex and its free end bearing the catch 62 will withdraw below the surface of bridge 18 into the cutout 58, thus disengaging the catch 62 from the abutment 44, and the arm can then be withdrawn from the mounting plate. Alternatively, it is also possible to drive the screw further in to such an extent that such a gap is created between the head of the screw and the rearward end of the arm that this rearward end can be lifted over the edge 64 of catch 62. However, the first-described method is to be preferred, since it assures that the arm, when later slipped onto the mounting plate, will snap over the protruding end of the leaf spring and then be automatically re-secured.
So that the force to be exerted on the head of the screw in order to flex the leaf spring 50 will not be too high, the leaf spring 50 has in the area between its threaded eye 56 and the riveted end the opening 66 which can be seen in FIG. 4, which in the narrow leaf-spring areas alongside the opening reduces the resistance of the leaf spring 50 to flexing in comparison to the broader areas of the leaf spring. In this manner a relatively stiff material can be used in making the leaf spring, in which the danger of any accidental distortion of the free end does not exist.
To prevent an excessive flexing of the leaf spring, possibly resulting in permanent deformation, when the arm 12 is released from the mounting plate 14 in the manner described, an abutment 68 is provided within the hollow of the bridge 18 of the mounting plate, beneath the cutout 58, and as soon as the edge 64 of the tongue 62 is lowered below the level of the surface of the bridge the free end of the spring will abut against it.
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Cabinet hinge whose cabinet-wall-related part in the form of a cantilever arm can be slipped onto a mounting plate installed on the wall of a cabinet and can then be fixed at selected positions on the mounting plate by tightening a screw. The mounting plate bears a resilient catch which, at the beginning of the installation of the cantilever arm engages an abutment on the latter and thus secures it against accidental withdrawal from the mounting plate, without interfering with its movement for longitudinal adjustment on the mounting plate. The catch is provided on a leaf spring which is fastened at one end within the mounting plate while its free end bearing the catch protrudes through an opening in the mounting plate. The arm-holding screw is passed with clearance through an oversize hole in the mounting plate and driven into a threaded eye in the leaf spring.
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BACKGROUND OF THE INVENTION
This invention relates to hammocks and, in particular, to a design that compensates for hammock sag without manual readjustment. My criteria were that the hammock had to be light and simple to install, easy to cover, and a better alternative to current hammock models, air mattresses, and foam pads.
Hammocks in one form or another have been in use for centuries. Other attempts have been made to create a level model.
In the Brazilian hammock, this was done by making the hammock bed so wide that the user could rest diagonally in its middle. The drawback is that the bed has to be held apart with adjustment cords not to impede the occupant. The hammock also funnels rainwater towards the user and is large and difficult to cover in wet weather.
Canvas and rope hammocks made flat by being very tightly strung were previously utilized in various navies. They could, however, only be slung in specific locations, took practice to install, and were not meant to be portable.
The Hennesy hammock, U.S. Pat. No. 6,185,763 B1, addresses the problem of hammock sag. It has an adjustable ridgeline for sag compensation. However, this has to be done manually and the line must be re-tightened depending on the load. Also, the Hennesy hammock has to be spread apart with side adjustment cords to allow the user to lie flat along its diagonal.
BRIEF SUMMARY OF THE INVENTION
This invention was made to create a flat, light and more comfortable alternative to resting on the ground using an air mattress or foam pad. To utilize a hammock was an obvious solution, but as most people are not comfortable sleeping on their back only, I found it necessary to re-design the conventional hammock so it had a flat bed. My hammock is portable, easy to install, and does not require re-adjustment depending on the load. It needs no side adjustment cords to be held apart and the user rests in it lengthwise which makes it compact and easy to install.
Originally my hammock was intended for long distance hikers who needed to travel light but the resulting product is equally well suited for home and garden use.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a top view of the hammock's webbing frame only, including the loops for attaching the ropes that suspend it.
FIG. 2 is a top view of the hammock bed before being attached to the frame. It depicts the arched head end, the flared out foot end and the sewn-in webbing pieces.
FIG. 3 shows the arched piece of netting before being attached to the foot end of the hammock.
FIG. 4 is an end view of the hammock with the arched piece of netting attached.
FIG. 5 depicts a side view of the hammock showing the built-in droop as it appears when the bed is not loaded.
FIG. 6 is a top view of the hammock with the short level and the storage pocket attached.
FIG. 7 shows a top view of the suspended hammock including the spreader bars and anchor points.
FIG. 8 depicts the posture of a person lying in the hammock and the shape of its bed under load.
DETAILED DESCRIPTION OF THE INVENTION
This description is of a hammock that is designed so it compensates for hammock sag and becomes flat when loaded.
The hammock consists of a rectangular frame made from webbing, preferably nylon. The webbing is folded and joined together in each corner, so four loops for anchoring the hammock are created, FIG. 1 . The two longer parallel pieces of webbing for the sides and the shorter piece for the foot end are joined at right angels, 2 and 2 ′. The fourth piece, 4 and 4 ′ for the head end, is made long enough to form an arch, the secant of which is as long as the webbing at the foot end.
For the hammock bed a section of pre-cut non extendable material, for instance UV-treated netting, is applied. Netting eliminates condensation between the sleeping bag and the hammock bed during cold conditions. The material for the bed must be cut to the same length as the webbing frame and fashioned to a curved shape at the head end that matches the curve of the webbing, FIG. 2, 14 and 14 ′. From the head end and for about two thirds of the length of the hammock, 12 and 12 ′, the mesh for the bed must be slightly wider than the frame. For the remainder of its length it must gradually flare out to become one and one third wider than the frame at its foot end, 10 and 10 ′.
Two pieces of webbing are fastened to the foot end of the bed material in a V-shape. They terminate at the corners, FIG. 2, 10 and 10 ′, and must be long enough to join at the middle of the bedding material where it starts flaring out, 16 .
The sides of the hammock bed are fastened all along the sides of the webbing frame. As the bedding material at the front between 14 and 14 ′ is a little wider than the length of the webbing 4 and 4 ′ in FIG. 1, it must be gathered and slightly pleated all across as it is joined to the webbing. The flared out material at the foot end of the hammock is not attached to the frame. It will do part of the compensation for hammock sag.
An insert is required to give the material at the foot end a rounded shape across. The insert can be of the same type of material as the hammock bed and must be manufactured into a segment of a circle, FIG. 3 . The arch of the circular segment, 30 and 30 ′, must be as long as the netting is wide at the foot end of the hammock, FIG. 2, 10 and 10 ′. Secant 30 and 30 ′ in FIG. 3 must be as long as the hammock frame is wide at the foot end. The straight part of segment 30 and 30 ′ is fastened to the webbing of the frame in FIG. 1, 2 and 2 ′. The arch 30 and 30 ′ is joined to the end of the flared out material depicted in FIG. 2, 10 and 10 ′.
In an end view the shape of the hammock's foot end is as indicated in FIG. 4 . The circular segment fastened to the hammock also serves as a stop and a foot rest.
Seen from the side the shape of the hammock without a load is now as shown in plan view FIG. 5 . The flared out material at the foot end droops as indicated by 22 , 24 and 26 .
FIG. 6 is an overhead view of the hammock. A short level, 40 , is fastened midways along one of the hammock's sides, parallel with the webbing. It facilitates installing the hammock in equilibrium where no horizontal reference is visible, for instance on slopes. A storage compartment is added above the curved webbing at the head end. One side of the compartment is fastened to the webbing between 6 and 6 ′. The other side of the compartment hangs free. Care must be taken that the storage compartment does not impede the expansion of the hammock.
The hammock is suspended from non-stretch ropes tied to the four loops, FIG. 7 . If only one anchor point is available at each end as shown by 50 and 50 ′, two spreader bars are required, 52 , 52 ′ and 54 , 54 ′. They must be slightly longer than the hammock is wide and can be wood, fiberglass or a collapsible metal version for camping use. The ends of the spreader bars are notched to allow easy insertion and removal from between the ropes. To cut down on weight, spreader bars can be omitted during camping trips where dead wood is available. Temporary replacement bars can then be manufactured from available dead wood at the camp sites. If four conveniently located anchor points are found, no spreader bars are needed.
In FIG. 8 the spreader bars are installed and the hammock is loaded. The ropes apply a forward and outward pull to the curved section of the webbing at the head end. The pleated bedding material allows the hammock to widen and the curved webbing to move forwards as it becomes straighter. This applies an evenly distributed forward pull on the non-stretch bedding material that is directly proportional to the load in the hammock. The V-shaped webbing attached to the foot end pulls counter to the forward force without lifting up the foot end of the bed. The two forces combined keep the hammock bed tight and flat and allow no more drooping than the hammock is designed for. FIG. 8 is reproduced from a photograph.
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This disclosure describes a HAMMOCK design which compensates for sag. The lower part of the HAMMOCK becomes level when occupied and allows the user to lie flat on the back or the side as in a bed. The HAMMOCK is equally suited for recreation and camping and is simple to make and easy to install.
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BACKGROUND
[0001] Spacecraft that are in space are subject to a number of processes that result in a significant electrostatic charging. In the case of rendezvous and proximity operations of one or more spacecraft with one or more other bodies in space, a potential difference can exist between objects, which results in variable levels of electrostatic attractions and repulsions that can result in an electrostatic discharge. Electrostatic attraction and repulsion will result in non-linear forces that will increase the difficulty of the rendezvous and proximity operations. The electrostatic discharge due to the net charge difference between the spacecraft and the other body may or may not result in a larger discharge driven by the electrical system of one or more of the spacecraft. In either case, electrostatic discharge can result in problems with the spacecraft's electronics. The operations on the ground, virtually all spacecraft quality assurance and safety requirements include protection against electrostatic discharge to prevent electrostatic discharge damage. In the case of the international space station, this issue was identified in a subsequent study was carried out to investigate the risk to astronauts carrying out extra vehicle activities. The result was that under certain conditions, the discharge of up to 10,000 Amps at 160 V was possible. In the testing of the impact of the size of discharge, an entire spacesuit was melted into a puddle on the bottom of the test chamber. As result of this test, triply redundant microwave driven xenon plasma charge couplers were installed on the space station.
[0002] For the reasons stated above and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for an effective and efficient system for spacecraft to mitigate the charge differences between spacecraft, the surrounding plasma and another body.
SUMMARY OF INVENTION
[0003] The above-mentioned problems of current systems are addressed by embodiments of the present invention and will be understood by reading and studying the following specification. The following summary is made by way of example and not by way of limitation. It is merely provided to aid the reader in understanding some of the aspects of the invention.
[0004] In one embodiment, a charge neutralization system is provided. The charge neutralization system includes a reservoir, a plasma generator and a flow restricting transfer line. The reservoir is configured to hold matter to be ionized under pressure. The plasma generator is configured and arranged to create neutral low energy plasma on the vehicle with the matter to be ionized. The flow restricting transfer line provides a fluid communication between the reservoir and the plasma generator.
[0005] In another embodiment, a spacecraft with a charge neutralization system is provided. The charge neutralization system includes a reservoir, a plasma generator, a flow restricting transfer line and a ground plate. The reservoir is configured to hold matter to be ionized under pressure. The plasma generator is configured and arranged to generate neutral low energy plasma with the matter to be ionized. The flow restricting transfer line provides a fluid communication between the reservoir and the plasma generator. The ground plate is coupled to the spacecraft. The plasma generator is positioned to apply the generated neutral low energy plasma to the ground plate of the spacecraft.
[0006] In still another embodiment, a method of neutralizing electrostatic discharge on a spacecraft is provided. The method includes: Generating neutral low energy plasma; and applying the neutral low energy plasma to the spacecraft to level an electrostatic charge difference between the spacecraft and another object.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention can be more easily understood and further advantages and uses thereof will be more readily apparent, when considered in view of the detailed description and the following figures in which:
[0008] FIG. 1A is a diagram of a spacecraft with a charge neutralization system of an embodiment of the present invention;
[0009] FIG. 1B is a diagram of a spacecraft with another charge neutralization system of an embodiment of the present invention;
[0010] FIG. 2 is a diagram of a spacecraft with yet a different charge neutralization system of another embodiment of the present invention;
[0011] FIG. 3 is a short mission operational flow diagram of one embodiment of the present invention; and
[0012] FIG. 4 is a long mission operational flow diagram of an embodiment of the present invention.
[0013] In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the present invention. Reference characters denote like elements throughout Figures and text.
DETAILED DESCRIPTION
[0014] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the claims and equivalents thereof.
[0015] Embodiments of the present invention provide a radioisotope electrostatic charge neutralizer. Matter to be ionized such as, volatile gas, is directed into an ionizing source such as a plasma generation source volume (generally referred to herein as a plasma generator). Ionizing radiation from a radioisotope in the plasma generator ionizes the volatile gas creating a neutralizing plasma. The radio isotopic electrostatic charge neutralizer provides a source of neutral low-energy plasma for leveling the electrostatic charge between the spacecraft and another object. Charged particles are attracted to electrostatic fields based upon the relative charge difference, a positively charge spacecraft approaching a negatively charged space object results electrons from the radio isotopic generated plasma to be attracted to the positively charged spacecraft, and the positively charged ions will be attracted to the negatively charged other body. This results in a small current that will safely decrease the charge difference between the bodies. This process is self controlling due to the inherent attraction of electrostatic charge particles being attracted to the one body and repelled from the other body in the case of a charge difference. Depending upon the duration of the mission, the amount of charge that will need to be dissipated and the cost of the gas being used to neutralize the charge at the rate desired, it may or may not be necessary to provide a dynamic control of gas flow rate. If the rate of charge dissipation is achieved with a gas flow on the order of 1E-3 standard cubic centimeters per second or less it may be advantageous to provide gas flow through a fixed rate leak, which would not require any controls. If higher flow rates result in gas flow rates that would require too much gas to be used, valve control may be required to conserve gas. In either case, flowing gas through the radioisotope based ionizer (plasma generator) will result in charge neutralization between closely surrounding bodies.
[0016] Referring to FIG. 1A , a block diagram illustrating a first embodiment of a passive charge neutralization system 100 that mitigates electrostatic discharge associated with a spacecraft 110 is provided. This embodiment would be used when the duration of the flight is not long and the cost of gas is not prohibitive in letting the system constantly run during the flight. The charge neutralization device 100 includes a volatile liquid/gas 104 (matter to be ionized) such as, but not limited to xenon stored in a pressurized reservoir 105 . The gas/liquid 104 flows through a restricting transfer line 106 . In the restricting transfer line 106 , any remaining liquid evaporates to gas 107 . The restricting transfer line 106 delivers the volatile gas 107 to the plasma generator 102 . The plasma generator 102 (plasma generation source volume) generates a neutralizing plasma with the volatile gas 107 (matter to be ionized). That is, the ionizing radiation of the radioisotope in the plasma generator ionizes the volatile gas to generate the neutralizing plasma. The plasma generator 102 is electrically bonded to a ground plate 108 of the spacecraft 110 . This embodiment also illustrates an electrostatic charge sensor 111 that detects electrostatic charge on the spacecraft 110 . The electrostatic charge sensor 111 is in communication with a controller 120 . The controller 120 may be a guidance navigation control system of the spacecraft. The controller 120 monitors the electrostatic charge of the spacecraft 110 through the electrostatic charge sensor 111 and uses the information during operations. FIG. 1B illustrates another charge neutralization system 150 . In this system, the reservoir 105 that contains the matter to be ionized 104 is mounted outside the spacecraft 110 . Moreover, it is possible to mount the entire system outside the spacecraft.
[0017] FIG. 2 illustrates an embodiment of a passive charge neutralization system 200 that would be applied to longer missions or where it is important to conserve the volatile gas/liquid 104 / 107 . In this embodiment, instead of delivering a constant flow of volatile gas 107 from the pressurized reservoir 105 to the plasma generator 102 , a valve 202 , positioned in the restricting transfer line 106 , selectively turns on and turns off the flow. In this embodiment, the controller 120 is operationally coupled to the valve 202 to activate the valve 202 between an open and closed position. The controller 120 may control the valve 202 to conserve the volatile material 104 / 107 based on different trigger systems. The controller 120 may be part of the guidance and navigation control system of the spacecraft 110 . Moreover, the controller 120 may be a simple switch or a processing device that dynamically controls the valve based on events. For example, one or more electrostatic charge sensors 111 - 1 , 111 - 2 and 111 -n may be used to detect the electrostatic charge on the spacecraft 110 , or between the spacecraft 110 and another body 150 as the other body 150 gets close to the spacecraft 110 . When an electrostatic charge level is detected that is beyond a set limit, the controller 120 , based on the measured electrostatic charge by the one or more sensors 111 - 1 , 111 - 2 or 111 -n, opens the valve 202 until an electrostatic charge level is below the set limit. In another example, the passive charge neutralization system 200 may include a timer 132 . The controller 120 , in this embodiment, would periodically open and close the value 202 based on the timer 132 . In still another embodiment, the passive charge neutralization system 200 would include an input system 134 that would provide a signal to the controller that an event (such as docking with another object or a spacewalk by an astronaut) is about to occur. Based on a signal from the input 134 , the controller 120 would control the valve 202 .
[0018] FIG. 3 illustrates a short mission operational flow diagram 300 . As illustrated, the process starts by delivering volatile gas 107 (matter to be ionized) through a restricting transfer line to plasma generator 102 ( 302 ). As discussed above, the volatile gas/liquid 104 that is held in a pressured reservoir 105 is delivered as a gas 107 to the plasma generator 102 through the restricting delivery line 106 . The plasma generator 102 then creates a neutralizing plasma from the material to be ionized 104 ( 304 ). The plasma generator 102 uses ionizing radiation from the radioisotope, ionizing the matter to be ionized to create the neutralizing plasma that is applied to the ground plate 108 of the space craft 110 . The neutralizing plasma of the plasma generator 102 creates a charge neutralizing current on the spacecraft ( 306 ). In particular, as discussed above, as charged particles are attracted to electrostatic fields based upon the relative charge difference, a positively charged spacecraft approaching a negatively charged second object will result in electrons from the radio isotope generated plasma to be attracted to the spacecraft, and the positively charged ions will be attracted to the negatively charged other body. This results in a small current that will safely decrease charge difference between the bodies.
[0019] FIG. 4 illustrates a long mission operational diagram 400 of one embodiment. In this embodiment, the spacecraft 110 is monitored ( 402 ). In one embodiment, the spacecraft is monitored for the buildup of electrostatic charge. In another embodiment, the spacecraft 110 is monitored for a future event such as the docking with another object (such as another spacecraft, satellite, etc.) or a planned space walk by an astronaut. If it is determined that a neutralization of charge is not needed ( 404 ), the process continues monitoring at step ( 402 ). If it is determined that a neutralization of charge is needed ( 404 ), valve 202 is opened ( 406 ). Once the valve 202 is opened, gas 107 is delivered through the restricting transfer line 106 ( 408 ). The plasma generator 102 then creates a neutralizing plasma with the volatile gas 107 ( 410 ). The neutralizing plasma is applied to the spacecraft 110 to create a charge neutralizing current ( 412 ). It is then determined if the event is done or the electrostatic charge on the spacecraft has been neutralized ( 414 ). For example, the system may monitor for an indication that the event has been completed (i.e. the object has completed the docking process or the astronaut has returned to the spacecraft) or whether the electrostatic charge has been neutralized. If the event is not completed or the spacecraft 110 has not been neutralized ( 414 ), the value 202 remains open so the gas continues to be delivered to the plasma generator at step ( 408 ). If the event has been completed or it is determined that the spacecraft has been neutralized ( 414 ), the valve 202 is closed ( 416 ). Closing the valve 202 conserves the gas/liquid source 104 in the reservoir 105 . Once the valve is closed at step ( 416 ), the process continues by monitoring for an event or buildup of electrostatic charge at step ( 402 ).
[0020] The above described charge neutralization system is relatively inexpensive to build while its minimal size, weight and power consumption is ideal for implementation in a spacecraft. Moreover, because the radioisotope electrostatic charge neutralizer is primarily passive and is based on the fundamental properties of two materials (i.e. the ionizing radiation from the radioisotope of the plasma generator and the volatile gas), there are very few possible failure opportunities.
[0021] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
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A charge neutralization system is provided. The charge neutralization system includes a reservoir, a plasma generator and a flow restricting transfer line. The reservoir is configured to hold matter to be ionized under pressure. The plasma generator is configured and arranged to create a neutral energy plasma on a vehicle from the matter to be ionized. The flow restricting transfer line provides a fluid communication between the reservoir and the plasma generator.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of pending international application PCT/EP99/06514, filed on Aug. 21, 1999.
BACKGROUND OF THE INVENTION
[0002] The present invention concerns a new method for in vivo labeling of biopolymers, like proteins, nucleic acids, lipids, carbohydrates, and biodegradable plastic, with isotopes, especially stable isotopes and the use of chemolithotrophic bacteria for in vivo isotope labeling of biopolymers. The invention concerns in particular the use of CO 2 -fixing bacteria, like Ralstonia eutropha and similar methanogenic bacteria for in vivo isotope labeling, especially for labeling with the stable isotope 3 C and the use of isotope-labeled biomolecules in therapeutic and diagnostic applications, especially in spectroscopy methods and generally as tracer compounds.
[0003] The deliberate use of biomolecules in diagnosis and therapy requires knowledge of the structure and dynamics of these molecules. This information can be obtained, for example, by using nuclear magnetic resonance (NMR). A prerequisite for efficient use of this method, however, is labeling of the biomolecules of interest with stable isotopes, so-called S isotopes, like 2 H, 13 C and 15 N.
[0004] Since S isotopes are not radioactive and, except for deuterium, are not toxic either, they have considerable diagnostic potential. S isotopes have already been successfully used in metabolic diagnosis. In addition to 2 H, 13 C and 15 N, the nuclei 1 H, 7 Li, 11 B, 14 N, 17 O, 18 O, 19 F, 23 Na, 29 Si, 31 P, 33 S and 77 Se have been used above all for NMR spectroscopy of organic compounds (cf., Vogel, H. J. (1989), Methods in Enzymology, Vol. 177, 263).
[0005] Use of S isotope-labeled substances, especially labeled amino acids, is discussed in imaging NMR spectroscopy, especially NMR microscopy. With further development of imaging NMR methods, the area of application of S isotope-labeled substances will expand and will not be restricted merely to the aforementioned S isotopes 2 H, 1 C and 15 N.
[0006] Thus far, complete S isotope-labeling of proteins and other biopolymers has generally occurred by in vivo labeling, i.e., organisms are cultured on isotope-labeled media and the desired protein or another component is then isolated from the labeled organisms.
[0007] The medium necessary for culturing, which generally consists of a carbon source, nitrogen source and salts, is more demanding and more cost-intensive, the more complex it is. This is particularly true of the carbon source. Since nutrient media for higher, i.e., eukaryotic, organisms are particularly complex, expression of S isotope-labeled eukaryotic proteins mostly occurs in recombinant fashion in bacteria, in most cases in Escherichia coli (see, for example, Donne, D. G. et al. (1997), Proc. Natl. Acad. Sci. USA 94, 13452-13457). These bacteria use glucose as inexpensive 13 C-labeled carbon source. 13 C-labeled methanol, which is relatively cheap, has been used as an alternative to culture Methylophilus methylotrophus (Batey, R. et al. (1995), Methods in Enzymology 261, 300-322). The most cost-effective carbon source is 13 C-labeled CO 2 . Green algae (for example, Chlorella vulgaris, Chlorella pyrenoidosa, Chlorella fusca or Scenedesmus obliquus ) can fix carbon dioxide by photosynthetic reduction and therefore be completely labeled by feeding of 13 C-labeled CO 2 . The labeled algal hydrolyzate is then reused as carbon source to culture bacteria, especially E. coli.
[0008] The use of algal hydrolyzate instead of glucose is not only more economical, but in many cases also necessary for biological reasons. If foreign proteins are expressed in E. coli , the attainable cell density often drops, especially if minimal medium with glucose is used as carbon source. In many cases, the expression of a heterologous protein in E. coli is only possible by using algal hydrolyzate as C source; often at least the yield of heterologously expressed protein and thus the efficiency of the labeling method can be increased by supplying algal hydrolyzate.
[0009] Plasmid DNA from E. coli is manipulated for production of S isotope-labeled nucleic acids, especially DNA so that the desired nucleic acid sequence is displayed on the plasmid. An alternative method, which is obligatory for RNA and optional for DNA, is isolation of the entire RNA and DNA from labeled cells ( E. coli or algae). After hydrolysis of DNA or RNA, isolation of nucleotides and phosphorylation to ribonucleoside triphosphates or deoxyribonucleoside triphosphates, new nucleic acids are synthesized in vitro with appropriate polymerases (Mer, G. and Chazin, W. J. (1998), J. Am. Chem. Soc. 120, 607-608). according to the invention include Acidovorax facilis, Alcaligenes ruhlandii, Alcaligenes latus , Alcaligenes sp. 2625 , Ancylobacter aquaticus , Ancylobacter sp. 1106-1108, 2456, 2457, 2666-2669 , Aquifex pyrophilus, Aquaspirillum autotrophicum, Azospirillum amazonense , Azospirrillum sp. 1726, 1727 , Azospirilum lipoferum , Azotobacter sp. 1721-1723 , Bacillus schlegelii, Bradyrhizobium japononicum, Bacillus tusciae, Calderobacterium hydrogenophilum , Campylobacter sp. 806 , Derxia gummosa, Hydrogenophaga flava, Hydrogenobacter thermophilus, Hydrogenophaga palleronii, Hydrophaga pseudoflava, Hydrogenophaga taeniospiralis, Mycobacterium gordonae, Oligotropha carboxidovorans, Paracoccus denitrificans, Pseudomonas saccharophila, Pseudocardia autotrophica, Pseudocardia petroleophila, Pseudocardia saturnea, Ralstonia eutropha, Variovorax paradoxus, Xanthobacter agilis, Xanthobacter autotrophicus and Xanthobacter flavus . Labeling occurs with particular preference in Ralstonia eutropha (previously also named Alcaligines eutropha ).
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
[0011] [0011]FIG. 1 is a showing of plasmid pCH591;
[0012] [0012]FIG. 2 shows the Hind III/Eco RI fragment of pOF 39 containing GroESL gene and the cloning into plasmid pCH591 of FIG. 1; and
[0013] [0013]FIG. 3 is an SDS gel electrophoresis plot of the results of the expression of GroEl in R. eutropha . Track 1 and 11 shows reference proteins, GroEL from E. coli (track 1 ) and subunits of the RNA polymerase from E. coli (track 11 ) as molecular weight standard. Track 2 shows the protein pattern of R. eutrophas with the expression plasmid without GroEL/GroES gene, tracks 3 to 10 with GroEL/GroES gene. Tracks 3 and 4 show close 32 in clockwise orientation without (−) and in the presnet of (+) tetracycline, respectively. Tracks 5 and 6 show clone 32 in counter clockwise orientation without (−) and in the present of (+) tetracycline, respectively. Tracks 7 and 8 shows close 9 in clockwise orientation without (−) and in the presence of (+) tetracycline, respectively. Tracks 9 and 10 shows clone 9 in counter clockwise orientation with (−) and in the presence of (+) tetracycline, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] In contrast to green algae, which require electromagnetic radiation for fixation of carbon dioxide, chemolithotrophic bacteria use chemical redox reactions as energy source in which inorganic substrates are used as hydrogen donor. Carbon dioxide, which is fixed in the Calvin cycle, serves as carbon source for buildup of cell substance. Chemolithotropic bacteria are generally divided into the following subgroups: (i) nitrifying bacteria, in whose energy metabolism ammonium is oxidized to nitrite and then to nitrate or nitric acid, (ii) sulfur bacteria, which produce their metabolic energy by oxidation of one or more differently reduced or partially reduced sulfur compounds, (iii) iron- and manganese-oxidizing bacteria, and (iv) methanogenic bacteria, which include Ralstonia eutropha and the genus Hydrogenomonas which produce the required energy from reaction of oxygen and hydrogen, whose growth therefore requires the presence of hydrogen and oxygen. In contrast to most sulfur and nitrifying bacteria, the so-called methanogenic bacteria are only facultatively chemoautotrophic. This means that they grow heterotrophically in the presence of organic matter, like most bacteria and animals, and switch to the corresponding adequate type of metabolism in adaptation to the prevailing growth conditions. This offers the advantage that genetic manipulations in Ralstonia eutropha and other methanogenic bacteria can be conveniently conducted in the complex medium without H 2 and O 2 .
[0015] The isotope labeling according to the invention is more cost-effective and less demanding than the methods of the prior art. In particular, the method according to the invention is characterized by the use of less costly and less complex growth media. In the case of labeling with C isotopes, for example, the stable 13 C isotope, the detour via culturing of green algae on appropriately labelled, for example, 13 C-labeled carbon dioxide and production of algal hydrolyzate also drops out.
[0016] Moreover, CO 2 -fixing bacteria, like Ralstonia eutropha , and other strains can also be used for production of isotope-labeled hydrolyzate in cases in which labeling Escherichia coli is inaccessible, as in green algae and their hydrolyzates.
[0017] Another advantage of the method according to the invention relative to the use of algae is the fact that Ralstonia eutropha and similar CO 2 -fixing strains require no light for fermentation, grow more quickly than algae, reach higher cell densities, are less vulnerable to contamination and less sensitive overall than algae, so that culturing of the bacteria can generally occur much more easily and more cost effectively.
[0018] Another advantage of in vivo labeling in chemolithotrophic bacteria relative to E. coli consists of the fact that the concentration of carbon components during growth of CO 2 -fixing bacteria is easier to monitor so that homogeneous labeling by the method according to the invention is easier to conduct than with E. coli.
[0019] The overall growth conditions during use of chemolithotrophic bacteria in comparison with E. coli are easier and more efficient to control because of the simpler growth media, since the concentration of components of the medium can be followed much more easily.
[0020] Additional advantages over known methods follow from the fact that the nucleic acid and protein fraction in the total biomass of Ralstonia eutropha and similar bacteria, is higher than in green algae, since green algae have a comparatively higher percentage of carbohydrates. Higher yields of isotope-labeled proteins or nucleic acids can be achieved on this account.
[0021] Moreover, the method according to the invention offers the advantage that a simple in vivo labeling of lipids in the future will also be possible in this way. Metabolic intermediates and secondary metabolites from chemolithotropic bacteria, especially CO 2 -fixing bacteria and especially Ralstonia eutropha , can also be produced by the method according to the invention in isotope-labeled form. By using appropriate mutants, whose natural metabolic reactions are interrupted or destroyed, desired intermediates can be enriched. An example of an appropriate mutant suitable in the context of the method according to the invention is the PHB4 mutant, in which production of PHB (polyhydroxybutyrate) is disturbed (see, for example, Cook and Schlegel (1978), Arch. Microbiol. 119:231-235). The mutant PHB4 is deposited at the German Collection for Microorganisms and Cell Cultures (DSM Braunschweig) under deposit number DSM 541. Intermediates that are excreted or accumulated in mutant PHB4 include pyruvate, malate, citrate, fructose-6-phosphate and glucose-6-phosphate. In principle, any mutant is suitable in which the desired metabolites are excreted or enriched. Metabolism can therefore be deliberately or randomly disturbed so that new products form in the bacteria by enzymatic degradation or buildup.
[0022] In a particular variant, the method according to the invention for in vivo labeling of isotopes comprises the following steps:
[0023] a) Culturing of chemolithotrophic bacteria, especially methanogenic bacteria in/on a nutrient medium containing at least one component labeled with an isotope,
[0024] b) Harvesting of the bacteria and
[0025] c) Isolation of the labeled biopolymer.
[0026] In a preferred variant, isolation of the labeled biopolymer includes LaCl 3 precipitation, as described, for example, in Abe, S. et al. (1987), Agric. Biol. Chem. 51(6):1729-1731.
[0027] Isolation of in vivolabeled proteins from chemolithotropic bacteria preferably includes the steps:
[0028] i) Opening of the cells by suspension of the harvested cells in an appropriate buffer, for example, an ordinary Tris/EDTA buffer, and addition of SDS,
[0029] ii) Precipitation of nucleic acids and proteins with LaCl 3 ,
[0030] iii) Elution of the proteins by a suspension in SDS-containing buffer solution and then centrifuging,
[0031] iv) Precipitation of the proteins by ammonium sulfate precipitation.
[0032] Isolation of labeled nucleic acids preferably includes the steps:
[0033] i) Opening of the cells by suspension of the harvested cells and an appropriate buffer, for example, an ordinary Tris/EDTA buffer, and addition of SDS,
[0034] ii) Precipitation of nucleic acids and proteins with LaCl 3 ,
[0035] iii) Elution of proteins by suspension in SDS-containing buffer solution and then centrifuging,
[0036] iv) Dissolution of LaCl 3 pellets in EGTA-containing buffer solution (EGTA=ethylene glycol bis(β-aminoethyl ether)-N,N,N′,N′-tetraacetic acid),
[0037] v) Phenol extraction and then ethanol precipitation.
[0038] By using the method according to the invention, not only isotope-pure 13 C-, 11 C-and/or 14 C-labeling can be carried out using 13 C- or 11 C-, 14 C-labeled carbon dioxide as carbon source, but labeling with stable or unstable carbon isotopes can be simply combined with labeling of other isotopes, stable or unstable by choosing an appropriate nutrient medium containing the corresponding isotope. Thus, if exclusively 13 C- or 11 C-, 14 C-labeled carbon dioxide is used as C source, when isotope-pure 13 C- or 11 C-, 14 C-labeled cell mass of Ralstonia eutropha or other chemolithotrophic bacteria are to be obtained, 15 N 2 or 15 N-labeled salts can additionally be contained in the nutrient medium in order to obtain mixed labeling with isotope-pure 13 C and 15 N.
[0039] Isotope-pure 13 C- or 11 C-, 14 C-labeling can naturally also be combined with isotope-pure labeling with deuterium. In this case, 2 H-labeling can occur by culturing Ralstonia eutropha or other chemolithotropic bacteria in D 2 O and/or by supply of 2 H 2 .
[0040] Moreover, mixed labeling with isotope-pure 13 C and 15 N and 2 H can be conducted, in which a percentage of 2 H of about 65-85% is preferred (cf., LeMaster, D. M. (1989), Methods in Enzymology, 177, 23 ff). Partial deuteration and therefore dilution of the spin is achieved from this content of deuterium.
[0041] The invention therefore concerns a special variant of in vitro labeling with a C isotope in combination with labeling with one or more additional isotopes, especially combined labeling with 13 C and 15 N and/or 2H.
[0042] Isotope-pure labeling with 15 N by merely using 15 N 2 - or 15 N-labeled salts in the nutrient medium can naturally be conducted. The same applies for isotope-pure labeling exclusively with deuterium and mixed labeling with 15 N and 2 H. The method according to the invention based on carbon dioxide-fixing bacteria can, in principle, be conducted with all stable or unstable isotopes in which stable or unstable C isotopes are offered, in particular, in the form of labeled carbon dioxide as C source in the nutrient medium.
[0043] The invention therefore also concerns the use of chemolithotrophic bacteria, especially methanogenic bacteria, for labeling of biopolymers with stable and/or unstable isotopes, especially with 13 C, 11 C, 14 C, 15 N, 2H and 77 Se, individually or in combination.
[0044] The invention also concerns the use of genetically engineered chemolithotrophic bacteria, preferably methanogenic bacteria, for expression of in vivo labeled proteins. Expression of proteins, preferably a heterologous protein, under control of a homologous promoter or heterologous promoter, can be involved (for example, the T7 system). The protein being labeled is preferably expressed in Ralstonia eutropha under control of a homologous promoter, for example, the SH (soluble hydrogenase) or MBH (membrane-bound hydrogenase) promoter from R. eutropha (see Schwartz, E. et al. (1998), Journal of Bacteriology, 3197-3204).
[0045] As another aspect, the present invention concerns the use of S isotope-labeled biomolecules according to the invention for NMR spectroscopy.
[0046] High resolution NMR spectroscopy in large molecules requires their labeling with stable isotopes, especially with the S isotopes 2 H, 13 C and 15 N. Use of isotope-labeled biomolecules according to the invention is therefore the so-called heteronuclear NMR technique.
[0047] The invention also concerns the use of biomolecules labeled according to the invention in imaging NMR spectroscopy in which the S isotope-labeled compounds are used as markers whose incorporation in the organism can be followed.
[0048] The invention also concerns the use of S isotope-labeled compounds in other NMR techniques, like solid NMR.
[0049] Additional use possibilities of the biopolymers labeled according to the invention are offered in conjunction with infrared and Raman spectroscopy. The vibration frequencies of molecular groups can be shifted by S isotope-labeling and therefore identified. If individual amino acids or individual nucleotides in a nucleic acid are deliberately S isotope-labeled in a protein, assertions concerning the conformation of this labeled molecule can be worked out with the spectroscopic methods.
[0050] Another area of use is mass spectrometry. The homogeneity of biomolecules can be analyzed via their mass distribution by means of mass spectrometry. The results of such mass spectrometric investigation are only unequivocal when the molecules are homogeneous with respect to their isotope composition. Since our environment consists of a mixture of isotopes, biomolecules are not isotope-pure either. For example, 12 C is mixed in our environment with a few percent of 13 C. To be able to produce isotope-pure biomolecules, the organisms from which the desired biomolecules are isolated must be cultured beforehand on isotope-pure media.
[0051] S isotope-labeled biomolecules can also be used in neutron scattering. The isotopes 1 H and 2 H differ from each other in their spin. Since elastic scattering of neutrons occurs on the nuclear spin, 2 H-labeled protein components can be distinguished from unlabeled components. The spatial arrangement of labeled components can therefore be determined by neutron radiation.
[0052] The aforementioned probes with which S isotope-labeled compounds can be identified or followed in an organism have enormous application potential in the life sciences, medicine, biology and biotechnology, since they (i) permit nondestructive analysis in most cases and (ii) the S isotope-labeling necessary for this purpose, with the exception of deuterium labeling, is not toxic. Use of these techniques, however, has thus far been limited by the availability of S isotope-labeled biopolymers, since labeling with ordinary methods is cost-intensive and the homogeneity of labeling required for most applications is connected with considerable technical and financial demands.
[0053] These drawbacks are overcome by using the method according to the patent, since the invention permits labeling at lower costs and higher quality, i.e., especially higher homogeneity, then ordinary methods.
[0054] A review of the mentioned spectroscopy techniques, especially NMR, mass, infrared and Raman spectroscopy can be found in Hesse, M., Meier, H. and Zeeh, B. in “Spectroscopic methods in organic chemistry”, 5 th edition, 1995, Georg Thieme Verlag, Stuttgart.
[0055] The invention also concerns the use of biomolecules labeled according to the invention with unstable isotopes, especially 11 C or 14 C in diagnostic and therapeutic applications, for example, as tracer compounds.
[0056] The invention will be better understood with references to the following examples. All percentages are set forth in molar percentages except when quantities by weight are indicated. These examples are presented for purposes of illustration only, and are not intended to be construed in a limiting sense.
EXAMPLES
Example 1
Culturing of R. eutropha
[0057] Strains of R. eutropha can be obtained from the German Collection of Microorganisms (DSM, Braunschweig) or the American Type Culture Collection (ATCC), for example, strain H16, which is deposited at DSM under deposit number DSM 428 and at the ATCC under number 17699.
[0058] [0058] R. eutropha can be cultured in standard media, for example, as described in Schwartz et al. (1998), supra, or Eberz, G. and Friedrich, B. (1991), Journal of Bacteriology 173, 1845-1854.
[0059] For chemolithotrophic growth of R. eutropha , the medium referred to as H-3 medium can be used, which is described in the “DSMZ catalog 1998” (German Collection of Microorganisms and Cell Cultures, Mascheroder Weg 1 B, 38124 Braunschweig).
[0060] H-3:
KH 2 PO 4 2.3 g Na 2 HPO 4 × 2H 2 O 2.9 g NH 4 Cl 1.0 g MgSO 4 × 7H 2 O 0.5 g NaHCO 3 0.5 g CaCl 2 × 2H 2 O 0.01 g Fe(NH 4 ) citrate 0.05 g Trace element solution SL-6 5.0 mL Distilled water 980.0 mL
[0061] [0061] ZnSO 4 × 7H 2 O 0.1 g MnCl 2 × 4H 2 O 0.03 g H 3 BO 3 0.3 g CoCl 2 × 6H 2 O 0.2 g CuCl 2 × 2H 2 O 0.01 g NiCl 2 x 6H 2 O 0.02 g Na 2 MoO 4 × 2H 2 O 0.03 g Distilled water 1000 mL
[0062] After adjustment of the pH value to 6.8, it was autoclaved at 121° C. for 15 minutes. Fe(NH 4 ) citrate (0.05 g in 20 mL H20) is sterilized separately and then added to the medium. For chemolithotrophic growth of the bacteria, the culture is incubated under an atmosphere of 2% (v/v) O 2 , 10% CO 2 , 60% H 2 and 28% N 2 at a temperature of about 80° C. for about 4 hours. The atmosphere is produced by means of two communicating vessels (each about 10 L), one of which is filled with water (pH 3-5 in order to keep the solubility of CO 2 in water low). The different gases are forced into the water-filled supply vessel according to the above data. The volume of filled gases is obtained from the volumes of displaced water. The displaced water fills the second 10 L vessel. The water column produced in the second vessel serves to pressurize the gas mixture in the fermenter.
[0063] For the heterotrophic growth, the H-3 medium is supplemented by an appropriate carbon source (for example, 0.2% carbohydrate or 0.1% organic acid). NH 4 Cl is left out for growth in/on a nitrogen-free medium and the culture is incubated under an atmosphere of 2% (V/V) O 2 , 10% CO 2 , 10% H 2 and 78% N 2 or heterotrophically under 2% O 2 and 98% N 2 .
[0064] During in vivo labeling, the corresponding components of the medium or atmosphere are replaced by correspondingly isotope-labeled compounds, for example, CO 2 is replaced with 13 CO 2 during labeling with 13 C. During labeling with 15 N, either N 2 is replaced with 15 N 2 or the N salts are replaced by 15 N containing salts. During in vivo isotope labeling with 2 H, H 2 O is replaced by 2 H 2 O and H 2 by 2 H 2 .
[0065] Labeling with several isotopes occurs by a combination of the corresponding isotope-labeled components. Partial labeling occurs by changing the isotope concentration of the corresponding element.
[0066] Labeled starting substances, like 13 C-labeled CO 2 , can be obtained from Cambridge Isotope Laboratories (CIL), Massachusetts, USA.
Example 2
Isolation of Isotope-Labeled Proteins
[0067] a) Opening of the Cells
[0068] After harvesting of the bacteria, 1.0 g cells are suspended in 10 mL TE buffer (100 mM Tris/EDTA, pH 7.5) and 1 mL 10% SDS (sodium dodecylsulfate) is added. The suspension is then incubated for 30 minutes at 37° C. and for another 30 minutes at 55° C. The solution is forced eight times through a syringe (diameter 0.1 mm) or in larger amounts through a French press. The solution is then centrifuged for 30 minutes at 18,000 rpm and the obtained supernatant transferred to a vessel. The bacterial pellet is taken up again in 10 mL TE buffer and 1 mL of 10% SDS is added. The suspension is then incubated again for 30 minutes at 37° C. and for another 30 minutes at 55° C. The solution is again forced through a syringe or French press and then centrifuged for 30 minutes at 18,000 rpm. The obtained supernatant is combined with the first supernatant so that the final volume is 20 mL.
[0069] b) Precipitation of DNA, RNA and Proteins
[0070] 20 mL of 20 mM LaCl 3 is added dropwise during agitation to the supernatant from step a), then centrifuged for 20 minutes at 18,000 rpm. The pellet is washed with 10 mL H 2 O and then centrifuged again for 20 minutes at 18,000 rpm.
[0071] c) Elution of the Proteins
[0072] 10 mL TE buffer containing 1% SDS is added to the pellet and the pellet is then thoroughly suspended. It is centrifuged at 18,000 rpm for 15 minutes and the supernatant transferred to a fresh vessel. 10 mL TE buffer containing 1% SDS is again added to the pellet and after resuspension of the pellet, the centrifuging step is repeated. The supernatant containing the proteins is combined with the first supernatant. The proteins can then be precipitated, for example, by ammonium sulfate precipitation, which can be caused by adding 7.0 g (NH 4 ) 2 SO 4 (i.e., 3.5 g (NH 4 ) 2 SO 4 per 10 mL of solution).
Example 3
Isolation of Isotope-Labeled DNA and RNA
[0073] The LaCl 3 pellet obtained in step b) in example 2 is taken up in 10 mL EGTA buffer (0.2M Tris base, 50 mM EGTA (ethylene glycol bis(β-aminoethyl ether)-N,N,N′,N′-tetraacetic acid), 50 mM KOH, 25 mM Mg(OAc) 2 and 10 mL of neutral phenol is added. The mixture is centrifuged in conjunction with deproteinization and DNA and RNA are precipitated from the aqueous phase with 2 volume units of ethanol.
[0074] For isolation of RNA, the DNA/RNA pellet is first taken up in 10 mL TE buffer. 300 μL of 1M MgCl 2 (up to 0.03M) and 1.0 mL 1M NaAc, pH 4.0 are then added. 10 mL phenol saturated with 0.1M NaAc, pH 4.0 is then added and the suspension centrifuged after thorough mixing. The aqueous phase is transferred to a new vessel and 10 mL of TE buffer is added again to the phenol phase. On conclusion of mixing and centrifuging, the aqueous phase is withdrawn and combined with the first aqueous phase. 2 mL 2M Tris base is added to the collected aqueous phases (20 mL volume) and the RNA precipitated with 2.5 to 3 volume units of ethanol.
[0075] For isolation of DNA 10 mL of 10 mM EDTA (ethylenediaminetetraacetic acid) and 1 mL 2M Tris base are added to the phenol phase. The suspension is then carefully mixed and heated at 80° C. for 5 minutes. Finally, the suspension is shaken for 5 minutes and then centrifuged.
[0076] The aqueous phase is removed and transferred to a fresh vessel. 10 mL of 10 mM EDTA and 1 mL of 2M Tris base are again added to the phenol phase. The suspension is then again carefully mixed and heated at 80° C. for 5 minutes. After shaking for 5 minutes and then centrifuging, the aqueous phase is combined with the first aqueous phase.
[0077] The DNA is precipitated from the collected aqueous phases (20 mL volume) with 2 volume units ethanol and 0.6 mL 3M NaAc, pH 4.8.
[0078] The yields of DNA, RNA and protein per g of cells of Ralstonia eutropha are as follows:
[0079] DNA: about 10.4 mg
[0080] RNA: about 11.4 mg
[0081] Protein: about 110 mg
Example 4
Preparation of a Genetically Altered Bacterium for Expression of Heterologous Proteins
[0082] The vector plasmid pCH 591 (3.1 kb) based on Litmus 29, New England Biolabs, was used for cloning of the E. coli Chaperonin-GroESL gene. This plasmid carries an ampicillin resistance marker and a DNA fragment of Ralstonia eutropha , which includes the promoter region and the Shine-Dalgarno sequence of the soluble hydrogenase (soluble hydrogenase, SH) gene of R. eutropha , followed by a polylinker. Plasmid pCH 591 is shown in FIG. 1. The plasmid pOF 39 (R. Stegmann (1999), dissertation, Munich Technical University) served as source for the GroESL gene. As shown in FIG. 2, a 2.5 kb long Eco RI/Hind III fragment was isolated from pOF 39, which contains the GroESL gene. The Eco RI/Hind fragment isolated by agarose gel electrophoresis was then digested with the restriction enzyme Bsa AI in order to obtain blunt ends. This treatment led to elimination of the E. coli promoter and part of the transcription sequence, including the +1 transcription initiation nucleotide. The DNA region containing the Shine-Dalgarno sequence, as well as the initiation codon for the protein synthesis, were retained in the DNA region. The vector pCH 591 was treated with the restriction enzyme Nde I and the sticky ends filled up with Klenow DNA polymerase, followed by dephosphorylation using alkaline phosphatase. Finally, the treated vector was ligated with the Bsa AI fragment containing the GroESL gene using T4-DNA ligase and the supercomponent cells Solo Pack™ Gold cells (Stratagene) transformed with the ligation charge. The desired construct contains two Shine-Delgarno sequences, namely one from E. coli and another from R. eutropha . In a second cloning strategy for cloning of the GroESL gene, the Shine-Delgarno sequence of E. coli was eliminated, i.e., the desired constructs contained only the Shine-Delgarno sequence from R. eutropha . In the context of this strategy, the Eco RI/Hind III-GroESL fragment was treated with the restriction enzymes Bsa AI and SspI, in which the latter cuts the fragment at the site of the first two codons of the GroESL gene so that these two codons, as well as the E. coli Shine-Delgarno sequence, are eliminated. After treatment of vector pCH 591 with restriction enzyme Nde I, the 10-mer oligonucleotide depicted in FIG. 2 was ligated on the ends of the linearized DNA fragment. Not only is the Nde I-cleavage site reproduced by this oligonucleotide, but the oligonucleotide contains an Nco I cleavage site and codes for the amino acid Met and the two amino acids Pro and Trp (see FIG. 2). The obtained DNA fragment was ligated with the Bsa AI/SspI fragment containing the GroESL gene and the construct transformed to supercompetent Solopack Gold cells. The transformation was selected on LB medium containing 75 μg/mL ampicillin and isolated plasmid DNA was analyzed with respect to insertion of GroESL by means of a Hind III-Spe I restriction analysis in conjunction with the first cloning strategy and by Nde I or Nco I restriction digestion in conjunction with the second cloning strategy. The correct orientation of the GroESL fragment was then checked by appropriate restriction digestion. In addition, the desired fusion transitions were verified by sequencing. In the next step, the Hind III-Spe I fragment containing the R. eutropha promoter, Shine-Dalgarno sequence and GroEL/GroES gene is transformed in a wide host-range vector, in the present case the vector pEDY309 (21.2 kb) (derived from pEDY305, Schwartz et al. (1998), supra) and the obtained construct transformed in supercompetent Solo Pack™ Gold cells. The plasmid pEDY 309 contains a tetracycline-resistant gene, for which reason the transformants were cultivated on an LB medium containing 10 μg/mL tetracycline. The isolated plasmid DNA was analyzed by Hind III restriction digestion and the desired orientation additionally checked by sequence reactions and also PCR reactions. The desired DNA construct was transformed in E. coli S 17-1 and then conjugation of R. eutropha H16 cells carried out with the retransformed E. coli cells according to the conventional method. The conjugates were selected in the standard medium containing 0.4% succinate and 10 μL/mL tetracycline (see also Schwartz et al. (1998), supra).
Example 5
Expression of Heterologous Proteins in R. eutropha on the Example of E. coli Chaperonin GroEL/GroES Protein
[0083] The recombinant R. eutropha cells from example 4 were cultured in a medium containing 0.2% fructose, 0.2% glycerol and 10 μg/mL tetracycline. After growth of the cells, the cells were harvested by centrifuging, resuspended in 100 μL of 10 mM HEPES, pH 7.5. 100 μL of 10% SDS was added and after heating for 2 minutes at 95° C. 20 μL of 0.1M MgCl 2 was added to the suspension. After removal of the DNA pellet by centrifuging, a 10 mL aliquot of the supernatant was analyzed in SDS gel electrophoresis. The result of expression of GroEL in R. eutropha is shown in the SDS gel depicted in FIG. 3. The cells were opened and the cell contents applied to the gel with further purification. Track 2 shows the protein pattern of R. eutropha with the expression plasmid without GroEL/GroES gene, tracks 3 - 10 with GroEL/GroES gene. Two clones ( 9 and 32 ) are shown, both in each orientation (direct clockwise and reverse counterclockwise) in the presence (+) and without (−) tetracycline. Tracks 1 and 11 show reference proteins, GroEL from E. coli (track 1 ) and subunits of the RNA polymerase from E. coli (track 10 ) as molecular weight standard. Comparison of the protein pattern in track 2 (expression without E. coli GroEL gene) with those in tracks 3 to 10 shows that a band with a molecular weight of 57 kDa is missing. This band corresponds to the E. coli GroEL protein. It can be concluded from the absence of the band in track 2 that E. coli GroEL was successfully expressed in R. eutropha . This could be confirmed by Western blotting. Expression of the heterologous GroEL protein is on the same order of magnitude as that of the homologous GroEL.
[0084] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above methods without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense.
[0085] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
[0086] Particularly it is to be understood that in said claims, ingredients or compounds recited in the singular are intended to include compatible mixtures of such ingredients wherever the sense permits.
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The invention relates to a novel method for the in-vivo labeling of biopolymers such as proteins, nucleic acids, lipids, carbohydrates and biodegradable plastic using isotopes, especially stabile isotopes. The invention also relates to the use of chemolithotrophic bacteria for the in-vivo isotopic labeling of biopolymers. In particular, the invention relates to the use of CO 2 -fixing bacteria, such as Ralstonia eurtropha and related methanogenic bacteria for the in-vivo isotopic labeling, especially for labeling using the stable isotope 13 C alone and in combination with other isotopes. In addition, the invention relates to the use of isotropically labeled biomolecules in therapeutic and diagnostic applications, especially in spectroscopic methods and generally as tracers.
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FIELD OF THE INVENTION
This invention relates to the catalytic polymerization of ethylene using an aluminum-phosphinimine catalyst component.
BACKGROUND OF THE INVENTION
The use of transition metals, especially chromium or Group 4/5 metals such as titanium, zirconium and hafnium as catalysts in the polymerization of ethylene is well known. These polymerization reactions may use simple aluminum alkyls of the general formula ALR 3 as cocatalysts.
U.S. Pat. No. 5,777,120 (Jordan et al) discloses aluminum-amidinate complexes which catalyzes the polymerization of ethylene in the absence of transition metals.
We have now discovered an aluminum-phosphinimine complex which may be used to catalyze the polymerization of ethylene in the absence of transition metals.
SUMMARY OF THE INVENTION
In one embodiment, this invention provides a catalyst component for ethylene polymerization comprising an aluminum complex which is characterized by containing a phosphinimine ligand.
In another embodiment, this invention provides a process for the (co)polymerization of ethylene and at least one additional alpha olefin having from 3 to 20 carbon atoms wherein said process comprises the catalytic (co)polymerization of said ethylene and said at least one additional alpha olefin in the presence of a catalyst system comprising:
1) an aluminum complex which is characterized by containing a phosphinimine ligand; and
2) an activator.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
1.1 Description of Catalyst Components
Aluminum is a member of the Group 13 (also known as Group IIIA) elements. The group 13 elements are trivalent and are, by convention, described by the general formula “ML 3 ” wherein M is the metal and L is a ligand. However, as will be appreciated by those skilled in the art, such ML 3 compounds may “behave as Lewis acids and can accept either neutral donor molecules or anions to give tetrahedral species”; and “react with themselves to form dimeric molecules” (see, for example, Advanced Inorganic Chemistry, fifth edition, edited by Cotton and Wilkinson, ISBN 0-471-84997-9, p. 209). Thus, even though aluminum compounds form dimers and adducts with neutral donors, these compounds are conventionally referred to by the “ML 3 ” formula.
We have used the ML 3 convention in this specification to describe the catalyst components of this invention. As noted above, this convention is intended to be inclusive of dimers and oligomers and/or adducts with neutral donor molecules.
Thus, the present catalyst components may be conveniently described by the formula:
Al(Pl)X 2
wherein Pl is a phosphinimine ligand (as described in section 1.2 below) and each X is an activatable ligand (as described in section 1.3 below).
1.2 Phosphinimine Ligand
The catalyst component must contain a phosphinimine ligand which is covalently bonded to the metal. These phosphinimine ligands are characterized by containing a nitrogen which is bonded to the aluminum by a single covalent bond and a phosphorus (V) atom which is doubly bonded to this nitrogen atom. Preferred phosphinimine ligands are defined by the formula:
wherein each R 1 is independently selected from the group consisting of a hydrogen atom, a halogen atom, C 1-20 hydrocarbyl radicals which are unsubstituted by or further substituted by a halogen atom, a C 1-8 alkoxy radical, a C 6-10 aryl or aryloxy radical, an amido radical, a silyl radical of the formula:
—Si—(R 2 ) 3
wherein each R 2 is independently selected from the group consisting of hydrogen, a C 1-8 alkyl or alkoxy radical, C 6-10 aryl or aryloxy radicals, and a germanyl radical of the formula:
Ge—(R 2 ) 3
wherein R 2 is as defined above.
Preferred phosphinimines are those in which each R 1 is a hydrocarbyl radical (especially a hydrocarbyl radical having from 1 to 20 carbon atoms). A particularly preferred phosphinimine is tri-(tertiary butyl)phosphinimine (i.e. where each R 1 is a tertiary butyl group).
1.3 Activatable Ligand
The term “activatable ligand”, X, refers to a ligand which reacts with an “activator” to facilitate olefin polymerization. Activators are described in section 2 below.
Exemplary activatable ligands are independently selected from the group consisting of a hydrogen atom, a halogen atom, a C 1-10 hydrocarbyl radical, a C 1-10 alkoxy radical, a C 5-10 aryl oxide radical; each of which said hydrocarbyl, alkoxy, and aryl oxide radicals may be unsubstituted by or further substituted by a halogen atom, a C 1-8 alkyl radical, a C 1-8 alkoxy radical, a C 6-10 aryl or aryl oxy radical, an amido radical which is unsubstituted or substituted by up to two C 1-8 alkyl radicals; a phosphido radical which is unsubstituted or substituted by up to two C 1-8 alkyl radicals. Preferred activatable ligands are C 1-10 hydrocarbyls, especially methyl.
1.4 Preparation of Al(Pl)X 2
The preferred preparation of Al(Pl)X 2 is by the reaction of a trialkyl aluminum (especially trimethyl aluminum) with a hydrido-phosphinimine (i.e. HN═PR 3 ). The reaction is assisted by heating. The reaction is convenient and facile, as illustrated in the Examples. Moreover, the reaction may be undertaken in-situ (i.e. in the polymerization reactor). The in-situ reaction may employ a trivalent aluminum precursor (such as a trialkyl aluminum—especially TMA, as shown in example 2) or an alumoxane (as shown in example 1) and a hydrido-phosphinimine.
2.0 Activators
Alumoxanes and so-called “ionic activators” are preferred, as described below.
The alumoxane activator may be of the formula:
(R 4 ) 2 AlO(R 4 AlO) m Al(R 4 ) 2
wherein each R 4 is independently selected from the group consisting of C 1-20 hydrocarbyl radicals and m is from 0 to 50, preferably R 4 is a C 1-4 alkyl radical and m is from 5 to 30. Methylalumoxane (or “MAO”) is the preferred alumoxane.
Alumoxanes are well known as activators for metallocene-type catalysts and are widely described in the academic and patent literature.
Activation with alumoxane generally requires a molar ratio of aluminum in the activator to aluminum in the catalyst component Al(Pl)X 2 from 20:1 to 1000:1. Preferred ratios are from 50:1 to 250:1.
2.1 Ionic Activators
Ionic activators are also well known for metallocene catalysts. See, for example, U.S. Pat. No. 5,198,401 (Hlatky and Turner). These compounds may be selected from the group consisting of:
(i) compounds of the formula [R 5 ] + [B(R 7 ) 4 ] − wherein B is a boron atom, R 5 is a cyclic C 5-7 aromatic cation or a triphenyl methyl cation and each R 7 is independently selected from the group consisting of phenyl radicals which are unsubstituted or substituted with from 3 to 5 substituents selected from the group consisting of a fluorine atom, a C 1-4 alkyl or alkoxy radical which is unsubstituted or substituted by a fluorine atom; and a silyl radical of the formula —Si—(R 2 ) 3 ; wherein each R 2 is independently selected from the group consisting of a hydrogen atom and a C 1-4 alkyl radical; and
(ii) compounds of the formula [(R 8 ) t ZH] + [B(R 7 ) 4] − wherein B is a boron atom, H is a hydrogen atom, Z is a nitrogen atom or phosphorus atom, t is 2 or 3 and R 8 is selected from the group consisting of C 1-8 alkyl radicals, a phenyl radical which is unsubstituted or substituted by up to three C 1-4 alkyl radicals, or one R 8 taken together with the nitrogen atom may form an anilinium radical and R 7 is as defined above; and
(iii) compounds of the formula B(R 7 ) 3 wherein R 7 is as defined above.
In the above compounds preferably R 7 is a pentafluorophenyl radical, and R 5 is a triphenylmethyl cation, Z is a nitrogen atom and R 8 is a C 1-4 alkyl radical or R 8 taken together with the nitrogen atom forms an anilium radical which is substituted by two C 1-4 alkyl radicals.
The “ionic activator” may abstract one or more activatable ligands so as to ionize the catalyst center into a cation but not to covalently bond with the catalyst and to provide sufficient distance between the catalyst and the ionizing activator to permit a polymerizable olefin to enter the resulting active site.
Examples of ionic activators include:
triethylammonium tetra(phenyl)boron,
tripropylammonium tetra(phenyl)boron,
tri(n-butyl)ammonium tetra(phenyl)boron,
trimethylammonium tetra(p-tolyl)boron,
trimethylammonium tetra(o-tolyl)boron,
tributylammonium tetra(pentafluorophenyl)boron,
tripropylammonium tetra(o,p-dimethylphenyl)boron,
tributylammonium tetra(m,m-dimethylphenyl)boron,
tributylammonium tetra(p-trifluoromethylphenyl)boron,
tributylammonium tetra(pentafluorophenyl)boron,
tri(n-butyl)ammonium tetra(o-tolyl)boron,
N,N-dimethylanilinium tetra(phenyl)boron,
N,N-diethylanilinium tetra(phenyl)boron,
N,N-diethylanilinium tetra(phenyl)n-butylboron,
N,N-2,4,6-pentamethylanilinium tetra(phenyl)boron,
di-(isopropyl)ammonium tetra(pentafluorophenyl)boron,
dicyclohexylammonium tetra(phenyl)boron,
triphenylphosphonium tetra(phenyl)boron,
tri(methylphenyl)phosphonium tetra(phenyl)boron,
tri(dimethylphenyl)phosphonium tetra(phenyl)boron,
tropillium tetrakispentafluorophenyl borate,
triphenylmethylium tetrakispentafluorophenyl borate,
benzene(diazonium)tetrakispentafluorophenyl borate,
tropillium phenyltrispentafluorophenyl borate,
triphenylmethylium phenyltrispentafluorophenyl borate,
benzene(diazonium)phenyltrispentafluorophenyl borate,
tropillium tetrakis(2,3,5,6-tetrafluorophenyl)borate,
triphenylmethylium tetrakis(2,3,5,6-tetrafluorophenyl)borate,
benzene(diazonium)tetrakis(3,4,5-trifluorophenyl)borate,
tropillium tetrakis(3,4,5-trifluorophenyl)borate,
benzene(diazonium)tetrakis(3,4,5-trifluorophenyl)borate,
tropillium tetrakis(1,2,2-trifluoroethenyl)borate,
triphenylmethylium tetrakis(1,2,2-trifluoroethenyl)borate,
benzene(diazonium)tetrakis(1,2,2-trifluoroethenyl)borate,
tropillium tetrakis(2,3,4,5-tetrafluorophenyl)borate,
triphenylmethylium tetrakis(2,3,4,5-tetrafluorophenyl)borate, and
benzene(diazonium)tetrakis(2,3,4,5-tetrafluorophenyl)borate.
Readily commercially available ionic activators include:
N,N-dimethylaniliniumtetrakispentafluorophenyl borate,
triphenylmethylium tetrakispentafluorophenyl borate, and
trispentafluorophenyl borane.
The use of boron containing ionic activators is preferred in the catalyst systems and process of this invention. The mole ratio of boron:aluminum (i.e. boron in activator:aluminum in catalyst component) is preferably from 0.5:1 to 2:1 especially from 0.9:1 to 1.1:1.
3. Homogeneous or Heterogeneous Catalyst
The catalyst system of this invention is preferably used in a homogeneous form in solution polymerization (where the term “homogeneous” means that the catalyst and cocatalyst/activator are soluble in, or miscible with, the polymerization solvent). However, when the catalyst is employed in a slurry or gas phase polymerization, it is preferred to use the catalyst in a heterogeneous or “supported form”. It is also preferred that the catalyst does not cause reactor fouling. The art of preparing heterogeneous catalysts which do not lead to reactor fouling is not adequately understood, though it is generally accepted that the catalytic material should be very well anchored to the support so as to reduce the incidence of fouling resulting from the deposition of catalyst or cocatalyst which has dissociated from the support.
In general, heterogeneous catalysts may be grouped into three main categories:
3.1 Unsupported Cocatalyst/Catalyst Mixtures
These catalysts may be easily prepared by evaporating the solvent or diluent from a liquid mixture of cocatalyst and the catalyst component. This approach is particularly suitable when using alumoxane as a cocatalyst because the resulting product is a solid at room temperature due to the comparatively high molecular weight of the alumoxane. There are two disadvantages to this approach, namely cost (i.e. alumoxanes are comparatively expensive—and the alumoxane is used as an expensive “support” material) and “reaction continuity/fouling” (i.e. the alumoxane may partially melt under polymerization conditions, leading to reactor instability/fouling). U.S. Pat. No. 4,752,597 (Turner, to Exxon) illustrates this approach for the preparation of a heterogeneous catalyst.
3.2 Conventionally Supported Catalysts
These catalysts are prepared by depositing the catalyst component and a cocatalyst on a support which may be, for example, a polymeric material or an inorganic material such as a metal oxide. Porous metal oxide supports are in wide commercial use and are preferred. Thus, the catalyst and cocatalyst are substantially contained within the pore structure of the metal oxide particle. This means that a comparatively large metal oxide particle is used (typically particle size of from 40 to 80 microns). The preparation of this type of supported catalyst is described in U.S. Pat. No. 4,808,561 (Welborn, to Exxon).
3.3 Filled/Spray Dried Catalysts
This method of catalyst preparation is also well known. For example, U.S. Pat. Nos. 5,648,310; 5,674,795 and 5,672,669 (all to Union Carbide) teach the preparation of a heterogeneous catalyst by spray drying a mixture which contains a metallocene catalyst, an alumoxane cocatalyst and a “filler” which is characterized by having a very small particle size (less than one micron) and by being unreactive with the catalyst and cocatalyst. The examples illustrate the use of very fine particle size “fumed” silica which has been treated to reduce the concentration of surface hydroxyls. The resulting catalysts exhibit good productivity. Moreover, they offer the potential to provide a catalyst which is not prone to “hot spots” (as the catalyst may be evenly distributed, at low concentration, throughout the heterogeneous matrix). However, these catalysts suffer from the potential disadvantage of being very friable because they are prepared with a fine, “inert” filler material which does not react with/anchor to the catalyst or cocatalyst.
Friable catalyst particles lead to the formation of “fines” in the polyethylene product, and may also aggravate reactor fouling problems.
An alternative approach is the preparation of spray dried catalysts using a hydrotalcite as a “reactive” filler (as opposed to the unreactive filler described in the above mentioned U.S. Patent to Union Carbide). This method of catalyst preparation is described in more detail in a commonly assigned patent application. Either approach is suitable for use with the catalysts of this invention.
4. Polymerization Processes
The catalysts of this invention are suitable for use in any conventional olefin polymerization process, such as the so-called “gas phase”, “slurry”, “high pressure” or “solution” polymerization processes.
The use of a heterogeneous catalyst is preferred for gas phase and slurry processes whereas a homogeneous catalyst is preferred for the solution process.
The polymerization process according to this invention uses ethylene and may include other monomers which are copolymerizable therewith such as other alpha olefins (having from three to ten carbon atoms, preferably butene, hexene or octene) and, under certain conditions, dienes such as hexadiene isomers, vinyl aromatic monomers such as styrene or cyclic olefin monomers such as norbornene.
The present invention may also be used to prepare elastomeric co- and terpolymers of ethylene, propylene and optionally one or more diene monomers. Generally, such elastomeric polymers will contain about 50 to abut 75 weight % ethylene, preferably about 50 to 60 weight % ethylene and correspondingly from 50 to 25 weight % of propylene. A portion of the monomers, typically the propylene monomer, may be replaced by a non-conjugated diene. The diene may be present in amounts up to 10 weight % of the polymer although typically is present in amounts from about 3 to 5 weight %. The resulting polymer may have a composition comprising from 40 to 75 weight % of ethylene, from 50 to 15 weight % of propylene and up to 10 weight % of a diene monomer to provide 100 weight % of the polymer. Preferred but not limiting examples of the dienes are dicyclopentadiene, 1,4-hexadiene, 5-methylene-2-norbornene, 5-ethylidene-2-norbornene and 5-vinyl-2-norbornene. Particularly preferred dienes are 5-ethylidene-2-norbornene and 1,4-hexadiene.
The polyethylene polymers which may be prepared in accordance with the present invention typically comprise not less than 60, preferably not less than 70 weight % of ethylene and the balance one or more C 4-10 alpha olefins, preferably selected from the group consisting of 1-butene, 1-hexene and 1-octene. The polyethylene prepared in accordance with the present invention may be linear low density polyethylene having density from about 0.910 to 0.935 g/cc. The present invention might also be useful to prepare polyethylene having a density below 0.910 g/cc—the so-called very low and ultra low density polyethylenes.
The most preferred polymerization process of this invention encompasses the use of the novel catalysts (together with a cocatalyst) in a medium pressure solution process. As used herein, the term “medium pressure solution process” refers to a polymerization carried out in a solvent for the polymer at an operating temperature from 100 to 320° C. (especially from 120 to 220° C.) and a total pressure of from 3 to 35 mega Pascals. Hydrogen may be used in this process to control (reduce) molecular weight. Optimal catalyst and cocatalyst concentrations are affected by such variables as temperature and monomer concentration but may be quickly optimized by non-inventive tests.
Further details concerning the medium pressure polymerization process are well known to those skilled in the art and widely described in the open and patent literature.
The catalyst of this invention may also be used in a slurry polymerization process or a gas phase polymerization process.
The typical slurry polymerization process uses total reactor pressures of up to about 50 bars and reactor temperature of up to about 200° C. The process employs a liquid medium (e.g. an aromatic such as toluene or an alkane such as hexane, propane or isobutane) in which the polymerization takes place. This results in a suspension of solid polymer particles in the medium. Loop reactors are widely used in slurry processes. Detailed descriptions of slurry polymerization processes are widely reported in the open and patent literature.
In general, a fluidized bed gas phase polymerization reactor employs a “bed” of polymer and catalyst which is fluidized by a flow of monomer which is at least partially gaseous. Heat is generated by the enthalpy of polymerization of the monomer flowing through the bed. Unreacted monomer exits the fluidized bed and is contacted with a cooling system to remove this heat. The cooled monomer is then re-circulated through the polymerization zone together with “make-up” monomer to replace that which was polymerized on the previous pass. As will be appreciated by those skilled in the art, the “fluidized” nature of the polymerization bed helps to evenly distribute/mix the heat of reaction and thereby minimize the formation of localized temperature gradients (or “hot spots”). Nonetheless, it is essential that the heat of reaction be properly removed so as to avoid softening or melting of the polymer (and the resultant—and highly undesirable—“reactor chunks”). The obvious way to maintain good mixing and cooling is to have a very high monomer flow through the bed. However, extremely high monomer flow causes undesirable polymer entrainment.
An alternative (and preferable) approach to high monomer flow is the use of an inert condensable fluid which will boil in the fluidized bed (when exposed to the enthalpy of polymerization), then exit the fluidized bed as a gas, then come into contact with a cooling element which condenses the inert fluid. The condensed, cooled fluid is then returned to the polymerization zone and the boiling/condensing cycle is repeated.
The above-described use of a condensable fluid additive in a gas phase polymerization is often referred to by those skilled in the art as “condensed mode operation” and is described in additional detail in U.S. Pat. No. 4,543,399 and U.S. Pat. No. 5,352,749. As noted in the '399 reference, it is permissible to use alkanes such as butane, pentanes or hexanes as the condensable fluid and the amount of such condensed fluid preferably does not exceed about 20 weight per cent of the gas phase.
Other reaction conditions for the polymerization of ethylene which are reported in the '399 reference are:
Preferred Polymerization Temperatures: about 75° C. to about 115° C. (with the lower temperatures being preferred for lower melting copolymers—especially those having densities of less than 0.915 g/cc—and the higher temperatures being preferred for higher density copolymers and homopolymers); and
Pressure: up to about 1000 psi (with a preferred range of from about 100 to 350 psi for olefin polymerization).
The '399 reference teaches that the fluidized bed process is well adapted for the preparation of polyethylene but further notes that other monomers may be employed—as is the case in the process of this invention.
EXAMPLES
The invention will now be illustrated in further detail by way of the following non-limiting examples. For clarity, the examples have been divided into two parts, namely Part A (Compound Synthesis) and Part B (Polymerization).
Polymer Analysis
Gel permeation chromatography (“GPC”) analysis was carried out using a commercially available chromatograph (sold under the name Waters 150 GPC) using 1,2,4-trichlorobenzene as the mobile phase at 140° C. The samples were prepared by dissolving the polymer in the mobile phase solvent in an external oven at 0.1% (weight/volume) and were run without filtration. Molecular weights are expressed as polyethylene equivalents with a relative standard deviation of 2.9% and 5.0% for the number average molecular weight (Mn) and weight average molecular weight (Mw), respectively.
DSC was conducted on a DSC 220 C from Seiko Instruments. The heating rate is 10° C./min from 0 to 200° C.
FT-IR was conducted on a Nicolet Model 750 Magna IR spectrometer.
The following abbreviations are used in the examples:
t Bu=tertiary butyl (e.g. t Bu 3 =tri-tertiary butyl)
Me=methyl
Et=ethyl
1 H NMR=proton nuclear magnetic resonance
Mw=weight average molecular weight
Mn=number average molecular weight
PD=polydispersity (or Mw/Mn)
PE=polyethylene
Cat=catalyst
Hr=hour
M=molar
DSC=differential scanning calorimetry
GPC=gel permeation chromatography
MeOH=methanol
PMAO-IP=methylaluminoxane, purchased from Akzo Nobel
Tm=polymer melting point
FT-IR=Fourier Transform Infrared Analysis
PART A: Compound Synthesis
A.1 Preparation of t Bu 3 P═NH
t Bu 3 P═N—SiMe 3 (10 g, 35 mmol, prepared from the reaction of t Bu 3 P with neat Me 3 SiN 3 at 90° C.) was dissolved in a mixture of toluene (50 mL) and methanol (50 mL). 14 small drops of concentrated H 2 SO 4 was then added to the stirred solution. The solution was heated to 60° C. for 6 hours to complete the reaction. The solution was pumped to dryness and the residue was extracted with heptane (3×20 mL). The combined heptane extract was dried over anhydrous MgSO 4 and was filtered. The filtrate was pumped to dryness to give the product in 82% yield (6.13 g, white solid).
No further purification was required. 1 H NMR (toluene-d 8 , δ): 1.203 (d, J=12 Hz).
A.2 Synthesis of { t Bu 3 P═NAlMe 2 } 2 ; (Parts A.2.1 and A.2.2)
A.2.1 Preparation of t Bu 3 P═(H).AlMe 3
To a toluene (25 mL) solution of AlMe 3 (1 mL, 2M toluene solution, 2 mmol) at −78° C. was added a toluene (25 mL) solution of t Bu 3 P═NH (0.434 g, 2 mmol). The solution was warmed to room temperature and stirred for one hour. The toluene was evaporated under vacuum to dryness to give a white solid. Yield: 100%. 1 H NMR (toluene-d 8 , δ): 1.01 (d, 3 J P-H =13.3 Hz, 27H), −0.30 (s, 9H).
A.2.2 Synthesis of [ t Bu 3 P═NAlMe 2 ] 2
t Bu 3 P═N(H).AlMe 3 (0.289 g, 1.00 mmol) in toluene (20 mL) was refluxed for one hour. The toluene was evaporated under vacuum to dryness to give a white solid. Yield: 100%. 1 H NMR (toluene-d 8 , δ): 1.36 (d, 3 J P-H =12.6 Hz, 27H), −0.12 (s, 6H).
A.3 Synthesis of t Bu 3 P═NAl 2 Me 5
A mixture of t Bu 3 P═(H).AlMe 3 (0.289 g, 1.00 mmol) in toluene (20 mL) and AlMe 3 (0.5 mL, 2M toluene solution, 1 mmol) was refluxed for one hour. The toluene was evaporated under vacuum to dryness to give a white solid. Yield: 100%. 1 H NMR (toluene-d 8 , δ): 1.15 (d, 3 J P-H =12.8 Hz, 27H), 0.52 (s, 3H), −0.31 (s, 12H).
Polymerization Results
All the polymerization experiments described below were conducted using a 500 mL Autoclave Engineers Zipperclave reactor. All the chemicals (solvent, catalyst and cocatalyst) were fed into the reactor batchwise except ethylene which was fed on demand. No product was removed during the polymerization reaction. The feed streams were purified prior to feeding into the reactor by contact with various absorption media to remove impurities such as water, oxygen, sulfur and polar materials. All components were stored and manipulated under an atmosphere of purified argon or nitrogen. The reactor uses a programmable logical control (PLC) system with Wonderware 5.1 software for the process control. Ethylene polymerizations were performed in the reactor equipped with an air driven stirrer and an automatic temperature control system.
The initial polymerization temperature was 50° C. or 70° C. The polymerization reaction time varied from 20 to 40 minutes for each experiment. The reaction was terminated by adding 5 mL of methanol to the reactor and the polymer was recovered by evaporation of the toluene or by drying it in vacuum. The polymerization activities were calculated based on the weight of the polymer produced.
Toluene was purchased from Aldrich and purified over molsieves prior to use. Trimethyl aluminum (TMA) was purchased from Aldrich and contained 2 M of TMA in toluene. [CPh 3 ][B(C 6 F 5 ) 4 ] was purchased from Asahi Glass Inc.
All reported pressures are gauge pressures.
PART B: Polymerizations
Example 1
PMAO-IP Plus HNPtBu 3 For Ethylene Homopolymerization
Toluene (216 mL) was transferred into the reactor with 0.9 mL of PMAO-IP (4.04 mmol). The solution was heated to 50° C. and saturated with 300 pounds per square inch gauge (psig) of ethylene. HNPtBu 3 (67.4 mmol, 14.6 mg) was dissolved in toluene (12.2 mL) and then injected into the reactor. No temperature rise was observed and the polymerization reaction was terminated by adding 5 mL of MeOH after 22 minutes. The polymer was dried. Yield=0.8 g. Activity=32.4 gPE/mmolcat*hr. Tm=127.1° C.
Example 2
TMA Plus HNPtBu 3 Activated By [CPh 3 ][B(C 6 F 5 ) 4 ] For Ethylene Homopolymerization
Toluene (216 mL) was transferred into the reactor with 9.4 mL of toluene solution of TMA (0.281 mmol, 0.141 mL) as a scavenger and catalyst precursor. The solution was heated to 50° C. and saturated with 300 psig of ethylene. The HNPtBu 3 (0.067 mmol, 14.6 mg) was dissolved in toluene (12.2 mL) and then injected into the reactor. After one minute, [CPh 3 ][B(C 6 F 5 ) 4 ] (0.067 mmol, 61.8 mg) in 12.2 mL of toluene was injected into the reactor. Polymerization occurred quickly and the reaction temperature slowly increased to 70° C. The reaction was terminated by adding 5 mL of MeOH after 40 minutes. The polymer was dried. Yield=7.0 g. Activity=167.3 gPE/mmolcat*hr. Tm=133.7° C. Mw=203,900; Mn=13,400; Pd=15.22.
Example 3
TMA Plus HNPtBu 3 Activated By [CPh 3 ][B(C 6 F 5 ) 4 ] For Ethylene And 1-Octene Copolymerization
Toluene (216 mL) and 30 mL of 1-octene was transferred into the reactor with 10 mL of toluene solution of TMA (0.281 mmol, 0.141 mL) as a scavenger and catalyst precursor. The solution was heated to 50° C. and saturated with 300 psig of ethylene. The HNPtBu 3 (0.067 mmol, 14.6 mg) was dissolved in toluene (12.6 mL) and then injected into the reactor. After one minute, [CPh 3 ][B(C 6 F 5 ) 4 ] (0.067 mmol, 61.8 mg) in 12.2 mL of toluene was injected into the reactor. Polymerization occurred quickly but no increase in temperature was observed. The reaction was terminated by adding 5 mL of MeOH after 40 minutes. The polymer was dried. Yield=3.7 g. Activity=85.65 gPE/mmolcat*hr. Tm=125.1° C. 3.2 branches per 1000 carbon atoms were detected by FT-IR. Mw=691,600; Mn=73,000; Pd=9.47.
Example 4
TMA Plus HNPtBu 3 Activated By [CPh 3 ][B(C 6 F 5 ) 4 ] For Ethylene And 1-Octene Copolymerization
Toluene (216 mL) and 30 mL of 1-octene was transferred into the reactor with 10 mL of toluene solution of TMA (0.281 mmol, 0.141 mL) as a scavenger and catalyst precursor. The solution was heated to 70° C. and saturated with 300 psig of ethylene. The HNPtBu 3 (0.067 mmol, 14.6 mg) was dissolved in toluene (12.6 mL) and then injected into the reactor. After one minute, [CPh 3 ][B(C 6 F 5 ) 4 ] (0.067 mmol, 61.8 mg) in 12.2 mL of toluene was injected into the reactor. Polymerization occurred quickly and the temperature increased to over 80° C. The reaction was terminated by adding 5 mL of MeOH after 30 minutes. The polymer was dried. Yield=6.0 g. Activity=179.7 gPE/mmolcat*hr. Tm=121.1° C. 4.7 branches per 1000 carbon atoms were detected by FT-IR. Mw=919,200; Mn=199,100; Pd=4.62.
Example 5
TMA Plus [CPh 3 ][B(C 6 F 5 ) 4 ] For Ethylene Homopolymerization
Toluene (216 mL) was transferred into the reactor with 10 mL of toluene solution of TMA (0.281 mmol, 0.141 mL) as a scavenger and catalyst precursor. The solution was heated to 50° C. and saturated with 300 psig of ethylene. [CPh 3 ][B(C 6 F 5 ) 4 ] (0.067 mmol, 61.8 mg) in 12.2 mL of toluene was injected into the reactor. The reaction was terminated by adding 5 mL of MeOH after 30 minutes. The polymer was dried. Yield=0.210 g. Activity=6.48 gPE/mmolcat*hr. Tm=134.1° C.
Example 6
[NPtBu 3 AlMe 2 ] 2 Activated By [CPh 3 ][B(C 6 F 5 ) 4 ] For Ethylene Homopolymerization
Toluene (216 mL) was transferred into the reactor with 0.06 mL of PMAO-IP as a scavenger. The solution was heated to 50° C. and saturated with 300 psig of ethylene. The [NPtBu 3 AlMe 2 ] 2 (0.065 mmol, 35.44 mg) was dissolved in toluene (12.2 mL) and loaded into the catalyst injection bomb. [CPh 3 ][B(C 6 F 5 ) 4 ] (0.136 mmol, 125.52 mg) was also dissolved in toluene (12.2 mL) and loaded into the cocatalyst injection bomb. Both components were injected into the reactor simultaneously. Polymerization occurred slowly and the reaction temperature increased to 65° C. after 20 minutes. The reaction was terminated by adding 5 mL of MeOH after 40 minutes. The polymer was dried. Yield=0.774 g. Activity=17.92 gPE/mmolcat*hr.
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Aluminum-phosphinimine complexes function as a component in a catalyst system for the (co)polymerization of ethylene. The inventive catalyst components form a highly productive polymerization system when activated with so-called “ionic activators”. The need for conventional transition metal catalyst metals (such as titanium, hafnium, zirconium or vanadium) is eliminated.
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FIELD OF THE INVENTION
The invention relates to a power steering apparatus which utilizes an electric motor, and more particularly, to such apparatus which is designed to prevent sounds of percussion from occurring which may be caused by a backlash of a gear which provides a power transmission from an electric motor to a steering shaft.
DESCRIPTION OF THE PRIOR ART
An electrically driven power steering apparatus is known in the art, as disclosed in Japanese Laid-Open Patent Application No. 226,362/1986, for example, comprising a steering shaft which is rotatably mounted and coupled to a steering wheel, a bevel gear of a reduced diameter which is coupled to an electric motor, and a bevel gear of a greater diameter mounted on the steering shaft for meshing engagement with the bevel gear of reduced diameter.
In the described apparatus, a backlash occurs between the teeth of the both bevel gears, giving rise to producing sounds of percussion as the teeth of the both gears abut against each other during the rotation of the steering shaft. In order to prevent such backlash from occurring, the teeth of the both gears must be machined very precisely, but as a matter of practice, it has been difficult to achieve a complete elimination of the backlash.
In the prior art practice, the bevel gear of greater diameter has been mounted on the steering shaft either by fitting the gear to the steering shaft through a splined engagement or by utilizing a key member which engages both the steering shaft and the bevel gear. However, when the both members are splined together, a very small clearance will be produced between the splined parts of the both members, and if the both members are coupled together by means of the key member, a small clearance will also be produced between the key member and either member. Such clearance gives rise to the occurrence of sounds of percussion as the bevel gear abuts against the steering shaft or the key member abuts against either member.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to prevent sounds of percussion from occurring in an electrically driven power steering apparatus which may be caused by a backlash of a power transmitting gear or gears.
Specifically, the invention is applied to an electrically driven power steering apparatus including a steering shaft rotatably mounted and coupled to a steering wheel, a bevel gear of a reduced diameter which is coupled to an electric motor, and a bevel gear of a greater diameter mounted on the steering shaft for meshing engagement with the bevel gear of a reduced diameter. In accordance with the invention, the bevel gear of greater diameter is mounted on the steering shaft so as to be axially displaceable relative thereto, and means is provided for urging the teeth of the bevel gear of greater diameter toward the teeth of the bevel gear of reduced diameter, thereby enabling such means to couple the bevel gear of greater diameter to the steering shaft in a manner which prevents a relative rotation therebetween.
With the described arrangement, the urging means urges the teeth of the bevel gears of both greater and reduced diameter toward each other to thereby prevent a backlash from occurring between the teeth of these gears. In this manner, the occurrence of sounds of percussion which may result from the abutment of the teeth of these gears against each other may be prevented.
It is to be noted that because the bevel gear of greater diameter is coupled to the steering shaft in a manner to prevent a relative rotation therebetween by means of the urging means, a clearance between the splined parts or between a key member and its associated member which may be produced when the both members are splined together or the both members are connected together by means of the key member in order to prevent a relative rotation circumferentially as experienced in the prior art cannot be produced, thus preventing the occurrence of sounds of percussion.
Above and other objects, features and advantages of the invention will become apparent from the following description with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation, principally in section, of one embodiment of the invention;
FIG. 2 is a cross section taken along the line II--II shown in FIG. 1, and
FIG. 3 is a cross section corresponding to FIG. 2 for another embodiment of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
Referring to the drawings, several embodiments of the invention will now be described. An electrically driven power steering apparatus 1 shown in FIG. 1 includes a casing 2 in which a steering shaft 3 is rotatably mounted. The steering shaft 3 comprises an input shaft 4 having an end which projects externally of the casing 2 and on which a steering wheel, not shown, is mounted, an output shaft 6 having a pinion 6a formed thereon which meshes with a rack 5 mechanically coupled to a road wheel, not shown, and a torsion bar 7 which couples the input shaft 4 and the output shaft 6 together in a manner to permit a relative rotation therebetween within a given range of angle.
The output shaft 6 includes a portion 6b of a greater diameter in which the lower end of the torsion bar 7 is fitted and on which a bevel gear 11 of a greater diameter is mounted. The bevel gear 11 is formed by a hypoid gear including teeth 11a which face upwardly. The bevel gear 11 meshes with a bevel gear 12 of a reduced diameter which is rotatably mounted in the casing 2.
The bevel gear 12 of reduced diameter is coupled through a solenoid operated clutch 13, which is disposed adjacent thereto, to the drive shaft 14a of an electric motor 14. Accordingly, when a controller, not shown, operates the motor 14 and the clutch 13 is turned on, the bevel gear 12 may be driven for rotation in either forward or reverse direction. Upon rotation of the bevel gear 12, the bevel gear 11 of greater diameter which meshes with the bevel gear 12 of reduced diameter as well as the output shaft 6 will be driven to rotate through a given angle either forwardly or reversely, thus enabling a steerable wheel, not shown, to be driven through the rack 5.
A detection mechanism 15, which is constructed in a known manner, is disposed within the casing 2 above and adjacent to the bevel gear 11 of greater diameter and in surrounding relationship with the output shaft 6. The purpose of the detection mechanism 15 is to derive a detection signal delivered to the controller mentioned above by detecting a relative displacement in the circumferential direction and the direction of such displacement of the torsion bar 7 connected between the input shaft 4 and the output shaft 6 as such bar is twisted.
The controller mentioned above normally maintains the clutch 13 in its on condition, and operates to drive the motor 14 for rotation in either forward or reverse direction on the basis of an input signal from the detection mechanism 15 and data which is previously stored, thus causing the rack 5 to be driven through the both bevel gears 12, 11 and the output shaft 6.
As the output shaft 6 is driven for rotation in this manner, the angle through which it has rotated and the direction in which it has rotated is detected by an angle of rotation detector 16 which engages the bottom end of the output shaft 6, the detector 16 delivering a signal to the controller mentioned above. In response to signals fed from the detection mechanism 15 and the detector 16, the controller compares these signals against each other and if an error occurs therebetween which exceeds a permissible extent, it turns the clutch 13 off, thus disengaging the bevel gear 12 from the motor 14.
The described arrangement and its operation are essentially the same as those of a conventional electrically driven power steering apparatus. However, it is to be noted that in the present embodiment, the bevel gear of greater diameter 11 is mounted on the output shaft 6, by forming a through-opening 11b in the central portion of the bevel gear 11, which is fitted around the portion 6b having a greater diameter of the output shaft 6 in a rotatable and slidable manner. The bevel gear 11 and the output shaft 6 are connected together by a leaf spring 17 to permit the bevel gear 11 and the output shaft 6 to be displaced axially relatively to each other, but to be incapable of relative displacement in the rotational direction.
Referring to FIG. 2, the leaf spring 17 is in the form of a generally triangular frame which surrounds the output shaft 6. At the apices of the triangle, it includes first connection points 17a which are disposed radially outermost and which are connected to the lower surface of the bevel gear 11 around its outer periphery by means of bolts 18. The leaf spring also includes second connection points 17b which are located intermediate adjacent first connection points 17a. The second connection points 17b are also offset radially inward of the first connection points 17a and are axially displaced from the first connection points 17a. These second connection points 17b are connected to a flange 6c on the output shaft 6, located below the portion 6b having a greater diameter, by means of bolts 18.
When the output shaft 6 and the bevel gear 11 of greater diameter are connected together by the leaf spring 17 in the manner mentioned above, the resilience of the leaf spring 17 is effective to urge the bevel gear 11 upward, whereby the teeth 11a of the bevel gear 11 is urged into abutment against the teeth 12a of the bevel gear 12 to prevent a backlash therebetween from occurring. This prevents the occurrence of sounds of percussion which might otherwise occur as a result of the abutment of the teeth 11a, 12a of the both gears 11, 12 against each other, and also prevents impacts or rattling during a kickback.
Since the bevel gear 11 of greater diameter and the output shaft 6 are connected together by the leaf spring 17 in a manner to disable a relative rotation therebetween, sounds of percussion which might result from the presence of a clearance between connected parts as when the both members are splined together or the key member is used to connect them together is prevented. In addition, the manufacturing cost can be reduced as compared with the use of a splined coupling or the key connection.
It is to be recognized that a great difficulty will be experienced to fabricate all the teeth of the both bevel gears 12 and 11, which comprise hypoid gears, to an equal, exact configuration. Accordingly, a fluctuation in the torque will be produced during the meshing engagement between these gears, but the resilience of the leaf spring 17 is effective to relax such fluctuation in the torque, thus improving a steering feeling transmitted to a driver through the steering shaft 3. Conversely, the hypoid gears which comprise the bevel gears 12 and 11 may be machined with a rough or reduced accuracy without degrading the steering feeling, thus facilitating the fabrication of these gears.
Referring to FIG. 3, a second embodiment of the invention will be described. In the first embodiment mentioned above, the single leaf spring 17 in the form of a frame has been used to connect the output shaft 6 and the bevel gear 11 of greater diameter together. However, in the second embodiment, pairs of leaf springs 117, each disposed in V-configuration, are disposed at three points around an output shaft 106. Each free end of the respective leaf spring 117, which is located radially inward, is connected to a flange 106c formed on the output shaft 106 by means of a bolt 118 while the junction of the V-shape or the other end of the respective leaf spring 117, which is located radially outward, is connected to a bevel gear 111 of a greater diameter by a bolt 118. In this embodiment, parts corresponding to those used in the first embodiment are designated by like numerals as used in the first embodiment, to which 100 is added. It will be apparent that a similar function and effect can be achieved in this embodiment as in the first embodiment.
While the use of hypoid gears has been assumed to construct the both bevel gears 11 and 12 in the described embodiments, it should be understood that these bevel gears are not limited to hypoid gears.
While the invention has been described above in connection with several embodiments thereof, it should be understood that a number of changes, modifications and substitutions therein will readily occur to one skilled in the art from the above disclosure without departing from the scope and spirit of the invention defined by the appended claims.
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An improvement to an electrically driven power steering apparatus which utilizes an electric motor is disclosed. A bevel gear of a greater diameter is mounted on a steering shaft so as to be axially displaceable thereon, and an urging mechanism is connected between the bevel gear and the steering shaft. The urging mechanism renders the bevel gear to be incapable of rotation relative to the steering shaft, and also urges the teeth thereof toward the teeth of a bevel gear of a reduced diameter which is coupled to the electric motor. This prevents a backlash from occurring between the both bevel gears, thus preventing the occurrence of sounds of percussion as the both gears abut against each other.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a pattern recognition system for handling an image of a DNA microarray and particularly relates to an image analysis system for a Stanford type microarray having a plurality of blocked spots.
[0003] 2. Background Art
[0004] Stanford type microarrays are available which have a plurality of blocked spots. For example, one microarray has 4×8 blocks each of which is constituted of X×Y spots. After a specimen is brought into contact with the microarray, a fluorescent intensity of each spot is optically measured. In the optical measurements, each spot is divided into N×M pixels and the pixels are sequentially or simultaneously measured. Since a quite a number of measurements are performed with a massive amount of data, microarray image analysis systems are developed to perform statistical analysis on obtained data.
[0005] For example, as to automatic recognition of the position and size of a spot in a microarray, a filtering system described in JP Patent Publication (Kokai) No. 2002-189026 is known. The system described in the document performs processing such as filtering, segmentation, and morphological operation during an automatic analysis on an image of a microarray and the like so that useful information is separated from various noise sources causing an erroneous interpretation.
[0006] As described in the document, the system automatically recognizing the position and size of a spot after filtering is available. However, a flag is manually set by changing the status of a spot lacking reproducibility and quantitativeness. The flag is set to remove the spot in the subsequent data analysis.
[0007] An example of a spot lacking reproducibility and quantitativeness includes a spot with dirt, a damaged spot, and a doughnut-shaped spot. A similar status needs to be set for a spot symmetrical with respect to the center of a spot region.
[0008] Further, according to the characteristic of a method of producing a microarray, spots having similar spot coordinates in a block are prone to have similar statuses.
[0009] An object of the present invention is to provide a system for semi-automatically setting a flag on a spot. The flag is manually set by the user at present.
SUMMARY OF THE INVENTION
[0010] In order to attain the above object, the present invention relates to a DNA microarray image analysis system comprising status automatic setting means for setting spot regions in a DNA microarray image after hybridization and then automatically setting one of a plurality of statuses which can be arbitrarily set by the user for each of the spot regions, learning means for learning the set status by using a pixel value of each of the spot regions and storing the learning results in storage means, and automatic decision means for performing automatic decision using the learning results.
[0011] The status of the present invention indicates a state of each spot that is significant in a microarray analysis and is also referred to as a flag. The kind of status includes the presence (abnormal) or absence (normal) of a problem in an analysis, the presence or absence of a spot, the presence or absence of dirt, and an abnormal shape of a spot. Other kinds of status may be properly set in response to the needs of an analyzer.
[0012] Further, in the present invention, an automatically set status is learned using a pixel value of each of the spot regions and the number of stored learning results is not particularly limited. An analyzer can set the number of stored learning results as appropriate in consideration of the kind of status, a demanded analysis accuracy, and the number of test samples.
[0013] In the present invention, it is preferable that the means for automatically setting one status is constituted of a feed-forward neural network where a status set by the user is a teacher signal (training data).
[0014] Besides, it is preferable that input serving as a teacher signal (training data) to the feed-forward neural networks is each pixel value included in a spot region selected by the user.
[0015] Moreover, input serving as a teacher signal (training data) to the feed-forward neural network may be each pixel value included in a selected image which is horizontally, vertically, or vertically and horizontally reversed, instead of each pixel value included in the selected spot region. Similarly instead of a pixel value included in an image, input serving as a teacher signal (training data) to the feed-forward neural network may be each pixel value included in an image rotated by 90°, 180°, or 270°. According to the graphical symmetry of spots to be set at the same status, the vertically and horizontally reversed image and the rotated image are also used as teacher signals, thereby enriching the teacher signal (training data) with little learning.
[0016] It is preferable that input serving as a teacher signal (training data) to the feed-forward neural network is each pixel value included in an image and a value indicating a spot position in a block.
[0017] Moreover, each pixel value included in a spot region with an undecided status may be inputted to the feed-forward neural network after learning, expected values may be calculated for a plurality of statuses, and a status with the highest expected value may be outputted out of the expected values of the plurality of statuses.
[0018] Additionally, the microarray of Stanford type with a plurality of blocked spots is preferable for implementing the microarray analysis system of the present invention.
[0019] Furthermore, the user can optionally select the function of automatically setting similar statuses for spots having similar spot coordinates in a block.
[0020] The feed-forward neural network configured thus is made storable and readable so as to increase the ability of the feed-forward neural network. The present invention enables the user to select a feed-forward neural network according to the manufacturing state of a chip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a hardware structural diagram showing a microarray image analysis system according to the present invention;
[0022] [0022]FIG. 2 is a diagram showing an image of a DNA microarray;
[0023] [0023]FIG. 3 is an enlarged view showing a spot;
[0024] [0024]FIG. 4 is a conceptual diagram showing a feed-forward neural network;
[0025] [0025]FIG. 5 is a diagram showing a logistic function;
[0026] [0026]FIG. 6 is an overall flowchart showing the present invention;
[0027] [0027]FIG. 7 is a flowchart showing a part for learning; and
[0028] [0028]FIG. 8 is a flowchart showing a part for automatic decision.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] An embodiment of the present invention will be specifically described below in accordance with the accompanying drawings.
[0030] [0030]FIG. 1 is a diagram showing an example of the configuration of a DNA microarray image analysis system according to the present invention. The system is broadly constituted of input/output devices including a display 1 , a keyboard 2 , and a scanner 3 , a CPU 4 , and an external memory 5 . A DNA microarray image analysis program 40 is stored in the memory region of the CPU 4 . The DNA microarray image analysis program 40 is composed of a status automatic setting section 41 for automatically setting one of a plurality of statuses which can be arbitrarily set by the user for each spot region of a DNA microarray image after hybridization, a status learning section 42 for learning the set status by using a pixel value of each spot region and storing the learning results in the external memory 5 , an automatic decision section 43 for performing automatic decision by using the learning results, and an analysis section 44 using the above-described means. The external memory 5 stores data 50 which includes data read by the scanner 3 and the learning results. The DNA microarray image analysis program 40 can be provided through recording media such as a floppy (trademark) disk, a CD-ROM, a DVD-ROM, and an MO. Alternatively the DNA microarray image analysis program 40 can be provided through a communication network such as the Internet.
[0031] [0031]FIG. 2 is a diagram showing an image of a DNA microarray. FIG. 2 shows a kind of microarray which is spotted in blocks according to the structure of a spotter. Reference numeral 201 denotes the range of one block. Reference numeral 202 denotes examples of spots having similar spot coordinates in blocks.
[0032] [0032]FIG. 3 is an enlarged view of a spot region. The fluorescence intensities of N×M pixels are converted into numbers.
[0033] [0033]FIG. 4 is a conceptual diagram showing a feed-forward neural network. Reference numeral 401 indicates that the fluorescence intensities of the M×N pixels that are converted into numbers are inputted to an input layer according to FIG. 2. Reference numeral 402 denotes the input layer of the feed-forward neural network. The number of input units for pixel values is equal to the number of pixels in the spot region and the number of units for inputting spot positions in a block is equal to the number of X-coordinate spots+the number of Y-coordinate units. An output function is a linear function. Reference numeral 403 denotes an intermediate layer of the feed-forward neural network. An output function is a logistic function shown in FIG. 5. Reference numeral 404 denotes an output layer of the feed-forward neural network. The number of units is equal to the number of kinds of statuses to be set. An output function is the logistic function shown in FIG. 5. Reference numeral 405 denotes a status determined by the output values of the output layer. When a sigmoid function is used as the logistic function, a value close to 1 or 0 is outputted. A value close to 1 is regarded as a status corresponding to an output unit. In the case of a system not permitting the setting of two or more statuses for one spot, a status of an output unit closest to 1 is adopted.
[0034] Reference numeral 406 indicates that the X coordinates of spots in a block of FIG. 2 are inputted. 1 is inputted only to units corresponding to the X coordinates and 0 is inputted to the other units. In the case of a setting not using spot coordinates in a block, 0 is inputted to all the units in 406 and thus the X coordinates of the spots in the block do not affect the output of a status. Reference numeral 407 indicates that the Y coordinates of spots in a block of FIG. 2 are inputted. 1 is inputted only to units corresponding to the Y coordinates and 0 is inputted to the other units. In the case of a setting not using spot coordinates in a block, 0 is inputted to all the units in 407 and thus the Y coordinates of the spots in the block does not affect the output of a status.
[0035] Reference numeral 408 indicates that the input of spot coordinates in the block is directly outputted to the output layer without passing though the intermediate layer. Hence, the decision of a status according to pixel values and the decision of a status according to spot coordinates in a block produce independent networks. The sum of results serves as the output of a status.
[0036] In 405 , a status is decided by each output value.
[0037] [0037]FIG. 5 shows a logistic function which is frequently used for feedback error learning in a neural network and is a differentiable function similar to a step function. A function having the minimum value of 0 and the maximum value of 1 is called a sigmoid function, which is used for the output layer requiring the output of 0 or 1 in the present invention.
[0038] [0038]FIG. 6 is a flowchart showing the overall flow of DNA microarray image analysis. A part for learning and a part for automatic decision will be described in the subsequent drawings. Step 601 is a starting step where image data obtained from experiment results using a DNA microarray is inputted to a system including the present invention. The image data includes a scanned fluorescent intensity. Step 602 is associated with the input of a pixel value according to the present invention and spot regions are decided in this step. Processing from step 603 relates to the present invention. When the learning results of the feed-forward neural network have been stored in this step, the learning results can be read in this step.
[0039] In step 604 , the user selects a spot for learning or automatic decision. Two or more spots can be selected.
[0040] In step 605 , the user selects learning or automatic decision.
[0041] When the user selects learning in step 605 , the user sets a status, in step 606 , for a spot selected in step 604 . Step 607 is a learning step which is specifically shown in FIG. 7. In step 608 , learning results are stored. When the user desires, learning results are stored in this step. In step 609 , the user decides whether the system should be ended or not. When the system is not ended, for example, when another status is set or automatic decision is performed, the processing returns to step 604 and a spot is selected again.
[0042] When it is decided in step 605 that learning is not selected, that is when automatic decision is selected, automatic decision is performed in step 610 . The detail is shown in FIG. 8. In step 611 , the user decides whether the system should be ended or not. When the system is not ended, for example, when learning is started over, the processing returns to step 604 and a spot is selected again.
[0043] [0043]FIG. 7 is a flowchart showing the learning of step 607 . In step 701 , a pixel value in the spot region of one spot is calculated. Step 702 is a branching step depending upon whether or not learning is performed using a spot position in a block. In step 703 , a spot position in a block is used. A pixel value and a spot position are inputted to the feed-forward neural network and learning is performed with a status serving as a teacher signal. In step 704 , a spot position in a block is not used. A pixel value is inputted as it is to the feed-forward neural network but 0 is inputted to all units for inputting spot positions, and learning is performed with a status serving as a teacher signal.
[0044] In step 705 , an image of a spot region is horizontally reversed. When a horizontally reversed image has not been inputted to the feed-forward neural network, the processing returns to step 701 to calculate a pixel value and learning is performed. In step 706 , an image of a spot region is vertically reversed. When a vertically reversed image has not been inputted to the feed-forward neural network, the processing returns to step 701 to calculate a pixel value and learning is performed. In step 707 , an image of a spot region is rotated. When a rotated image has not been inputted to the feed-forward neural network, the processing returns to step 701 to calculate a pixel value and learning is performed. In step 708 , it is decided whether selected spots are all used for learning. When there is a spot not being used for learning, the processing returns to step 701 to calculate a pixel value of the spot.
[0045] [0045]FIG. 8 is a flowchart showing the automatic decision of step 710 . In step 801 , a pixel value in the spot region of one spot is calculated. Step 802 is a branching step depending upon whether or not automatic decision is performed using a spot position in a block. Step 803 is a case where a spot position in the block is used, a pixel value and a spot position are inputted to the feed-forward neural network and output results are obtained. When learning is performed in a setting not using a spot position in a block, combined loads remain initial values of sufficiently small random numbers and thus any spot position in a block does not affect the results. In step 804 , a spot position in a block is not used. A pixel value is inputted as it is to the feed-forward neural network but 0 is inputted to all units for inputting spot positions and output results are obtained. When learning is performed in a setting using a spot position in a block, 0 is inputted to all units for inputting spot positions and thus any spot position in a block does not affect the results. In step 805 , a status of a spot is decided using the output results of the feed-forward neural network. In the case of a system not permitting the setting of two or more statuses for one spot, a status of the output unit closest to 1 is adopted. In step 806 , it is decided whether selected spots are all used for automatic decision. When there is a spot not being used for automatic decision, the processing returns to step 801 to calculate a pixel value of the spot.
[0046] According to the present invention described above, in the process at some midpoint of an expression analysis from a DNA microarray image, for the setting of a status on a spot which is unsuitable for an expression analysis due to the intrusion of dirt and a contamination and a spot which is somewhat significant for other reasons, decision is automatically performed by causing the feed-forward neural network to learn the decision of the user and thus the working time of the user is shortened, and the accuracy of an expression analysis is improved by preventing a mistake and an oversight.
[0047] In this case, by setting a status of one spot, a vertically and horizontally reversed spot image and a rotated spot image are automatically formed and learned, thereby enhancing the effect of automation.
[0048] Further, in consideration of a characteristic in that spots having similar spot coordinates in a block are prone to have similar statuses in a spotter of a DNA microarray, a spot position in a block can be optionally inputted to the feed-forward neural network. Regarding this function, whether a spot position in a block should be used or not is switched in the same network, thereby eliminating the necessity for relearning.
[0049] By adding the function of storing and reading learning results, feed-forward neural networks to be used can be switched according to the kind of DNA microarray.
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In a microarray image analysis system, when one of a plurality of statuses is set for a spot of a microarray by the user, the status of a similar spot is automatically determined.
In a microarray image, the user determines a status of a spot, the pixel value matrix of an image in a spot region is learned by a neural network, a vertically and horizontally symmetrical image and an image rotated about the center of the region are formed and are learned by the neural network, and the neural network formed by repeating these steps is used for automatically recognizing the status of an undecided spot.
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This application is a continuation-in-part of application Ser. No. 09/033,819, filed on Mar. 3, 1998, now abandoned.
BACKGROUND AND SUMMARY OF INVENTION
The present invention is directed to pumps and shut off valves and, more particularly, to pumps and shut off valves for use in reverse osmosis water purification systems.
In reverse osmosis water purification systems, the feed water to be purified is supplied under pressure to one side of a reverse osmosis membrane in a pressure vessel and a pressure differential is maintained across the membrane. This differential drives the water in the feed water through the membrane to produce the desired purified permeate. A substantial percentage of the feed water input to the pressure vessel is bypassed and discharged through a flow restrictor to continuously purge the feed side of the membrane. The magnitude of the pressure differential across the membrane is important because it has a direct function on the rate and amount of water that may be purified in any given amount of time. The greater the pressure differential, the greater the amount of permeate produced per given amount of time. In view of the foregoing, it will be appreciated that for a given pressure of feed supply to be purified, it will therefore be desirable to reduce the level of back pressure on the permeate or discharge side of the membrane. Assuming a given supply pressure, each increment that the back pressure may be reduced will result in an increased rate and volume of production of permeate.
Reverse osmosis permeate pumps have been developed which are capable of reducing the back pressure to somewhat less than 5 psi. One such pump is disclosed in U.S. Pat. No. 5,460,716. It employs a diaphragm which defines a pumping chamber on one side for pumping the permeate and a working chamber on the other side which is connected to the feed water which is being bypassed. Valves are positioned to alternately admit the bypassed feed water to the working chamber of the pump and then drain it to set up a pumping action in the pumping chamber to pump the permeate. The disadvantages of such a pump is its relatively large size, its relatively discontinuous operation and the fact that back pressure reduction to only about 5 psi is possible.
Permeate reverse osmosis pumps with shut off valves constructed in accordance with the present invention are surprisingly capable of further substantial reductions in the back pressure in a reverse osmosis system and, thereby, a substantial increase in the pressure drop across the membrane with its accompanying advantages. In the pumps and shut off valves of the present invention, the back pressure may actually be reduced to zero and in many cases as low as substantial negative pressure. This, of course, results in a substantial increase in rate of production of permeate compared to the prior systems having a back pressure reduction of only down to about 5 psi. Moreover, in the pumps and shut off valves of the present invention, the size and pumping capacity of the pump may be reduced to as little as a quarter to a half of the prior pumps, the pumping of permeate is substantially continuous rather than discontinuous, and bypass feed and drain valves of the prior systems are substantially eliminated. Moreover, a separate source of electrical or other energy is not necessary in one of the pump and shut off valve embodiments of the present invention, and the valve may be readily operated simply by the feed bypass from the pressure vessel which is to be discharged to a drain anyway, and which provides ample driving power for the embodiment of the pump and shut off valve of the present invention. In another embodiment of pump and shut off valve of the present invention, the pump may be powered by a source of energy other than the bypassed brine and is capable of producing substantial negative pressures across the membrane of much larger magnitude than were previously known while enjoying a substantial reduction in pump size and capacity.
In one principal aspect of the present invention, a pump and shut off valve comprise a pumping compartment, a feed supply compartment and a drive including a drive shaft which is driven by the drive and extends into the pumping compartment. A piston in the pumping compartment divides the pumping compartment into first and second chambers, and a drive transmitting connector extends between the drive shaft and the piston to reciprocally move the piston toward and away from the first and second chambers, respectively, to alternately increase and decrease the volume in the respective chambers. First and second fluid inlets for introducing a fluid to the first and second chambers, respectively, and first and second fluid discharges for discharging the fluid from the first and second chambers, respectively, are also provided. A check valve in each of the first and second fluid inlets permits the flow of fluid to each of the chambers, but prevents the flow from each of the chambers, a check valve in each of the first and second fluid discharges permits the flow of fluid from each of the chambers, but prevents the flow to each of the chambers, and the first and second discharges communicate with the feed supply compartment. A fluid inlet to the feed supply compartment for introducing a fluid to the feed supply compartment and a fluid discharge from the feed supply compartment for discharging the fluid from the feed supply compartment are also provided. A valve in the feed supply compartment is movable in response to a decreased fluid pressure in the first and second discharges from the first and second chambers to permit the flow of fluid between the fluid inlet and discharge of the feed supply compartment, and in response to an increased fluid pressure in the first and second discharges from the first and second chambers to block the flow of fluid between the fluid inlet and discharge of the feed supply compartment.
In another principal aspect of the present invention, the check valve in the first inlet and the check valve in the second discharge close and fluid is discharged from the first chamber through the first discharge and introduced to the second chamber through the second inlet when the piston moves toward the first chamber, and the check valve in the second inlet and the check valve in the first discharge close and fluid is discharged from the second chamber through the second discharge and introduced to the first chamber through the first inlet when the piston moves toward the second chamber.
In still another principal aspect of the present invention, the aforementioned pump and shut off valve includes a drive compartment, a first fluid inlet to the drive compartment for introducing a fluid to the drive compartment, and a fluid discharge from the drive compartment for discharging the fluid from the drive compartment. The drive is positioned in the drive compartment and includes a drive mechanism which is driven by contact with the fluid which passes through the drive compartment. A transmission which is powered by the drive mechanism and which drives the drive shaft.
In still another principal aspect of the present invention, the drive mechanism comprises a wheel which is rotated by the fluid which passes through the drive compartment, and the transmission is a gear set.
In still another principal aspect of the present invention, the drive includes a motor which is coupled to the drive shaft to drive it.
In still another principal aspect of the present invention, the drive transmitting connector is a crank arm.
In still another principal aspect of the present invention, the valve in the feed supply compartment comprises a piston which moves reciprocally in the compartment between a first position in which the flow of fluid between the fluid inlet and discharge of the third compartment is permitted, and a second position in which the flow of fluid between the fluid inlet and discharge of the feed supply compartment is blocked.
In still another principal aspect of the present invention, a spring is positioned in the third compartment which urges the valve toward the first position in one embodiment and toward the second position in another embodiment.
In still another principal aspect of the present invention, the pump and shut off valve are in combination with a reverse osmosis water purification system which includes a reverse osmosis membrane in a pressure vessel having a feed inlet, a feed discharge and a permeate discharge, and a tank for receiving the permeate from the permeate discharge, and wherein a source of feed to be purified communicates with the fluid inlet to the feed supply compartment, the feed to be purified from the fluid discharge from the feed supply compartment communicates with the feed inlet of the vessel, the permeate from the permeate discharge of the vessel communicates with the first and second fluid inlets for introducing fluid to the first and second chambers, and the permeate from the first and second fluid discharges for discharging the fluid from the first and second chambers, respectively, communicates with the tank.
In still another principal aspect of the present invention, in the last mentioned combination with a reverse osmosis purification system, the feed discharge of the vessel communicates with the earlier mentioned drive compartment to drive the drive.
In still another principal aspect of the present invention, the valve shuts off the feed to be purified when the tank is full of permeate and increases in pressure.
These and other objects, features and advantages of the present invention will be more clearly understood through a consideration of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
In the course of this description, reference will frequently be made to the attached figures in which:
FIG. 1 is a schematic diagram of a reverse osmosis water purifying system incorporating one preferred embodiment of permeate pump and shut off valve incorporating the principles of the present invention; and
FIG. 2 is also a schematic diagram of a reverse osmosis water purifying system incorporating a second preferred embodiment of permeate pump and shut off valve incorporating the principles of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With particular reference to FIG. 1, a reverse osmosis membrane water purification system is shown which includes a pressure vessel 10 which contains a reverse osmosis membrane (not shown) through which water will pass when the membrane is exposed to a pressurized feed solution which is to be purified and to a pressure drop across the membrane. The feed solution which is to be purified is supplied from a pressurized source of supply through a feed control valve 12. The source of supply may be any one of a number of sources, such as a natural body of water or a well, and is pressurized by a pump or the like (not shown). The feed water from the valve 12 is preferably passed through a filter 14 to filter out large particulate contaminants, and then through a conduit 16 to a feed inlet 18 into the pressure vessel 10. A certain proportion of the feed water, for example about 75% of the feed input to the vessel, is typically bypassed from the feed side of the membrane through a conduit 20 and flow restrictor 22 to a drain to continuously flush the feed side of the membrane. The remaining approximately 25% of the water in the feed input passes through the membrane to produce the desired purified permeate. This permeate is then conducted from the vessel 10 via a permeate conduit 24 from where it may pass, preferably through another filter 26 and conduit 28, to a tap or faucet or to a storage tank 30 to be stored for future use. The percentages of bypass and permeate are only given by way of example and may vary widely in any given system.
Some sort of a pump and shut off valve have been employed in reverse osmosis water purification systems of the type described to pump the permeate under pressure to the storage tank to maximize to the extent possible the pressure drop across the membrane. The greater the pressure drop, the greater the production rate of permeate. Such prior pumps and shut off valves also shut down the system when the tank has been filled and the back pressure increases. However, as previously discussed, these prior permeate pumps and valves have only, at best, been capable of reducing the permeate back pressure at the membrane to around 5 psi during operation of the system. In contrast, the permeate pump and shut off valve of the embodiment of the present invention as seen FIG. 1 is capable of reducing such back pressure to zero and, in some cases, to even as low as a negative 5 psi, while at the same time obviating the need for a separate source of power to drive the pump and one which might be susceptible to power failure.
The pump and shut off valve of the present invention as shown in FIG. 1 preferably comprises a single housing 32 for compactness. The housing 32 is preferably divided into three compartments, a first drive compartment 34, a second pumping compartment 36, and a third feed supply compartment 38. The first drive compartment 34 has a fluid inlet 40 which is connected to the feed bypass conduit 20 and flow restrictor 22 of the typical reverse osmosis system to receive bypassed feed water and introduce it to the drive compartment 34. The drive compartment 34 also includes a fluid discharge 42 for discharging the bypassed feed water from the drive compartment 34 to a drain.
A water driven drive mechanism, for example a water wheel 44, is located in the drive compartment 34 and is driven by the bypassed feed water which continuously impinges it after being introduced into that compartment through the fluid inlet 40. As the water wheel 44 is rotated by the incoming bypassed feed water, it drives a gear set 46 which, in turn, rotates a drive shaft 48 which extends through the wall between the first compartment 34 and into the second pumping compartment 36.
A piston 50 with sealing rings 51 is positioned in the pumping compartment 36 and the piston divides that compartment into a first chamber 52 and second chamber 54 as shown in the drawing. The piston 50 is reciprocally powered back and forth in the compartment 54 and toward and away from the first and second chambers 52 and 54 by a crank arm 56 coupled to an eccentric 58 which is mounted on the rotating drive shaft 48. The crank arm 56 preferably extends through the piston 50 and carries springs 57 and 59 on the left and right sides of the piston 50 as viewed in the drawings.
An inlet coupling 60 is also positioned on the housing 32 and the inlet divides into first and second inlets 61 and 62 for introducing permeate from the coupling 60 and conduit 24 to the first and second chambers 52 and 54, respectively. The first and second inlets 61 and 62 also include check valves 64 and 65, respectively, which permit the flow of permeate in the direction shown by the arrows into the respective first and second chambers 52 and 54, but prevent flow in the opposite direction. First and second discharges 67 and 68 are also provided from the respective first and second chambers 52 and 54, and each of these discharges also contains check valves 70 and 71. The check valves 70 and 71 permit the flow of permeate from the respective chambers 52 and 54 in the direction shown by the arrows, but prevent flow in the opposite direction. As shown in the drawing, the first and second discharges 67 and 68 communicate both with the feed supply compartment 38 and with a discharge coupling 72 on the housing 32, the latter of which conveys the permeate from the pump and shut off valve of the invention either to the conduit 28 for current service use or to the storage tank 30.
The feed supply compartment 38 also includes a fluid inlet 74 for introducing the feed which is to be treated from its source of supply and feed valve 12 to the compartment 38, and a fluid discharge 76 for discharging the feed from the compartment 38 through conduit 16 and feed inlet 18 to the pressure vessel 10 for treatment. A second piston 78 is positioned in the compartment 38 for reciprocal movement therein. The piston 78 is slightly biased to the left and in flow blocking direction between the inlet 74 and discharge 76, as shown in the drawing, by a spring 80 which may exert a force of, for example, about 5 psi against the piston 78 in the flow blocking direction. If only the force of spring 80 is exerted against the right side of the piston 78, it will be insufficient to hold the piston 78 in its flow blocking condition against the normal service pressure of, for example, 40-60 psi, and that service pressure will force the piston 78 to the right and maintain it out of flow blocking relationship between the inlet 74 and discharge 76.
Although it is believed from the foregoing description that the operation of the pump and shut off valve and system of the present invention will be understood by those stilled in the art, a brief description of the operation follows.
Upon start up of the system, the storage tank 30 will be empty or only partially filled and ready to accept permeate. The feed valve 12 to a pressurized source of supply of the feed water to be purified is opened, and the feed will pass through the filter 14 and fluid inlet 74 into the feed supply compartment 38 of the shut off valve of the invention, and will exert a supply line pressure of, for example, 40-60 psi against the left side of piston 78. Because the spring force exerted by spring 80 is substantially less than the line pressure, the piston 78 will move to the right in compartment 38 to permit flow of the incoming feed solution between the fluid inlet 74 and discharge 76 from compartment 38. This feed will then flow through conduit 16 and feed inlet 18 into the pressure vessel 10 and to the feed side of the membrane.
As previously discussed, typically about 75% of the incoming feed will be bypassed through the conduit 20 and flow restrictor 22. This bypassed feed which typically would otherwise simply be discharged to a drain, instead is diverted through the fluid inlet 40 to the drive compartment 34. This bypassed feed flow is amply sufficient to rotatably drive the water wheel 44, gear set 46 and drive shaft 48. Indeed, the size and capacity of the pump may be substantially reduced because it only need pump the permeate which only comprises about 25% of the total feed to the pressure vessel 10. After driving the wheel 44, the bypassed feed will then be discharged from the drive compartment 34 through the fluid discharge 42 to a drain.
The water in the remaining approximately 25% of the feed which was introduced to the pressure vessel 10 will pass through the membrane and be discharged from the vessel as purified permeate through the conduit 24 to the inlet coupling 60 of the housing 32 of the pump and shut off valve. This permeate will then pass through the first and second inlets 61 and 62 and their respective check valves 64 and 65 to fill the first and second chambers 52 and 54. As the bypassed feed water driven drive shaft 48 rotates, it will move the piston 50 back and forth in the pumping compartment 36 via the crank arm 56 and eccentric 58. As the piston 50 moves to the right toward the first chamber 52, it will pressurize that chamber to close check valve 64 and force the permeate that had previously accumulated in that chamber through the check valve 70 and first discharge 67, and out through the discharge coupling 72. Movement of the piston 50 to the right, as viewed in the drawing, also creates a reduced pressure or suction in the second chamber 54. This will close the check valve 71 in the second discharge 68 and draw permeate into the chamber 54 through check valve 65 in the second inlet 62. In the event that in the movement of the piston 50 to the right a stronger resistance is experienced than the force exerted by the crank arm 56, the spring 57 will be compressed to dissipate the resistance to permit the crank arm 56 to continue to move to the right to complete its cycle.
In contrast, when the piston 50 reverses to move to the left as viewed in the drawing, a pressure will be imparted on the permeate which has accumulated in the chamber 54 to shut check valve 65 in inlet 62, and to pump the permeate in the chamber 54 through check valve 71 and discharge 68 out through the discharge coupling 72. In turn, a suction now will be created in the first chamber 52 as the piston 50 moves to the left. This will cause permeate to flow through the check valve 64 and first inlet 61 into the chamber 52 to fill it with permeate, and to close the check valve 70. In the event that in the movement of the piston 50 to the left a stronger resistance is experienced than the force exerted by the crank arm 56, the spring 59 will be compressed to dissipate the resistance to permit the crank arm 56 to continue to move to the left to complete its cycle.
It will be appreciated that in the piston arrangement just described, the flow of pumped permeate that is discharged to the system will be essentially continuous, unlike the pumps of the prior art. This is because when the piston 50 has completed its pumping motion in one direction, it immediately continues its pumping motion in the opposite direction.
In this arrangement, the back pressure in the permeate conduit 24 and on the permeate side of the membrane will be reduced to at least zero and, in some instances, to as little as a negative 5 psi. Thus, as previously discussed, the production rate and capacity of the permeate pump and shut off valve of the present invention is substantially improved. By way of example, if the feed line pressure into the system on the feed side of the membrane is 60 psi and the total dissolved solids content in the feed is 300, the output rate of permeate, in for example gallons, will generally vary as follows for the following back pressures:
______________________________________ pressure drop flowback pressure, across membrane, rate,psi psi gal/time______________________________________5 55 18.50 60 20.5-5 65 22.0______________________________________
When enough permeate has been produced to fill the tank 30, the pressure in the fluid discharges 67 and 68 will rise to approach the level of the pressure of the incoming feed. This additional pressure will be exerted against the right side of the piston 78. When this pressure, together with the force exerted by spring 80, exceeds the incoming feed pressure, the piston 78 will move to the left, as shown in the drawing, to block the flow between the fluid inlet 74 and fluid discharge 76, and will shut down the system.
Referring now to FIG. 2, a reverse osmosis membrane water purification system is shown which has numerous similarities to that shown in FIG. 1, but in which a second embodiment of pump and shut off valve of the present invention is shown. Because many of the components shown in FIG. 2 have a substantially similar or identical counterpart in the system, pump and shut off valve as shown in FIG. 1, like reference numerals will be used to designate like elements.
In the pump and shut off valve shown in FIG. 2, the fluid inlet to the drive compartment 34 has been eliminated and the bypass conduit 20 is simply connected to the drain through the flow restrictor 22, as it has been in the past in prior conventional systems. Instead, a motor 82 which is powered by a traditional source of energy, such as electrical, is coupled to the gear set 46 to operate the piston 50 as previously described with respect to the embodiment shown in FIG. 1.
In addition, in the embodiment shown in FIG. 2, the spring 80 is reversed to the position 80' as shown in FIG. 2, and thereby tends to exert a force in a direction to the right as viewed in the drawing to open the piston valve 78, rather than close it as in the FIG. 1 embodiment. Reversal of the spring to the position 80', as shown in FIG. 2, permits opening of the valve at lower feed supply pressures than in the arrangement shown in FIG. 1 and also has the advantage that the end plate 84 may be adjusted back and forth in the direction shown by the arrows in FIG. 2, such as by slot 86 and threads 87, to adjust the force of the spring 80' and the point at which the fluid inlet 74 will be opened to communicate with the fluid discharge 76. A magnetic sensor 88 is preferably attached at the left side of the piston valve 78 so that whenever the piston valve is moved toward the end plate 84 and so as to block the flow of fluid between the fluid inlet 74 and fluid discharge 76, and as depicted in FIG. 2, the magnetic sensor 88 will activate a magnetic detector 90 to disconnect the power to the motor 82.
It will be appreciated that in the embodiment shown in FIG. 2, the pressure differential across the membrane in the pressure vessel 10 may be substantially increased over that which has been realized by the prior art and even over the improved pressure differentials which are enjoyed by the embodiment shown in FIG. 1. If the incoming feed water, for example, has a pressure of 60 psi as previously discussed, the independently powered motor 82 can create a permeate back pressure of as much as a negative 40 psi at the membrane. In this case, the pressure drop across the membrane would be 100 psi, i.e. 60 psi plus 40 psi. In fact, the embodiment described in FIG. 2 is particularly advantageous at lower feed water pressures which might otherwise be insufficient to adequately permit operation of other shut off valve constructions and even the shut off valve construction of FIG. 1. For example, if the feed water pressure is only 40 psi and the motor 82 is able to create a permeate back pressure of a negative 40 psi, the pressure drop across the membrane will be 80 psi, and the flow rate can actually be increased to as much as 27 gallons/unit of time.
Where the pressure differential is for example 80 psi across the membrane, the compressive force of the spring 80' is preferably set at approximately that pressure differential. Thus, whenever the compartment 38 reaches a pressure of slightly greater than 80 psi, the piston valve 78 will be moved to the left so that the flow between the fluid inlet 74 and the fluid discharge 76 is blocked. When this occurs the detector 90 is activated by the magnet 88 to shut down the power to the motor 82.
In typical reverse osmosis water purification systems, the conventional placement of the booster pump is at a location after the filter 14 and before the fluid inlet 74. In such installations, it will be necessary that the booster pump be of a size and capacity to manage the total feed water which is introduced to the system. However, as previously described, as much as up to 75% of the feed input water is typically bypassed from the feed side of the membrane through the conduit 20 and flow restrictor 22 to drain so as to continuously flush the feed side of the membrane. Only the remaining approximately 25% of the feed water in the input actually passes through the membrane to produce the desired purified water as permeate. In the preferred embodiments of the present invention, as shown both in FIGS. 1 and 2, the boost of pressure of only the permeate purified water is preferred. Thus, because that water represents only approximately 25% of the total feed water which is delivered to the membrane, the drives including the water wheel 44 drive shown in FIG. 1, as well as the independently powered motor 82 in FIG. 2 need only be about 25% of the size and capacity, and utilize only about 25% of the power, as compared to the conventional booster pumps placed in the feed line to fluid inlet 74.
Although various conduits have been shown coupling various components of the reverse osmosis system, it will also be appreciated that in a fully equivalent system one or more of these conduits may be essentially eliminated, and the respective components mounted directly to each other. By way of example, the fluid discharge 76 may be mounted directly to the feed inlet 18 on the pressure vessel 10, and/or the inlet coupling 60 may be directly mounted to the permeate discharge on the pressure vessel, thereby eliminating conduits 16 and/or 24, respectively.
It will also be understood that the preferred embodiments of the present invention as have has been described are merely illustrative of the principles of the present invention. Numerous modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention.
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In one embodiment a reverse osmosis permeate pump with shut off valve and reverse osmosis system employs bypassed feed water from the reverse osmosis membrane to drive a water wheel and gear set to reciprocate a piston back and forth between two chambers in the pump. Permeate from the membrane is introduced to the respective chambers by a pair of fluid inlets and discharged from the respective chambers through a pair of discharges to a storage tank. Flow through these respective inlets and discharges is a function of the direction in which the piston is moving and whether it is imparting a pressure or suction on a given chamber. A second piston is exposed to the pressure in the discharges from the chambers and the second piston moves between a position permitting incoming feed flow to the membrane, and a position blocking that flow upon increase in pressure in the fluid discharge from the chambers. In another embodiment, the reverse osmosis permeate pump is powered by an independent source of power. In both embodiments, the pump and shut off valve is on the permeate side of the membrane which permits a substantial reduction in pump size, and the permeate pumps and shut off valves of the invention permit substantially increased pressure drops across the membrane and increased system production capacities and rates.
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BACKGROUNG OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a coated paper used in printing and, particularly, to a new coated paper for use in printing which hardly generates any fluting in web-offset printing (in the Japanese printing industry, this may be referred to as “hijiwa”) which has been frequently generated during a process of drying after printing in web-offset printing. In addition, it also includes the manufacturing method of the coated paper. This is also very useful when used in rotogravure printing or flexographic printing from the standpoint that it will not cause so much out-of-register, i.e. mis-registration.
[0003] 2. Description of the Related Art
[0004] First of all, an explanation will be given on the fluting in web-offset printing. The trend toward less man-power and higher speed in the printing industry in recent years is changing printing process from sheet-fed (flat sheet) offset printing to offset rotary printing (hereinafter referred to as “web-offset printing”). Not only high-speed printing and simultaneous-double-sided printing but also saving labor in its back-end process can be carried out by the web-offset printing. The productivity of the web-offset printing is significantly higher than that of the sheet-fed (flat sheet) offset printing in view of, such as, labor saving of its following process.
[0005] However, since a hot air drying process is conducted immiediately after its printing process in case of web-offset printing, there are several quality defects that are not produced in sheet-fed offset printing. Among them, a problem that is known as most significant and difficult to solve is fluting in web-offset printing. Hitherto, the fluting in web-offset printing has been considered as a problem peculiar to web-offset printing, and is a phenomenon in which stripe-shaped wrinkles have been generated along the machine direction of the paper after a Web-offset printing operation is an pled, which is ant to occur in a coated paper that is required good printing finish. In a worse case, the printed material would become waved, like a waved galvanized sheet iron, so that its substantial commercial value will be greatly lowered. Thus, a coated paper for printing which will not generate such fluting or wrinkles in web-offset printing has been strongly demanded for a long time. However, such a paper has not been provided to the market as or vet.
[0006] Now, several study reports have been issued on the aforementioned fluting in web-offset printing and they maybe roughly classified into the following two types:
[0007] One is based on the thought of “tension wrinkles.” In this theory, it is considered that fluting in web-offset printing is formed by wrinkles which is initially generated by the tension added to the paper in web-offset printing and is then fixed by offset ink.
[0008] As to the other, it is considered that wrinkles are generated by the difference in the thermal shrinkage between the imaged area and the non-imaged area during the drying process in the web-offset printing operation (Takeshi Yamazaki/Pulp and Paper Research Conference Proceedings of JAPAN TAPPI: Vol. 49, P110-113/1982.)
[0009] One of the methods proposed as concrete means to suppress such a phenomenon as disclosed in publication of Japanese unexamined patent application No. 186700/1983. In this method, such fluting in web-offset printing is considered to be prevented by keeping the freeness of pulp used in a paper web within a specific scope and by controlling the air permeability simultaneously within a specific scope.
[0010] However, at the time of manufacturing coated paper for use ii web-offset printing, since the products are made through a series of processes such as the preparation of paper stock, paper-making, coating, press finishing with a calender and winding, it is not possible to obtain products in satisfactory quality merely by adjusting the pulp freeness or air permeability of the base paper. Any product that avoids the fluting in web-offset printing has not been made as of yet.
[0011] Further, according to publication of unexamined Japanese patent application No. 291496/1997, it is proposed that the fluting in web-offset printing can be either solved or alleviated by specifying the web moisture and the internal bond strength of a base paper. However, if the internal bond strength is lowered, this will require lowering of the moisture of a coated paper in view of countermeasure for blister resistance, which is considered as another problem of the coated paper for web-offset printing. As a result, there is a fear of causing a problem so called “fold-cracking trouble” which is a phenomenon that the surface of the coated paper for web-off set-printing is cracked in a subsequent bending process. Any improvement effect on solving the fluting in web-offset printing has not been made satisfactorily in accordance with the conventional method.
[0012] We, the inventors of the present invention, have sought for the factor generating the fluting in web-offset printing which is an important problem in quality and to be solved with regard to the coated paper for web-offset printing as mentioned above. And we have repeated careful studies so as to solve the problem. Consequently, we created the present invention, in which the fluting in web-offset printing can be prevented in advance by using a paper having small thermal shrinkage force in the cross direction (the CD direction).
[0013] Namely, since the fluting in web-offset printing has been generated mainly in coated paper having low basis weight (about the basis weight of 60 g/m 2 and below), the countermeasures therefor are intended for such coated paper having low basis weight. However, since the fluting in web-offset printing is also seen in coated papers having rather high basis weight of greater than 60 g/m 2 through the observation of the inventors, they have taken these facts into consideration and endeavored to obtain original coated paper that would not generate the fluting in web-offset printing.
[0014] Needless to say, the coated paper according to the invention will show significant effects in solving the fluting in web-offset printing, and besides “the mis-registration” which is easily caused by thermal drying can be effectively suppressed if it is utilized as paper for printing used in printing machines equipped with drying units, such as gravure printing machines and flexographic printing machines.
SUMMARY OF THE INVENTION
[0015] According to the invention, a coated paper for printing is provided with a coated layer mainly composed of a pigment and an adhesive on a base paper (which includes a paper web before preliminary treatment). The coated paper for printing is characterized in that the thermal shrinkage force R in the cross direction (CD direction) of the said coated paper satisfies the formula (1) when measured pursuant to the measuring method specified below.
0≦R≦45 gf (1)
[0016] [Measuring Method of Thermal Shrinkage Force R]
[0017] A sample coated paper of which moisture is previously adjusted pursuant to JIS P8111 (the moisture adjustment is made while the room temperature is 20° C., with a relative humidity of 65) is cut if to obtain a span of 2 mm width being fed into the machine with a length of 2 cm in the cross direction. Then, thus obtained coated pacer is set to a Thermo Mechanical Analyzer [TMA/SS6000: manufactured by Seiko Electronics Industries Co., Ltd.]. As PID Control Values of the terminal probe at the analyzer, P (Proportion)=100, I (Integration)=1, D (Differential)=100 are used. The shrinkage force “R” is obtained by the steps of expanding the span at the rate of 0.01 μm/minute under the condition that the initial load of 5 gf is added, raising the temperature from 20° C. at a heating speed of 200° C./minute to a predetermined temperature of 300° C., maintained at the predetermined temperature of 300° C. for 2minutes, then reading the shrinkage force generated by thermal drying at 1.5 minutes after the commencement of the rise in temperature.
[0018] Namely, TMA/SS is abbreviation for [Thermo Mechanical Analyzer/Stress Strain] and indicates a type of measuring device for thermal physical properties.
[0019] The subject of the present invention is a coated paper for printing comprising a coated layer mainly composed of a pigment and an adhesive on base paper or paper web in which the coated paper for printing comprises an air resistance (air resistance) of 80,000 seconds or higher when measured pursuant to J. TAPPI Pulp & Paper Testing Method No. 5 (B).
[0020] Moreover, as one of preferred embodiments of the coated paper for printing according to the present invention which satisfies R. in the above described formula (1) and air permeability (air resistance), a base paper which is obtained by coating a paper web both sides with an aqueous solution of polyvinyl alcohol thereinafter referred to as PVA) or aqueous liquid composed Gym polyvinyl alcohol and inorganic pigment in an amount of 0.5-5 g/m 2 per side surface after being dried may be used.
[0021] Further, as another preferred embodiment of the present invention, abase paper which is obtained by application of an aqueous solution of polyvinyl alcohol or aqueous liquid composed of polyvinyl alcohol and inorganic pigment and having air resistance of 1,000 seconds or higher when measured pursuant to JIS-P-8117 (1998; Gurley method), in which the above mentioned PVA will have a saponification degree of not less than 85 mol can be used.
[0022] Furthermore, in the above-mentioned coated paper for printing which has a coated layer mainly composed of pigments and adhesives on the base paper coated with an aqueous solution of PVA or aqueous liquid composed of PVA and inorganic pigment and dried since the paper surface is covered with above-described coated layer, the air resistance will become much higher in comparison with that of the base paper so that it is no longer possible to measure it by the measuring method pursuant to JIS-P-8117. Thus, the air permeability (air resistance) will be measured in accordance with J. TAPPI Pulp and Paper Testing Method No. 5 (B).
[0023] In this invention, the technical reason for using the aforementioned PVA is to heighten the air resistance of the paper by forming a kind of resin film on the surface of the paper by the said PVA. Thereby, it aims at preventing the wrinkles generated by the difference in the amount of shrinkage between in the imaged area and in the non-imaged area during the drying process in the web-offset printing operation. In other words, the inventors found that shrinkage caused by evaporation of moisture in the paper during drying process can be prevented beforehand. Thus, the resin film which will be applied in order to prevent the evaporation of the aforemenitioned moisture can be formed by using something other than the aforementioned PVA. For example, various SBR latex and synthetic resins such as polyester resins can also be used.
[0024] Since the terms “a paper web” and “a base paper” are distinguished and used to explain the present invention in this specification, a supplementary explanation will be added herein after. The terms “a paper web” and “a base paper” are both used to indicate an initial material sheet then used to obtain a coated paper of the present invention, which is the end product. More specifically, a paper sheet before the application of the finish coating is referred to as “a base paper” and it generally means a sheet having predetermined air resistance by means of a pre-forming resin film of, for example, PVA on the surface of a material sheet. Or the other hand, “a paper web” indicates a material sheet to be used to obtain the above-mentioned base paper. More particularly, indicates a paper sheet before being applied pre-treatment process that comprises a manufacturing method of a coated paper according to the present invention. That is to say, a paper sheet prior to having been treated with the process of forming-a resin film such as PVA, which is a component of the present invention, is referred to as “a paper web”.
[0025] In other words, “a base paper” is a paper sheet after having been coated with a resin liquid of, for example, PVA, and is a sheet before having been coated with a final finish coat. Namely, in the conventional method described hereinbefore, only the term “a base paper” is inclusively used and does not represent any distinguished meaning.
[0026] Incidentally, we, the inventors of this invention, have earnestly repeated our studies on the mechanism of generation of the fluting in web-offset printing which has been conventionally considered as a problem and also on the measures to solve this problem. As a result, we finally obtained the following knowledge on the generating mechanism of the fluting in web-offset printing.
[0027] First of all, if we observe the basic characteristics of fluting in web-offset printing, it may be considered to be a state that the printing material, which should be flat in its nature, has been folded several times over in the transverse direction. This may be considered that fluting in web-offset printing is the same as a phenomenon that an object has been buckled after it has been given compressive force in the transverse direction. Thus, its behavior may be defined by using equation (2) derived from the Euler's formula
P= ( n 2 π 2 bh 3 ) Ec/ 12 L 2 (2),
[0028] where
[0029] P: Stress to buckle the imaged area.
[0030] n: Number of buckling in the imaged area.
[0031] Ec: Modulus of elasticity of the imaged area in the transverse direction.
[0032] b: Length of the imaged area.
[0033] h: Thickness of the imaged area.
[0034] L: Width of the imaged area.
[0035] The right side of the equation (2) represents the factor which resists the force to buckle the paper, and it is considered as buckling resistance force.
[0036] In this regard, in order to make the right of the equation (2) more easily understood, we applied Gurley stiffness (S) to the right side of this equation. This Gurley stiffness is commonly used in to explain the characteristics of paper. Now, the Gurley stiffness (S) is defined as the equation (3) shown below:
S=kh 3 Ec (Derived from the definition of Gurley stiffness) (3),
[0037] where
[0038] S: Gurley stiffness
[0039] Ec: Modulus of elasticity of the paper
[0040] h: Thickness of the paper
[0041] k: Constant
[0042] Substituting the equation (3) into the equation (2), we can now obtain equation (4), which represents the number of fluting N. The number of fluting N is ½ of the number of buckling n in the imaged area.
N=kL ( P/bS ) 1/2 (4),
[0043] where
[0044] N: Number of fluting
[0045] k: Constant
[0046] L: Width of the imaged area
[0047] P: Compressive force in the transverse direction
[0048] b: Length of the imaged area
[0049] S: Gurley stiffness of the imaged area
[0050] Now, we would like to explain what the imaged area and the non-imaged area means, i.e. the imaged area means the portion where the ink has been transferred in web-offset printing, and the non-imaged area means the portion where the ink has not been transferred.
[0051] By the way, when the width (L) of the aforementioned imaged area is specified, the number of the fluting in web-offset printing is determined by three factors, namely, the compressive force (P) in the transverse direction, the length (b) of the imaged area, and the Gurley stiffness (S) of the imaged area. If the compressive force in the transverse direction increases, the fluting in web-offset printing will increase proportionally to the square root of such compressive force. On the contrary, if either the length of the imaged area becomes longer or the Gurley stiffness of the imaged area becomes larger, the fluting in web-offset printing will decrease in reverse proportion to their respective square root.
[0052] The compressive force (P) in the transverse direction which buckles a paper may be classified into two forces such as the Poisson's force which is generated by the tension and the shrinkage force which comes from the difference in the amount of shrinkage between the imaged area and the non-imaged area during the drying process.
[0053] With regard to the Poisson's force, if an object is stretched in the longitudinal direction, there is a property in which the object tends to shrink in the cross direction. In this regard, if we express the expansion in the longitudinal direction by εm, and the contraction in the cross direction by εc, respectively, the ratio υ=εc/εm has a value proper to the object, which is called Poisson's ratio.
[0054] If the paper had an infinite length, even if it were pulled in the longitudinal direction, the paper would merely bring the shrinkage in the lateral direction in accordance with its Poisson's Ratio. Of course, it does not mean, however, that the paper is able to shrink freely since both ends of the paper are actually fixed at a limited interval in a flowing direction of the machine. In addition, because the tension is subject to change, the compressive force will be generated in the lateral direction, which results in buckling of the paper. This is the mechanism in which wrinkles are generated by the Poisson's force.
[0055] As for the other lateral compressive force, it may be considered that the shrinkage force during the drying process is affecting thereto. In other words, in the web-offset printing operation, he paper shrinks during the drying process after the printing operation. In this instance, the shrinkage begins from the beginning of the drying process in the non-imaged area. On the contrary, the shrinkage will begin later in the imaged area in comparison with in the non-imaged area because the imaged area has been masked by the ink layer which prevents the moisture contained in this area from being evaporated. Consequently, the shrinkage of the non-imaged area will affect the imaged area with a compressive force so as to form buckling in the imaged area.
[0056] It is thus concluded that the aforementioned fluting in web-offset printing is the buckling formed in the imaged area by the two forces as described above. When an object is buckled, it will form such a shape that the object is folded at only one point where the least stress is required. However, the fact that the paper receives the tension in the longitudinal direction during the web-offset printing means that the reaction will work on the paper to sustain an even surface. This is the reason why the fluting in web-offset printing forms small peaks generating a waved galvanized sheet iron.
[0057] We, the inventors of this invention, conducted research and studies on compressive forces in the lateral direction that forms the fluting in web-offset printing in connection with all kinds of coated paper. As a result, it was found that the lateral compressive force generated by thermal shrinkage force was larger than the lateral compressive force generated by the Poisson's force. In addition, it was also found that it greatly varied in accordance with the changes of orientation of fiber or types of size presses, which led to the fact that the compressive force in the lateral direction which generates the fluting in the web-offset printing depended upon the thermal shrinkage force. Thus, as a result of studies made on the measurement of the thermal shrinkage force, we finally came to realize what was required primarily: the compressive stress which acts on the imaged area which shrinks simultaneously with the non-imaged area. However, regretfully, at present there is no means to measure such a stress completely.
[0058] On the other hand, as a result of the repeated studies, we found that the thermal shrinkage force measured by the following method had a close correlation with the generation of the fluting in web-offset printing so that it could be used sufficiently as an index, i.e. as a substitute value, of the compressive force in the lateral direction which forms the fluting in web-offset printing.
[0059] Thus, the measuring method of thermal shrinkage force R of this invention may be specified as follows:
[0060] In other words, sampling coated paper which has been prepared with moisture control [under conditions of the room temperature of 20° C. and the relative humidity (RH) of 65%] when measured-pursuant to JIS-P-8111 is cut off to obtain a span of 2 mm wide in the machine direction with a length of 2 cm in the cross direction (i.e. a direction that is perpendicular to the machine direction). Then, attach it to Thermo Mechanical Analyzer [TMA/SS6000: Seiko Electronics Industries Co., Ltd.] within initial load of 5 gf. In this instance, in order to control the span changes caused from shrinkage of the sample papers, P=100, I=1, and D=100 are used as a PID control value of the probe in the TMA apparatus. In addition, the span shall be set up so as to be expanded at the rate of 0.01 μm/minute while being measured in view of the program for the Thy apparatus which will require minimum change of the span. It is, however, believed that the span is substantially almost fixed.
[0061] To pursue the relation between the thermal shrinkage force of the paper samples and the fluting in web-offset printing, the temperature will be raised from 20° C. at a rising speed of 200° C./minute, up to the set temperature of 300° C., and maintain that state for 2 minutes so that the shrinkage force is measured 1.5 minutes after the temperature starts to rise. We found that the relation of the generation of the fluting in web-offset printing arid the shrinkage force caused from thermal drying is obtained with good reproducibility if such conditions have been set.
[0062] By the way, as shown in the above equation (4), except for the factor of the printed figure, the fluting in web-offset printing will be determined by the compressive force (P) in the cross direction and the Gurley stiffness (S) so that it may be considered that it required to specify both the thermal shrinkage force (R) which will be the substitute value of the compressive force (P) in the cross direction of a coated paper and the Gurley stiffness (S) to solve the fluting in web-offset printing. As well known, the Gurley stiffness (S) is physical property value that will be greatly influenced by elastic modulus of a paper and thickness of a paper, which the thickness of a paper has great influence on it, in the meantime the thickness of a paper is greatly influenced by the basis weight of the coated paper. However, we dare describe this invention without referring to the Gurley stiffness (S) and basis weight in the specification of the invention.
[0063] This is because when the users, i.e. the printers, select papers for printing between the high basis weight and the low basis weight, the range of tolerance to the fluting in web-offset printing will vary according to their selection. For example, if they adopt the papers of high basis weight, they will be careful to not allow even the slightest fluting in web-offset printing. On the other hand, if they adopt the papers of low basis weight, a large number of the wrinkles in web-offset printing will generally appear so that even a slight decrease of the fluting in web-offset printing will be evaluated as a sufficient improvement effect. That is, allowable range of the number of the fluting in web-offset printing, i.e. (N) in the above equation (4), will industrially vary according to the basis weight of a coated paper.
[0064] In consideration of the above mentioned circumstances, we neither refer to the Gurley stiffness of a coated paper which is another influence factor to the wrinkles in web-offset printing nor to the basis weight of a coated paper which will have extremely great influence on the Gurley stiffness. That is, the inventors ardently repeated the study as to the factor which may be related to the occurrence of the fluting in web-offset printing other than the Gurley stiffness or the basis weigh-., and as a result, we, the inventors, finally found the fact that a thermal shrinkage force of paper has great influence on it. In other words, we found that the fluting in web-offset printing was alleviated quite effectively when the thermal shrinkage force (R) of the coated paper measured under a certain condition satisfied the specified value as mentioned above, which means that the commercial value of the coated paper for printing will be greatly improved. Thus we have finally completed this invention.
[0065] In addition, the reason why the thermal shrinkage force (R) in formula (1) is specified at 45 gf or below, is that if (R) exceeds 45 gf, the compressive force in the cross direction during the drying process after the printing operation will become large, which makes the fluting in web-offset printing worse and the commercial value of the products will be reduced.
[0066] Furthermore, it is necessary that R is a positive value. The reason is that if R were a negative value, in other words, if such a phenomenon to elongate occurs, the compression force would affect rather the non-imaged area than the imaged area, which would result in the buckling in the non-imaged area leading to the fluting in web-offset printing. However, as long as an ordinary coated paper for printing is used, (R) seldom takes a negative value. Accordingly, (R) can be expressed by 0≦R≦45 gf, and more preferably, ii will be specified at 40 gf or below.
[0067] Zero, that is a level where absolutely no thermal shrinkage occurs, would he most desirable as to the lower limit. However, considering the fact that the product is mainly composed of natural fibers which contain moisture, it usually accompanies some thermal shrinkage by its nature.
[0068] The coated paper for printing according to the present invention comprises a coated layer mainly composed of a pigment and an adhesive on a base paper or paper web in which the basis weight is usually not less than 35 g/m. In addition, it is known that the fluting in web-offset printing and the mis-registration, which the present invention aims to solve, are apt to occur at the oasis weight of 130 g/m 2 or lower. When the present invention is used, it is preferable that it will be applied to a paper having a basis weight of 35-130 g/m 2 . More particularly, a paper having a basis weight of 60-130 g/m 2 will bring about even a better result.
[0069] By the way, since there are various adjustment methods of the thermal shrinkage force (R), it is possible to adopt a method arbitrarily, without being specifically limited. For example, the thermal shrinkage force (R) can be adjusted by suitably changing the beating condition of the pulp, types of chemicals for the size press, coating amount, conditions for the paper making, orientation of the fiber, types of pigments in the coated layer, types of binders, compounding ratio of binder and pigment and its coating amount or drying conditions at the coating process.
[0070] Furthermore, when considering the characteristics of a coated paper that will reduce the wrinkles in web-offset printing and/or the mis-registration that may be generated during the roto gravure printing or flexographic printing, if the coated paper has an extremely high air resistance (=poor permeance), we found that they can be effectively improved if the coated paper is finished to have an air resistance of not less than 80,000 seconds when measured pursuant to J. TAPPI Pulp and Paper Testing Method No. 5 (B). The reason for this is that the air resistance of the coated paper is so high that the moisture of the base paper will not be dispersed by the heat so that the thermal shrinkage of the coated paper will not occur easily. In other words, it is considered that since the thermal shrinkage is kept at a low level, the fluting in web-offset printing will not be generated, which prevents the occurrence of the mis-registration as well. Namely, it can not improve the wrinkles in web-offset printing or the mis-registration so satisfactorily if the coated paper has an air resistance of not greater than 80, 000 seconds when measured pursuant to J. TAPPI Pulp and Paper Testing Method No. 5 (B).
[0071] The upper limit of the air resistance is not defined particularly though, lower than 3,000,000seconds will be preferred in view of the balance with the blister resistance aptitude of the web-offset printing. However, the air resistance level of 3,000,000 seconds is out of the measuring range of the aptitude by the measuring method of the air resistance so that the measured value will include a certain fluctuation. Further, if the coated paper satisfies both values of the thermal shrinkage force (R) and air resistance defined in the present invention, it will be particularly preferred since such coated paper will effectively improve the fluting in web-offset printing or the mis-registration.
[0072] Moreover, as a result of our repeated study relating to the method to obtain a coated paper having particular thermal shrinkage force (R) and air resistance, it was found that it is preferred to use a base paper that will be obtained by applying an aqueous solution mainly composed of PVA to a paper web and drying under appropriate conditions. A base paper resulting in such coated paper for printing will be obtained by using a paper web coated on both sides with an aqueous solution of polyvinyl alcohol in an amount of 0.5-5 g/m per side surface after being dried; then, forming a coated layer mainly composed of pigments and adhesive thereon. Here, the aqueous solution of polyvinyl alcohol means an aqueous solution which is mainly composed of gelatinized PVA. Not only various auxiliaries such as antifoaming agent, antiseptic but also a water soluble resin such as starch, starch derivative, cellulose derivative and an aqueous dispersive resin such as styrene-butadiene copolymer latex can be added 50 parts or less per 100 parts of PVA (in terms of solid matter) to the aqueous solution of polyvinyl alcohol.
[0073] When applying such aqueous solution of PVA to a paper web, it is confirmed that a good PVA film can be formed on the paper web if it is applied with high viscosity so long as there is no problem in view of handling and operation and it is dried as fast as possible. When a coated paper for printing is made by use of thus obtained base paper, it can efficiently improve the fluting, in web-offset printing and mis-registration. Namely, it is preferred to adjust the viscosity of the aqueous solution of PVA in the range of 100-2000 mPa.s with Brookfield viscosity of 60 rpm (i.e. Brookfield viscosity is measured by revolving No. 3 spindle at 60 rpm) at temperature of aqueous solution of 20° C. when it is applied to the paper web. When the viscosity of the aqueous solution of PVA is lower than 100mPa.s, the PVA being applied is penetrated into inside of the paper web so that it is difficult to form a PVA film on the surface of the paper web. On the contrary, when the viscosity exceeds 200 mPa.s, the coating aptitude of the aqueous solution of PVA deteriorates so that it becomes difficult to coat uniformly on the paper web.
[0074] When the aqueous solution of PVA is applied to the paper web, coating equipment is not limited in particular. However, for example, a two roll size press coater, a gate roll coater, a bar crater, a roll coater, a blade coater, a film metering size press coater will be suitably used. Among them, in order to apply compositions having high viscosity, such as a gate roll coater, a film metering size press coater will be favorably used.
[0075] In this invention, it is preferred to use a base paper which is obtained by coating a paper web on both sides with an aqueous liquid composed of polyvinyl alcohol and inorganic pigment in an amount of 0.5-5 g/m 2 per side surface after dried and then drying it since when thus obtained base paper is finished as the coated paper for printing, not only the fluting in web-offset printing and mis-registration will be solved or reduced but also the printing finish, printability and runnability for the coating process will be improved. In this instance, there is no special limitation as to the inorganic pigments to be used though, pigments such as clay, kaolin, talc, calcium carbonate, and aluminum hydroxide are given as examples.
[0076] As to the amount of inorganic pigments to be added to the aqueous solution of PVA, 300 parts or less, preferably in the range of 50-200 parts per 100 parts of PVA in terms of solid matter will be prepared. Namely, if more than 300 parts of inorganic pigments are added, it is liable not to obtain significant improvement effect on the fluting in web-offset printing or on mis-registration, which is desired by this invention.
[0077] When the aqueous liquid of PVA and inorganic pigments is applied to, the paper web, the afore-mentioned coating machines that will he used for the application of the aqueous solution of PVA can be used.
[0078] It is preferred to coat the paper web with the aqueous liquid being composed of PVA aqueous solution and inorganic pigments and having viscosity in the range of 100-2000 mPa.s with Brookfield viscosity of 60 rpm at temperature of aqueous liquid of 20° C. The reason thereof is already described above and it will be desired to maintain the viscosity in the above-mentioned range.
[0079] In addition, the amount of the aqueous liquid of PVA aqueous solution and inorganic pigments to be applied will be preferably 0.5-5 g/m 2 by weight per side surface after being dried. When coating is made, it is preferable to make such coating on both surfaces approximately equal. Namely, if the coating amount on both surfaces is less than 1 g/m, it is difficult to obtain such effects that will solve or alleviate the fluting in web-offset printing desired by this invention. On the other hand, if the coating amount on one surface exceeds 5 g/m 2 , the effect will be saturated. When the coating amount exceeds it, various problems will occur on runnability or printability, which is not desirable. The application of the aqueous solution of PVA or aqueous liquid composed of PVA and inorganic pigments to the paper web will be made separately to form multi layers.
[0080] The characteristics of the base paper that will be obtained by the application of the PVA aqueous solution or the aqueous liquid composed of PVA and inorganic pigments to the paper web and the following drying process is that it has the air resistance of 1,000 seconds or higher when measured pursuant to JIS-P-8117, preferably 1,500seconds or higher. When a coated paper for printing is obtained by forming a coated layer mainly composed of a pigment and an adhesive on this base paper, the fluting in web-offset printing and the mis-registration will be significantly solved or reduced. Namely, if a base paper having the air resistance of less than 1,000 seconds is used to obtain the coated paper with the coated layer mainly composed of the pigment and the adhesive, it will be difficult to adjust the thermal shrinkage force (R) in the range of the present invention. It will be also difficult to adjust the air permeability (air resistance) in the range specified by the present invention when measured pursuant to J. TAPPI Pulp and Paper Testing Method No. 5 (B) so that it is liable not to obtain significant improvement effect on the fluting in web-offset printing or on mis-registration.
[0081] The PVA having the saponification degree of not less than 85 mol, preferably not less than 90 mol will be used as a preferred embodiment since significant improvement effect on the fluting in web-offset printing or on mis-registration will be obtained.
[0082] Moreover, why the base paper obtained by the application in the specified amount of the PVA aqueous solution or the aqueous liquid composed of PVA and inorganic pigments to the paper web, besides having PVA with high saponification degree is selectively used in this invention is that once such PVA is applied to the paper web and dried to be a film state, even if it comes into contact with water, will not dissolve easily. The film state will be maintained as it is. Although the reason for this is not entirely clarified, we presume as follows: that is to say, the base paper to which the said PVA is applied, will be finished as a coated paper by further application of aqueous pigment compositions in the following process. During the process, the PVA film will come into contact with a lot of water. In this case, if the PVA film has a strong waterproof property, the film-state will be sustained and will be finished as the coated paper. If such a coated paper is used in web-offset printing, during the printing process with high temperature drying treatment, the moisture contained in the coated paper will evaporate by the high temperature. In accordance with this, the coated paper begins to shrink. On the other hand, once heated, since the PVA film formed on the paper web has the property of spreading, which is opposite to the property of shrinking, the both will compensate each other so that the thermal shrinkage of the coated paper is suppressed as a whole. As a result, the thermal shrinkage force of the coated paper caused from the heat will be decreased, and accordingly, the fluting in web-offset printing will be alleviated.
[0083] Consequently, when the PVA aqueous solution or the aqueous liquid of PVA solution and inorganic pigments is applied to the paper web and dried, it is important that the PVA coat (film) is formed on the surface of the paper web. Whether or not the PVA coat is formed can he judged by measuring the air resistance of the base or coated paper. By its very nature, if the coat formation is weak, the air resistance comes to low (=good permeance), and if the coat formation is strong, the air resistance comes to high (=poor permeance). Thus, judgement can be made easily.
[0084] As above described, the coat of PVA on the paper web surface is influenced by the viscosity of the coating liquid. Thus, it is preferred to use the PVA having polymerization degree in the range of 100-3,000 to obtain a good coat. Various denaturation PVA can be used as long as it has good coat forming aptitude.
[0085] It is conventionally known that PVA is applied to the surface of a paper web (one example is described in publication of unexamined Japanese patent application No. 62294/1980), for the purpose of adding blister resistance to the paper web of the coated paper for web-offset printing. In this reference an attempt was made to manufacture a coated paper for the web-offset printing by adding surface-active agent to the PVA before having coated the paper web. In other words, it aims to improve the blister resistance that is one of the problems to be solved for the coated paper used in the web-offset printing. The summary of the said reference is to let the PVA penetrate into inside of the paper web layer by using it in combination with the surface active agent to strength the internal bond of the paper web while the formation of the PVA coat on the paper web surface will be restrained (i.e. the air permeance is accelerated by lowering the air resistance) so as to improve the blister resistance property. Consequently, the technical philosophy thereof is completely opposite from that of the present invention.
[0086] Now, a reference will be made to another publication of unexamined Japanese patent application No. 11314/1979. It discloses a base paper having an excellent blister resistance by applying PVA to the paper web so as to make the Z axis strength thereof higher than a certain level in the meantime the air resistance is kept lower than a certain value. Namely, according to this reference, the air resistance of the base paper is 100 seconds or below. Since the blister will be generated by the air resistance of several hundred seconds, the base paper according to this reference as obviously different from that, which exceeds 1,000 seconds, defined in the invention.
[0087] In short, both of the aforementioned references intend to improve the blister resistance in the web-offset printing by applying PVA to the paper web in order to heighten the internal bond strength and also in order to lower the air resistance as much as possible. On the other hand, in this invention, the air resistance is heightened by coating the paper web surface with PVA and forming a PVA film or the surface, in other words, a resin film composed of, such as, PVA will be formed on the surface of the paper web to obtain the air resistance of high degree, thereby the fluting in web-offset printing, that can not be solved by the prior arts, will be removed significantly so that it will be considered that the present invention is based on novel and distinguished technical concept which has not been existed conventionally.
[0088] Next, a reference is made to the constitution of the pulp that composes the paper web used to make the coated paper for the web-offset printing of the present invention. According to the present invention, there are no particular limitations on pulp to be used. For example, bleached hardwood raft pulp (LBKP), bleached soft wood kraft pulp (NBKP), high yield pulp, and deinked used paper pulp will be suitably selected and used. In addition to this, there are no particular limitations on the paper making method for a paper web so that either the acidic or alkaline method may be adopted to make the paper web. It is possible to pre-coat the paper web by using an ordinary coater such as two-roll size press coater, roll coater and blade coater.
[0089] In this invention, there are no specific limitations on the aqueous pigment coating composition, which mainly contains pigments and adhesives, to be applied to the base paper or paper web. However, one or more usual pigments for coated paper, such as clay, kaolin, aluminum hydroxide, calcium carbonate, titanium dioxide, barium sulfate, zinc oxide, satin white, calcium sulfate, talc and plastic pigment can be suitably selected and used.
[0090] Furthermore, according to the present invention, the adhesives, for example, a conjugate diene-based copolymer latex such as styrene-butadiene copolymer and methyl methacrylate-butadiene copolymer, an acrylic polymer latex such as a polymer or copolymer of acrylic acid ester and/or methacrylic acid ester, a vinyl based polymer latex like ethylene-acetic acid vinyl copolymer, and an alkali soluble or alkali non-soluble polymer and copolymer latexes made by denaturing the above-mentioned various copolymers with a functional-group containing monomer such as a carboxyl group, can be suitably selected and used. In addition to the above, the following adhesives may be used; starches such as cationized starch, oxidized starch, thermo-chemically modified starch, denatured enzyme starch, etherified starch, esterified starch, cold water soluble starch, celluloses such as carboxylmethyl cellulose, hydroxy methyl cellulose, and a water-soluble synthetic resin based adhesives such as polyvinyl alcohol, olefin-maleic anhydride resin, can be suitably selected and used.
[0091] Further, various additives such as dispersant, water resisting agent, rheology modifier, coloring agent and fluorescent whitening agent will be added to the aqueous pigment coating composition if necessary.
[0092] When the aqueous coating pigment composition is applied to the base paper or paper web, it will be applied to form a single or multi-layers by the on- or off-machine coaters used in usual coated paper manufacture, such as blade coater, air knife coater, roll coater, reverse roll coater, bar coater, curtain coater, die slot coater, gravure coater, champflex coater and size press coater. The solid content of the aqueous pigment coating composition to be applied will be prepared generally in the range of 40-75 weight though, a range of 45-70 weight will be desirable considering the runnability. The amount of the application will be preferably adjusted in the range of 5-20 g/m 2 per side surface in dry weight in general.
[0093] The coated paper for printing thus obtained is usually passed through calender rolls and wound up to finish as the product. With regard to the calenders, various types of calenders composed of metal rolls or metal drums and elastic rolls, for example, super calender, gloss calender, soft compact calender, etc., are properly used in the specification of on- or off-machine.
BRIEF DESCRIPTION OF THE DRAWINGS
[0094] The attached drawings illustrate the irregularity of the surface of the imaged area of the coated paper after printing by using the visible light laser type displacement sensor (LB-1000/Keyence Corporation) so as to measure the displacement of the above mentioned flutings in web-offset printing, and by using the waveform data observation software (WAVE SHOT/Keyence Corporation) to make it into graphs. It concretely shows that the more the surface is irregular, the worse the fluting in web-offset printing is.
[0095] [0095]FIG. 1 is a graph of the fluting in web-offset printing of the coated paper which corresponds to the example 1 of the present invention. A scale expresses 200 μm in the longitudinal direction and 6.9 mm in the lateral direction, respectively, in the graphs inclusive following ones.
[0096] [0096]FIG. 2 is a graph of the fluting in web-offset printing of the coated paper which corresponds to the example 2 of the present invention.
[0097] [0097]FIG. 3 is a graph of the fluting in web-offset printing of the coated paper which corresponds to the example 3 of the present invention.
[0098] [0098]FIG. 4 is a graph of the fluting in web-offset printing of the coated paper which obtained in the comparative example 1.
[0099] [0099]FIG. 5 is a graph of the fluting in web-offset printing of the coated paper which obtained in the comparative example 2 and, as described above, a scale expresses 200 μm in the longitudinal direction and 6.9 mm in the lateral direction, respectively, in the graphs.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0100] The present invention will be described more in detail in conjunction with a set of examples and comparative examples. However, it is understood that the present invention is not limited thereto. The term “part(s)” and “a” in the description mean “part(s) by weightt” and “by weight” unless otherwise specified.
[0101] In addition, the method of evaluation of the thermal shrinkage force (R) is shown as follows:
[0102] [Measuring method of Thermal Shrinkage Force R]
[0103] A sample coated paper whose moisture is previously adjusted pursuant to JIS-P-8111 (moisture adjustment is made under the condition of room temperature of 20° C., relative humidity of 65) is cut off to obtain a span of 2 mm wide in the machine direction with a length of 2 cm in the cross direction. Then, thus obtained coated paper is set to a Thermo Mechanical Analyzer [TMA/SS6000: manufactured by Seiko Electronics Industries Co., Ltd.] under the initial load of 5 gf. As the PID control value of the terminal probe at the analyzer, P (Proportion)=100, I (Integration)=1, D (Differential)=100 are used. The shrinkage force “R” is obtained by the steps of expanding the span at the rate of 0.01 μm/minute under the condition that the initial load of 5 gf is added, rising the temperature from 20° C. at a heating speed of 200° C./minute to the predetermined temperature of 300° C., maintained at the temperature of 300° C. for 2minutes, then reading the shrinkage force generated by drying of 1.5 minutes after the commencement of the rise of the temperature.
[0104] [Evaluation of the Fluting in Web-offset Printing]
[0105] A figure with four colors solid was printed on both sides by using the web-offset printing machine manufactured by Komori Printing Machine Co., Ltd. Then, the fluting in web-offset printing generated thereby was visually evaluated. The moisture of the coated papers used is fixed in the range of 4.5-5.0, at the print speed of 200 rpm and the paper surface temperature of 110° C. at the exit of the dryer.
EXAMPLE 1
[0106] To a pulp slurry consisting of LBKP 70 parts (freeness 410 ml/csf) and NBKP 30 parts (freeness 480 ml/csf), precipitated calcium carbonate was added as a filler to obtain the paper ash of 10. Then, as a sizing agent to the pulp slurry, 0.04 parts of AKD sizing agent (trade name: SKS-293F/Arakawa Chemicals Co., Ltd.) and 0.5 parts of aluminum sulfate were added, respectively. The slurry was then passed through an on-top paper machine to obtain a paper web. The antifoaming agent (trade name: SN defoamer 777/SUNNOPCE Ltd.) of 0.05 to PVA in terms of solid matter and solution of PVA (trade name: PVA-124, saponification degree: 98.5 mol, polymerization degree: 2,400/KURARAY Co. Ltd.), which was prepared to have 6 concentration, was applied to both sides of this paper web by a bar coater and after dried, a base paper to make the coated paper was obtained. The viscosity of the PVA aqueous solution at 20° C. was 450 mPa.s and the coating amount of the PVA solution was 2.8 g/m 2 per side surface after the coated material was dried. The basis weight of the base paper thus obtained was 52 g/m 2 .
[0107] [Preparation of Coating Composition]
[0108] Slurry of pigment was prepared using Cowless dissolver by means of dispersing the pigments consisting of 15 parts ground calcium carbonate (trade name: FMT-90/Fimatic Corporation), 20 parts precipitated calcium carbonate (trade name: TP-221GS/Okutama Industries Co., Ltd.), 40 parts fine kaolin (trade name: Amazon 80/CADAM Corporation) and 25 parts of a kaolin in general use (trade name: HT/Engelhard Corporation). Next, 10 parts styrene-butadiene copolymer latex as solid matter (trade name: SN307/Sumika A & L Co., Ltd.), 3 parts oxidized starch as solid matter (trade name: ACE A/Oji Corn Starch Co., Ltd.) and other agents were added to toe slurry so that the coating composition having the solid matter concentration of 63 was finally prepared.
[0109] [Manufacture of the Coated Paper For Printing]
[0110] The above mentioned coating composition was applied on both sides of the said base paper by blade coater in an amount of 11 g/m 2 per side surface after being dried. The coated paper obtained in this manner was then passed through the super calender comprised of metal rolls and cotton rolls to obtain a coated paper for printing having a density of 1.15 g/cm 3 . The thermal shrinkage force (R) a-d evaluation of the fluting in web-offset printing of the coated power thus obtained are shown in Table 1:
TABLE 1 Air permeability (air resistance) of the coated paper Air resistance of Thermal Evaluation J. the base paper shrinkage of Fluting in Tappi-No. 5 (B) Tappi-T536 hm85 JIS-P-8117 Mis-regis force web-offset (Sec.) Oken High pressure Low pressure tration (gf) printing Permeability Gurley (Sec.) Gurley (Sec.) (mm) Example 1 18 ⊚ 700,000 80,000 18,000 0.24 Example 2 22 ∘ 300,000 50,000 6,000 0.32 Example 3 13 ⊚ 1,500,000 250,000 60,000 0.18 Example 4 21 ∘ 600,000 70,000 15,000 0.30 Example 5 41 Δ 80,000 15,000 2,500 0.40 Example 6 14 ⊚ 650,000 76,000 15,000 — Example 7 25 ⊚ 730,000 82,000 20,000 — Example 8 40 ∘ 100,000 20,000 1,100 — Example 9 28 ⊚ 180,000 39,000 1,800 — Com. Example 1 51 x 5,000 300 20 0.85 Com. Example 2 54 x 20,000 2,000 140 0.92
EXAMPLE 2
[0111] Example 1 was repeated to produce a sheet of coated paper except that the coating amount of the PVA solution per side surface after being dried was changed to 1.5 g/m 2 . The thermal shrinkage force (R) and the evaluation of the fluting in web-offset printing of the coated paper thus obtained are shown in Table 1.
EXAMPLE 3
[0112] Example 1 was repeated to produce a sheet of coated paper except that the PVA solution used in Example 1 was replaced by the liquid mixture consisting of 50 parts kaolin (trade name: UW-90/Engelhard Corporation) and 50 parts PVA (trade name: PVA 124/KURARAY Co., Ltd.) having a concentration of 11 solid matter. The thermal shrinkage force (R) and the evaluation of the fluting in web-offset printing of the coated paper thus obtained are shown in Table 1.
EXAMPLE 4
[0113] Example 1 was repeated to produce a sheet of coated paper except that PVA-124 used in Example 1 was replaced by PVA (trade name: PVA-224, saponification degree: 88 mol, polymerization degree: 2,400/KURARAY Co., Ltd.). The thermal shrinkage force (R) and the evaluation of the fluting in web-offset printing of the coated paper thus obtained are shown in Table 1.
COMPARATIVE EXAMPLE 1
[0114] Example 1 was repeated to produce a sheet of coated paper except that no size press was used. The thermal shrinkage force (R) and the evaluation of the fluting in web-offset printing of the coated paper thus obtained are shown in Table 1.
COMPARATIVE EXAMPLE 2
[0115] Example 1 was repeated to produce a sheet of coated paper except that the size press solution used in Example 1 was replaced with an oxidized starch (trade name: Ace A/Oji Corn Starch Co., Ltd.) having the concentration of 10. The thermal shrinkage force (P) and the evaluation of the fluting in web-offset printing of the coated paper thus obtained are shown in Table 1.
EXAMPLE 5
[0116] Example 1 was repeated to produce a sheet of coated paper except that the coating amount of the PVA solution per side surface after being dried was changed to 0.5 g/m. The thermal shrinkage force (R) and the evaluation of the fluting in web-offset printing or the coated paper thus obtained are shown in Table 1.
[0117] After web-offset printing, the surfaces of the coated paper obtained in accordance with the above mentioned Examples 1-3, and Comparative examples 1-2 were made into graphs by using the visible light laser type displacement sensor and waveform observation software. As apparent from FIGS. 1 - 3 , the fluting in web-offset printing is negligible in Examples 1-3. On the other hand, apparent from FIGS. 4 and 5 which show the evaluation results of Comparative examples 1 and 2, considerably severe fluting in web-offset printing was confirmed.
[0118] In addition, the coated papers obtained in accordance with the aforementioned Examples 1-5 and Comparative examples 1-2 were now used for gravure rotary printing. The measurement results of the mis-registration were shown in the rightmost column of Table 1. Namely, the evaluation of mis-registration was made as follows:
[0119] [Evaluation of Mis-Registration]
[0120] Printing was conducted by using a gravure rotary printing machine manufactured by Hitachi Seiko Co., Ltd. The total amount of displacement between yellow (the first color) and black (the fourth color) of the register-marks on the right edge and the left edge, with an interval of 412 mm, was given as mis-registration. Each color was dried with hot air at the fixed temperature of 60° C. and no adjustment for mis-registration such as steam addition was made between the colors.
EXAMPLE 6
[0121] Example 1 was repeated to produce a sheet of coated paper except that the basis weight of the base paper was changed to 40 g/m 2 by reducing the basis weight of the paper web. The thermal shrinkage force (R) and the evaluation of the fluting in web-offset printing of the coated paper thus obtained are shown in Table 1.
EXAMPLE 7
[0122] Example 1 was repeated to produce a sheet of coated paper except that the basis weight of the base paper was changed to 83 g/m 2 by increasing the basis weight of the paper web. The thermal shrinkage force (R) and the evaluation of the fluting in web-offset printing of the coated paper thus obtained are shown in Table 1.
EXAMPLE 8
[0123] To a pulp slurry consisting of 30 parts LBKP (freeness 410 ml/csf), 50 parts deinked pulp (freeness 200 ml/csf) and 20 parts NBKP (freeness 480 ml/csf), precipitated calcium carbonate was added as a filler to obtain the paper ash of 10. Then, to the pulp slurry, 0.04 parts AKD sizing agent (trade name: SKS-293F/Arakawa Chemicals Co., Ltd.) and 0.5 parts aluminum sulfate were added, respectively. The slurry was then passed through a Fourdrinier paper machine, and subsequently was size press coated with a solution of oxidized starch glue liquid (concentration: 3.5, trade name: ACE A/Oji Corn Starch Co., Ltd.) and surface size agent (concentration: 0.1, trade name: polymalon 1329/Arakawa Chemicals Co., Ltd.) by a two roll size press coater to obtain a paper web. The coating amount at the size press was 1.2 g/m 2 on both surfaces after the coated material was dried. Next, the antifoaming agent (trade name: SN defoamer 777/SUUNPCO Ltd.),0.05 as compared to PVA in terms of solid matter, was added to make gelatinized aqueous solution of PVA (trade name: PVA-110, saponification degree: 98.5 mol, polymerization degree: 1,000/KURARAY Co., Ltd.). The PVA solution was then mixed with kaolin (trade name: UW-90/Engelhard Corporation) at a ratio of 50:50 as solid matter to obtain an aqueous liquid concentration of 25. Thus, the obtained liquid was coated to both sides of the paper web by a gate roll coater and then dried to obtain a base paper for coating. The viscosity of the mixture liquid of PVA (at 20° C.) and kaolin was 1,300 mPa.s when coated and the amount of the coating was 7 g/m 2 on both surfaces after it was dried. Namely, the coating amount per side surface was almost same when coated by the gate roll coater. The basis weight of the base paper was 83 g/m 2 .
[0124] The coating composition, prepared in the same method as in Example 1, was applied to both surfaces of the base paper and dried. Then the paper was put through a super calendar process and a coated paper for printing was obtained. The thermal shrinkage force (R) and the evaluation of the fluting in web-offset printing of the coated paper thus obtained are shown in Table 1.
EXAMPLE 9
[0125] Example 8 was repeated to produce a sheet of coated paper except that the solution composed of oxidized starch glue liquid and surface size agent applied by the two roll size press coater in Example 8 was replaced by the solution of PVA (trade name: PVA-110/KURARAY Co., Ltd.) containing the antifoaming agent (trade name: SN defoamer 777) of 0.05 (as compared to PVA in terms of solid matter) and having a concentration of 3.5. The thermal shrinkage force (R) and the evaluation of the fluting in web-offset printing of the coated paper thus obtained are shown in Table 1.
[0126] As clearly shown in the measurement results in Table 1, the coated paper for printing according to the present invention generates negligible fluting in web-offset printing and is excellent for high quality printing. In addition to this, because mis-registration rarely occurs, she aforementioned coated paper can also be used for gravure rotary printing with the equivalent standards of high quality printing.
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A coated paper used for printing and manufacturing method thereof. The coated paper comprises a coated layer mainly compose of a pigment and an adhesive on a base paper or paper web. The coated paper also comprises the thermal shrinkage force (R) which satisfies following formula when measured pursuant to the measuring method described in the specification;
0≦R≦45 gf
A sample coated paper is moisture-adjusted in accordance with JIS-P-8111. Then, it will be cut into specific dimension along with orthogonally to the cross direction. Next, the paper will be put through Thermo Mechanical Analyzer to obtain R that is measured by predetermined technique. The coated paper will be obtained easily by using a base paper coated with PVA having a saponification decree of not less than 85 mol in an amount of 0.5-5 g/m per side surface after the coating material was dried and dried.
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RELATED APPLICATION
[0001] The present application is a continuation of the Applicants' co-pending U.S. patent application Ser. No. 11/221,634, entitled “Propellant For Fracturing Wells,” filed on Sep. 8, 2005, which claimed priority to U.S. Provisional Patent Application 60/607,929, filed on Sep. 8, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to the field of well fracturing. More specifically, the present invention discloses a propellant assembly for fracturing wells.
[0004] 2. Statement of the Problem
[0005] Propellant charges have been used for many years to create fractures in oil, gas and water formations surrounding a well. FIG. 1 is a cross-section diagram of a well 10 with a packer 12 and a series of propellant charges 20 The propellant charges 20 are ignited to rapidly generate combustion gases that create sufficient pressure within the well bore to generate fractures in the surrounding strata.
[0006] In order to achieve proper pressure loading rates and adequate minimum pressures for sustained periods of time sufficient to extend fractures in the surrounding formations using gas-generating propellants, it is necessary that a sufficient surface area of propellant be burning to generate the volume of gas required to extend such fractures, as gas generation is a function of the surface area of the propellant burning at any given time. If ignition of the propellant is limited to small areas of the outer surface of the propellant, then the flame from the initial burning area of the propellant must spread across the face of the propellant to ignite the remaining surface area. This flame spread rate is a key limiting factor to achieving proper pressure loading rates and adequate minimum pressures for fracture propagation in the surrounding formations. If the flame spread from a localized ignition point is too slow, then the burning surface area at any given point in time will be limited, and the overall time that the propellant burns to completion may have to be extended sufficiently to compensate for the reduced amount of time that pressures exceed the minimum required fracture extension pressure, resulting in a longer but less efficient propellant burn.
[0007] In addition, the propellant burn should be predictable and reproducible for the purpose of accurately modeling the fracturing process. It is difficult to accurately model a propellant burn unless the entire exposed surface of the propellant is ignited almost simultaneously. Modeling of propellants has been contemplated in the past, but with the assumption that ignition of the propellant surface over the entire exposed area of the propellant is simultaneous. Practically speaking, such simultaneous ignition is difficult to achieve.
[0008] The problem is further complicated by the following. When propellants are submerged in well fluids such as water (or water and KCI), flame spread rates tend to decrease. In addition, certain chemical coverings that are used as surface coatings on propellants to prevent leaching of the propellant fuel oxidizers into the surrounding well fluids also tend to inhibit the flame spread rate, thus exacerbating the problem. When such coatings are not applied to the surface of the propellant, sufficient leaching of the fuel oxidizer takes place over relatively short periods of time (i.e., 1 hour) to result not only in a reduction in the available energy to do work on the formation, but further, creation of an outer boundary layer absent of fuel oxidizer and comprised primarily of the propellant binder, which tends to inhibit the flame spread rate because the exposed fuel oxidizer in the binder has been leached away. Furthermore, because gas generation is a function of the area of propellant burning at any given time, it is also useful to engineer a propellant fracturing system that accounts for the required initial burning surface area to provide adequate pressure rise, in addition to taking into account the flame spread rate.
[0009] In summary, the problem consists of igniting sufficient surface area of propellant simultaneously to overcome the effects of not only a limited flame spread rate, but also to mitigate the effects of any sealing coating placed on the propellant. In addition, one must be able to accurately predict the amount of gas generation by burning of the exposed surface area at any given point in time for proper modeling.
[0010] Solution to the Problem. The solution to the problem is to rapidly ignite the entire outer surface of the propellant charge by wrapping the ignition cord around the propellant charge in order to produce a burn that is reproducible, and can be accurately modeled to predict the resulting conditions in the well and surrounding strata during the fracturing process.
SUMMARY OF THE INVENTION
[0011] This invention provides an apparatus for fracturing wells that employs a propellant charge and an ignition cord wrapped around the outer surface of the propellant charge to rapidly ignite the outer surface of the propellant charge For example, the ignition cord can be either a detonating cord or a deflagrating cord. The resulting rapid ignition of the outer surface of the propellant charge can be modeled more accurately and results in a more efficient use of the propellant charge in fracturing the well.
[0012] These and other advantages, features, and objects of the present invention will be more readily understood in view of the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention can be more readily understood in conjunction with the accompanying drawings, in which:
[0014] FIG. 1 is a cross-sectional diagram of a well 10 with a packer 12 and a series of propellant charges 20 .
[0015] FIG. 2 is a side elevational view of a propellant charge assembly embodying the present invention.
[0016] FIG. 3 is a side elevational view of a propellant charge 20 with a helical groove to receive the ignition cord 30 .
[0017] FIG. 4 is a cross-sectional view of an embodiment with a metal sheath 35 surrounding the ignition cord 30 and a protective coating 40 covering the entire assembly.
[0018] FIG. 5 is a side elevational view of another embodiment with the ignition cord 30 wrapped longitudinally around the propellant charge 20 .
[0019] FIG. 6 is a side elevational view of a propellant charge 20 with longitudinal grooves to receive the ignition cord.
[0020] FIG. 7 is an end view of the propellant charge 20 corresponding to the FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0021] Turning to FIG. 2 , a side elevational view of a first embodiment of the present invention is shown. The outer surface of the propellant charge 20 has a generally cylindrical shape. Ignition of the outer surface of the propellant charge 20 is accomplished by an ignition cord 30 wrapped around the propellant charge 20 in a helical pattern.
[0022] Preferably, the ignition cord 30 is a high-speed mild detonating cord. The ignition cord 30 can be ignited conventionally (e.g., with an igniter patch 15 ). The detonating cord can either be enclosed in a metal sheath 35 (e.g., a mild steel tube designed to fail directionally toward the propellant charge 20 ), or placed directly in contact with the surface of the propellant 20 . Mild detonating cord is also commercially available with various metal sheathes, such as lead, silver, aluminum or tin, A grain size of approximately 2.5 to 15 gr/ft has been found to be satisfactory to reliably produce a speed of about 17,000 to 22,000 ft/sec.
[0023] Alternatively a rapid deflagrating cord could be employed, although rapid deflagrating cord has a much slower speed on the order of about 1000 ft/sec. Both detonating cord and deflagrating cord should be considered as examples of the types of the ignition cords that could be used.
[0024] The pitch and/or distance between each turn of the ignition cord 30 can be modified to reduce the spacing between each adjacent turns, to thus limit or substantially eliminate the reliance on the initial flame spread rate to achieve the desired surface burning area. Thus, the amount of time required for the flame to spread becomes insignificant, and the entire surface area of the propellant charge 20 is in effect ignited simultaneously.
[0025] FIGS. 3 and 4 illustrate an embodiment in which the outer surface of the propellant charge 20 includes a helical groove 25 to receive the ignition cord 30 and substantially increase the burning surface area of the propellant charge 20 . The initial surface area burning can be modified by changing the depth and/or cross-sectional geometry of the groove 25 into which the cord 30 is placed. Thus, initial gas generation rates can also be modified by the design of the groove 25 . In addition, the groove 25 reduces the overall diameter of the assembly and helps to protect the cord 25 from damage,
[0026] Optionally, because the ignition cord 30 is in contact with such a large percentage of the total surface area of the propellant charge 30 and flame spread is no longer an issue, the assembly can be coated and sealed from the well bore fluids, thus helping to preventing leaching. For example, the propellant charge 20 and ignition cord 30 can be wrapped or sealed in a protective coating or layer 40 , as depicted in the cross-section view depicted in FIG. 4 . The protective layer 40 serves to protect both the propellant charge 20 and ignition cord 30 during transportation, handling, and insertion into the well bore, and also keeps them isolated from the well bore fluids. The assembly can be wrapped in a water tight aluminum scrim, heat shrink plastic, or other similar materials. For example, the propellant charge 20 and ignition cord 30 can be wrapped with a polymeric shrink-wrap material, such as the VITON 200 material marketed by the 3 M Corporation of St. Paul, Minn.
[0027] FIGS. 5 through 7 illustrate another embodiment with the ignition cord 30 wrapped longitudinally around the propellant charge 20 . FIG. 5 is a side elevational view of this embodiment. FIGS. 6 and 7 show a side elevational view and an end view, respectively, of a propellant charge 20 with longitudinal grooves to receive the ignition cord in this longitudinally-wrapped configuration. It should be understood that other wrapping configurations or combinations of wrapping configurations could be readily substituted.
[0028] The above disclosure sets forth a number of embodiments of the present invention described in detail with respect to the accompanying drawings. Those skilled in this art will appreciate that various changes, modifications, other structural arrangements, and other embodiments could be practiced under the teachings of the present invention without departing from the scope of this invention as set forth in the following claims.
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An apparatus for fracturing wells employs a propellant charge and an ignition cord wrapped around the outer surface of the propellant charge to rapidly ignite the outer surface of the propellant charge.
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This is a divisional of copending application Ser. No. 344,780, filed on Apr. 28, 1989.
BACKGROUND OF THE INVENTION
This invention relates to a reaction vessel or tank structure for use in a suspension polymerization for the manufacture of polyvinyl chloride or vinyl chloride.
In the polymerization process there is an excessive heat build up due to the reaction process and it is necessary to remove such heat to control the speed of reaction process. As larger apparatus or vessels are used to more economically provide the end product it has become necessary to use thicker walls to provide the necessary strength to withstand the increase in pressure. However with this increase in size of vessel and wall thickness there is also a substantial increase in the need to more efficiently remove the heat to properly control the reaction process.
The prior art provision of removing heat in the form of cooling tubes within the reactor vessel is unsatisfactory because of the difficulty of cleaning the interior walls of the vessel and the exterior walls of the cooling tubes due to polymer adhesion thereto and the resulting build-up or accumulation thereon. The provision of external cooling jacket encompassing the reactor vessel has presented the problem of not providing sufficient cooling capacity because of the thickness of the vessel wall prevents efficient cooling. The instant invention provides an internal cooling jacket with a thin innermost wall as one continuous surface thereby presenting a smooth inner wall which inhibits the unsatisfactory build-up of polymer adhesion and accumulation.
SUMMARY OF THE INVENTION
A pressure proof reactor vessel and the method of making such vessel wherein the reactor vessel has an outer cylindrical shell encompassing a cylindrical inner liner made from a single one-piece sheet of metal. Either a spiral support or vertical supports are attached to the inner liner first and then the inner liner and its supports are cooled while the outer shell is heated and then located onto the inner liner to encompass such liner. On equalizing the temperatures of the shell and liner, the liner and supports are firmly secured to the shell and define a flow path for circulating coolant to effect proper cooling. The cross sectional thickness of the walls of the liner and supports are substantially less than the cross sectional thickness of the shell.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view partly in cross-section of a reactor vessel;
FIG. 2 is an enlarged sectional view of the circled portion of the reactor vessel shown in FIG. 1;
FIG. 3 is a side elevational view in cross-section of a modified embodiment of the invention similar to the view in FIG. 1;
FIG. 4 is an enlarged cross-sectional view of a portion of the wall of the vessel and the cooling jacket taken on line 4--4 of FIG. 3;
FIGS. 5A and 5B are plan views of the assembling of the cooling jacket to the internal wall of the reactor vessel shown in FIGS. 1 and 2, showing the vessel wall encompassing and being secured to the jacket;
FIGS. 6A and 6B are plan views of a modified construction of a reactor tank and a cooling jacket showing the securing of the cooling jacket to the tank constructed according to the invention shown in FIGS. 3 and 4.
DETAILED DESCRIPTION
Referring to the drawings wherein like reference numerals designate like or corresponding parts throughout the several views, there is shown in FIGS. 1 and 2 a closed reactor vessel 10 having a main cylindrical portion or shell 11 with its lower end closed by a lower semi-spherical or dish-like member 12 and its upper end closed by an upper semi-spherical or dish like member 13. Vessel as used hereinafter means a tank or container of large capacity as of 1000 gallons or more. Such dish like members 12 and 13 are suitably welded to the shell or the cylindrical portion 11 to form the closed reactor vessel 10. The lower dish like member 12 has an outlet port 14 which is suitably controlled by a valve means not shown. The upper dish like member 13 has a central opening 15 through which extends a shaft 16 having mounted on its one end a paddle 17 that is suitably rotated to perform a mixing function within the reactor tank. Such upper dish like member 13 also has suitable (manhole) openings not shown for charging or introducing products into the reactor vessel.
An inner jacket is located within such cylindrical portion 11 of the reactor vessel 10 and consists of a thin one piece cylindrical sleeve 20 with a continuous spiral support or ribbon 21 encircling such sleeve 20 and suitably connected thereto as by welding as at 22 (FIG. 2). Such welding of the spiral support 21 to the sleeve 20 is done to the external or radially outermost wall surface of the sleeve 20. Such support or ribbon 21 forms a radial partition or wall that is perpendicular to the cylindrical portion 11 and sleeve 20 of the reactor vessel 10. The sleeve 20 and the continuous spiral support 21 may take the form of a strip which is connected to the sleeve 20 in one continuous operation exterior of the vessel 10 prior to its insertion into the cylindrical portion 11. As seen in FIGS. 1 and 2, two adjacent supports 21 cooperate with the sleeve 20 and the cylindrical portion 11 of the reactor vessel 10 to define a spiral chamber or passageway 24 that extends from the upper end portion of the reactor vessel spirally to the lower end portion of the reactor vessel. The lower cylindrical portion 11 of the reactor vessel 10 has an inlet 25 connected to the passageway 24 at the lower portion of the reactor vessel while the upper cylindrical portion 11 has an outlet 26 connected to the passageway 24 to provide a continuous flow path for coolant fluid around the entire sleeve 20.
As seen in FIG. 1, the upper and lower dish like members 12 and 13 have an annular flange 28 and 29 respectively that abut the sleeve 20 to provide a seal for the passageway 24. Such juncture of the flanges 28, 29 and the sleeve 20 can be welded to assure a fluid tight fit.
As an example of the dimensions of the passageway formed by the support and sleeve, the vertical distance "a" between two adjacent supports 21 (FIG. 2) can be 2 (5.08 cm) to 3 (7.62 cm) inches while the width or distance "b" of such passageway is between 1/2 inch (1.27 cm) to one inch (2.54 cm) and with the wall thickness of the sleeve 20 approximately 0.25 inch (0.635 cm).
To assemble such reactor vessel, the sleeve 20 is made from a thin piece of metal (thin relative to the thickness of the outer cylindrical shell 11) into a cylinder loop and welded also a single line. Thereafter a continuous strip or support 21 is welded as at 22 in a spiral path around such cylinder 20. With the chilling of such sleeve 20 along with its support 21 while heating the outer cylindrical portion 11 of the reactor vessel, such sleeve 20 is slipped into the cylindrical portion 11 and then upper and lower dish like members 12 and 13 are secured thereto along with the inlet 25 and outlet 26. With such structure the inner sleeve 20 has the same coefficient of expansion as the cylindrical portion 11 providing a smooth inner cylindrical continuous surface that is resistant to polymer adhesion and build up while also providing an efficient cooling of the reacting medium in the reactor vessel due to the very thinness of the sleeve 20 relative to the thickness of cylindrical portion 11 wherein the thickness of the sleeve 20 is substantially less than the thickness of the outer shell or cylindrical portion 11 of reactor vessel 10, which outer shell can be made of sufficient thickness to withstand the tremendous pressures of the polymerization process. With such inner sleeve 20 made from a one-piece structure the innermost wall surface is smooth and inhibits unsatisfactory polymer build-up.
FIGS. 5A and 5B illustrate an alternative method of assembling the reactor tank described above. Herein, on completion of the sleeve 20 and support 21 as previously described, the exterior shell 11 is then wrapped around the sleeve 21 with sufficient pressure applied as illustrated in FIG. 5B until the respective ends 30 and 31 of the outer shell closely abut each other after which such ends 30 and 31 are welded to form a unitary whole.
A further embodiment of the reactor vessel is shown in FIGS. 3 and 4 wherein a cylindrical sleeve 35 is made from a flat thin rectangular piece of metal such as austenitic-ferritic stainless steel wherein such thin metal sheet is formed into a cylindrical loop and welded. Thereafter thin vertical strips 36 of steel are spot welded as at 37 to the periphery of the cylindrical sleeve 35. In performing this operation, the strips 36 are all of the same length however alternate strips 36 have their one ends (upper ends) 38 located along a plane that is flush with the upper end portion of the sleeve 35 while the remaining alternate strips 3 have their lower ends 39 located along a plane that is flush with the lower end portion of the sleeve 35, thus leaving the respective ends below or above adjacent one ends 38 and 39 to define a serpentine flow path to be described An outer cylindrical shell 40 of substantial greater thickness than the sleeve 35 is formed around the vertical strips 36. Such shell 40 is formed from a rectangular piece of metal, preferably austro ferric stainless steel, the same metal used to form the sleeve 35 and is formed around the strips into a cylindrical shell and then welded as described in the first embodiment. Thereafter an upper dish like member 42 and a lower dish like member 44 are suitably welded to the respective upper and lower portion of the sleeve 35 and the shell 40. With the annular flanges 45 and 46 on the respective dish like members 42 and 44, and the strips 36 alternating in height, there is formed a continuous serpentine passageway 48 as depicted by FIG. 3.
The lower end of cylindrical shell 40 has an inlet opening 50 communicating directly with passageway 48 while the upper end of cylindrical shell 40 has an outlet opening 51 also communicating with passageway 48 such that with coolant fluid pumped into passageway 4B via inlet opening 50, such coolant flows in a serpentine path around such sleeve 35 and exiting via outlet opening 51. The number of inlet and outlet openings used on the shell 40 can be varied to provide the desired cooling of the reactor tank as discussed above.
A modification of the assembly of such reactor vessel other than described above is to cut a sheet of metal into a rectangular piece or shape and then form such rectangular piece into a cylindrical loop and weld such loop along adjoining or abutting edges. This operation forms a smooth internal surface to the cylinder. Thereafter the thin vertical strips 36 are welded to the external surfaces of the sleeve 35 in the manner and location as described above. The outer cylindrical shell 40 which can be preformed is heated while the internal sleeve 35 with its vertical strips 36 are chilled, after which the heated shell 40 is slipped over the sleeve 35 and then both are brought to the same ambient temperatures and are shown in FIG. 6A. Upper and lower dish like members 42 and 44 are secured to the shell 40. Inlets 50 and 51 are identical as described above and provide the continuous flow path. A further modification of the assembling of such structures is shown in FIG. 6B which discloses that the inside diameter of the outer shell 40 can be slightly larger than the outside diameter of the sleeve 35 with its vertical strips 36 and that after slipping the outer shell 40 over sleeve 35, such shell 40 can be deformed at ninety (90°) degree locations around the vessel to provide a frictional engagement between the components of the shell 40 and the vertical strips 36.
It is preferred that the vessel's inner sleeve and the spiral support or the vertical strip supports along with the outer shell be of high strength Austenitic-Ferritic Stainless Steel although a variation thereon may have the outer shell of conventional carbon steel. Where the vertical strips provide a serpentine flow, there can be four separate zones 1.e. four inlet pipes 50 and four outlet pipes 51, with each zone able to pass three hundred gallons of cooling fluid per minute. Austenitic-ferritic stainless steel has a higher thermal and a much higher strength than conventional stainless steel. By electropolishing the inner surface of the sleeve there is less build-up of polymer on the wall surface. The number of separate flow zones used can be varied to achieve a desired cooling result.
It will be apparent that, although a specific embodiment and certain modifications of the invention have been described in detail, the invention is not limited to the specifically illustrated and described constructions since variations may be made without departing from the principles of the invention.
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A pressure proof reactor vessel and the method of making such vessel wherein the vessel has a cylindrical one-piece outer wall and a cylindrical one-piece cylindrical inner liner, which liner has a smooth continuous interior surface spaced radially inwardly from the outer wall and concentric thereto. The inner cylindrical wall is formed from a one-piece material with its radial thickness being substantially less than the radial thickness of the outer cylindrical wall. Support means in the form of a spiral is positioned in said space between the cylindrical outer wall and the cylindrical inner liner defining a pathway for the flow of coolant between the outer wall and the inner wall. The support spiral is secured to the outer surface of the one-piece cylindrical inner liner prior to assembling of the inner liner to the outer cylindrical one-piece outer wall.
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FIELD OF THE INVENTION
This invention relates generally to the use of non-naturally occurring specific gold-binding proteins or peptides for use in analytic, exploration or recovery methods in the gold mining industry.
BACKGROUND OF THE INVENTION
Gold is one of the rarest precious metals on earth. It occurs naturally as the reduced metal (Au°) or associated with quartz or pyrites as telluride (AuTe 2 ), petzite (AuAg) 2 Te or sylvanite (AuAg)Te 2 . The electronics and space industries use gold's properties of electrical conductivity and heat reflection. Gold has applications in radar equipment, home computers, satellites and space exploration. Gold is also used in considerable quantities in the form of gold leaf (having a thickness of less than 0.2 μm) for sign writing and book binding lettering. Gold film has been used in glass windows to reflect heat. Liquid gold is a suspension of very finely divided gold particles in vegetable oil that is used in the decoration of china articles. Gold salts are used for toning in photography, and in coloring glass.
Most frequently gold in nature is dispersed in low concentration throughout large volumes of material, usually rock. Gold deposits occur in belts across the earth's crust in various forms: placers or quartz veins in sedimentary or indigenous formation, blanket or pebble beds or conglomerates, or as base metal ore associations. Gold occurs in ore bodies described as lodes or veins, replacement deposits, contact (skarn) deposits, volcanogenic deposits, deposits associated with intrusive activity (such as ‘porphyry’ systems and breccia pipes) and deposits associated with ferruginous sediments (banded iron formations) and cherts. Gold bearing veins are found in rocks of all compositions and geologic ages, deposited in cavities and associated with rocks such as slates or schists. Lode deposits consist of gold particles contained in quartz veins or country rock. Lode deposits usually are mined in deep underground mines using a variety of methods, although sometimes lode deposits are surface mined. The blanket or reef-type deposits are deposits in which the gold exists in quartz conglomerates. Disseminated gold deposits have three identifying characteristics. The gold mineralization is fairly evenly distributed throughout the deposit rather than being concentrated in veins (as in lode deposits) or in pay-streaks (as in placer deposits); the deposits consist of in place materials rather than transported materials; and the disseminated deposits are less flat. Generally, these types of deposits are mined using surface mining techniques.
Gold also exists in secondary ore deposits. All rock outcrops exposed at the surface of the earth are subjected to the natural elements of weathering and erosion, causing eventual breakdown of rock into fragments which are carried away by wind, water or ice. The fragments are then redeposited in river systems, lakes or in the sea. During the erosive cycle, the heavier and more durable gold is concentrated into rich deposits, even though the original rock may have contained low values. Residual deposits of gold are found close to the gold bearing outcrop after the other rock fragments have weathered and been carried away. Eluvial deposits are formed when gold or gold bearing rock fragments have been transported short distances from their source (generally by gravity) and have been concentrated within the soil horizon. Alluvial deposits are formed by the concentration of gold particles within stream systems, under the action of running water. Beach placers, where gold is concentrated in beach sands by wave action, are a type of alluvial deposit. Leads are former stream courses, containing gold, where barren sands have covered the original passage of the stream. Deep leads are gold deposits in former stream beds which have been covered with basaltic lava. Nuggets are formed, either as rich fragments of primary deposits which have been transported and deposited in a sedimentary environment, or a chemical accretion of small gold particles into larger fragments. Some nuggets may have formed through the chemical action of host soils or sediments on a gold solution. Placer deposits are flat-laying deposits composed of unconsolidated materials, such as gravel and sands, in which the gold particles occur as free particles ranging in size from nuggets to fine flakes. They are the result of erosion and transport of rock. Placer deposits most commonly are mined using water based surface methods, including hydraulic methods, dredging and open pit mining. These deposits usually are not mined in underground operations.
Methods for recovering gold from its ores (termed “beneficiation methods”) are extremely expensive and labor and heavy machinery intensive. Gold is one of the least reactive metals on earth. It does not combine with oxygen or with nearly any other chemicals, no matter how corrosive. Some gold ores are free milling and allow the separation of coarse gold using methods that depend on the high specific gravity of gold. All other commonly used methods depend on the use of cyanide which is highly toxic, hazardous to the environment and difficult to remove. Basically, the first step in all methods is to subject the ore to cyanide leaching followed by a gold recovery process. The three known methods for extracting gold from the cyanide leach solution are the “Merrill-Crowe” or zinc dust precipitation process, the carbon-in pulp process, and the carbon in-leach process. Other gold recovery processes use gravity methods to extract the high proportion of free gold and flotation-roasting leaching to extract the remaining gold.
Cyanide and cyanide by-products from cyanide leaching operations are responsible for several environmental impacts, including air and water pollution and solid waste disposal contamination. Free cyanide and various cyanide complexes are the by products of current leaching methods. Although cyanide will degrade, for example in a surface stream exposed to ultraviolet light, aeration and complexing with various chemicals present in the stream water, in-stream degradation is a wholly unsatisfactory approach to removing cyanide from the environment. Cyanide solutions are often kept in open ponds and frequently birds or other animals are exposed and killed by the toxic material.
Air pollution with cyanide also is an unavoidable result of prior art methods for heap-leaching of gold. Cyanide solutions are sprayed onto the heaps, the cyanide drifts and contaminates the surrounding environment. As is the case with cyanide released into water, eventually the cyanide is degraded by ultraviolet light, but not until after it has adversely affected the environment. The EPA directs considerable efforts and expense in regulating cyanide releases into the air and water. Chronic cyanide toxicity due to long-term exposures to low levels is also a health factor to be considered, and the effects such exposures are not presently well known. For these reasons there has been a long standing need for gold mining processes which do not pollute the environment with cyanide and cyanide byproducts.
Gold recovery from secondary sources such as electronic scrap and waste electroplating solutions, as well as recovery from primary sources such as leach solutions is also an important technology. Various processes such as carbon adsorption, ion exchange, membrane separation, precipitation, and solvent extraction have been used for isolation of metal ions, including gold.
Recently, methods for the utilization of naturally occurring proteins or biologic materials in analytic or gold recovery, including microbial biomass, as an adsorbent for metals have been studied. Bontideau et al., Anal. Chem. 70:1842-1848 (1997) is a physical chemical study of the two-dimensional binding properties between a naturally occurring protein and a gold substrate. The arrangement and enzymatic activity of a myosin sub-fragment were characterized with special focus on the direct attachment of the thiol groups of cysteines in the protein to the gold substrate.
The current process for gold recovery includes treatment with cyanide to form a gold cyanide complex. U.S. Pat. No. 5,378,437 of Kleid et al teaches the use of cyanide-secreting microorganisms that also absorb the cyanide gold complex once formed.
A large body of research exists that describes, as an alternative to cyanide, the utilization of biomass to recover gold from aqueous solution or suspension. U.S. Pat. No. 4,789,481 of Brierley describes an improvement over the basic biomass extraction process whereby the biomass—in this case Bacillus subtilis —is treated with a caustic solution prior to use. U.S. Pat. No. 4,769,223 of Volesky et al., is directed to the biomass process where the biomass is derived from the growth of the marine algae of the genus Sargassum. U.S. Pat. No. 5,567,316 of Spears et al., describes a process for recovering metals from solutions using an immobilized metalloprotein material. There is no suggestion that this process would be useful for the recovery or detection of gold.
Different processes of enrichment of gold-containing ore are known in the art. Flotation is one of the most widely used of these processes. In this method, separation is accomplished by treating ground ore with chemical reagents that cause one fraction to sink to the bottom of a body of water and the other fraction to adhere to air bubbles and rise to the top. The flotation process was developed on a commercial scale early in the 20th century to remove very fine mineral particles that formerly had gone to waste in gravity concentration plants. Most kinds of minerals require coating with a water repellent to make them float. By coating the minerals with small amounts of chemicals or oils, finely ground particles of the minerals remain unwetted and will thus adhere to air bubbles. The mineral particles are coated by agitating a pulp of ore, water, and suitable chemicals; the latter bind to the surface of the mineral particles and make them hydrophobic. The unwetted particles adhere to air bubbles and are carried to the upper surface of the pulp, where they enter the froth; the froth containing these particles can then be removed. Unwanted minerals that naturally resist wetting may be treated so that their surfaces will be wetted and they will sink. Processing the flotation concentrate in order to recover gold is simpler and cheaper than treatment of total ore stock. Current flotation technology, however, still does not recover all of the gold that is present, especially the gold in finely-dispersed ore. At least one attempt has been made to improve the flotation process using a microorganism culture. Cormack, et al., Gold Extraction Process for Bioflotation, WO 97/14818. In this method, a microorganism culture is introduced into flotation tails and the mixture is agitated.
Most reported research in the area of protein/gold interactions describes the adsorption of gold or other metals by proteins in a non-specific fashion. Ishikawa & Suyama, Recovery and Refining of Au by Gold-Cyanide Ion Biosorption Using Animal Fibrous Proteins, App. Biochem. and Biotech., 1998, 70-72:719-728, is typical. Animal fibrous proteins which were insoluble and stable in water, such as chicken feather protein and hen eggshell membrane, adsorbed gold in a non-specific fashion. In this reference, eggshell membrane was utilized in a column and was able to remove very low concentrations of gold from aqueous solution. Another typical reference which provides generic disclosure of protein/gold or protein/metal ion interactions is Alasheh & Duvnjak, Adsorption of Copper by Canola Meal, J. Hazardous Mat., 1996, 48:83-93. Niu & Volesky, Gold-cyanide Biosorption with L-cysteine, J. Chem. Tech, and Biotech., 2000, 75:436-442, describe the chelation properties of a particular amino acid. In this reference, biomass was “loaded” with L-cysteine by contacting dried, protonated biomass with a solution of L-cysteine, and resulted in the ability of the biomass to adsorb higher concentrations of gold-cyanide. The authors postulate that the enhanced binding probably results from binding the gold-cyanide complex to the cysteine NH 3 + , while the cysteine COO − binds to positive charges on the biomass.
Brown, Nat. Biotech. 199715:269-72, herein incorporated by reference in its entirety, has engineered a fusion protein including E. coli alkaline phosphatase and an engineered gold binding peptide domain. The identification of the gold binding domain involved fusion of a combinatorial library of peptide repeat sequences to an outer membrane protein of E. coli. Cells were selected for their ability to attach to Au beads. The Au-binding domains that appeared to have high specificity and affinity for Au were then engineered as fusion peptides to the E. coli enzyme alkaline phosphatase (referred to as gold-binding protein or GBP). The attachment of the Au-binding domain to the enzyme provided a convenient means to follow (quantify) binding to Au surfaces. With respect to applications of this novel material, the article was principally concerned with studies on metal protein interactions. Woodbury et al., Biosensors and Bioelectronies, 13:1117-1126 (1998), is directed to the general application of the gold-binding peptides suggested by Brown. The biosensors described in the Woodbury et al. reference utilized the gold-binding peptides to attach recognition elements to the gold sensor surface. Detection of binding events to the recognition element is performed by surface plasmon resonance (SPR). Although the gold-binding peptide and its affinity to gold is an element of this article, the gold-binding peptides affinity to gold is not exploited for analytic or gold recovery applications.
SUMMARY OF THE INVENTION
The present invention provides methods for detecting gold in ore samples, using a gold-specific protein for binding to the sample. Such methods may be qualitative or quantitative. In one embodiment, the method is a direct-binding method. In another embodiment, the non-specifically bound gold-binding protein is proteolyzed and detected. The methods have been adapted for a high-throughput format, such as a multiwell plate.
The present invention also provides methods for extracting gold from a mineral suspension containing gold and magnetite, using a magnetite-binding gold-specific protein to form a magnetic complex and extracting gold using a magnetic field.
The present invention also provides flotation methods for extracting gold from a mineral suspension, using a gold-specific protein with a hydrophobic tail as a flotation reagent.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows localization of gold with the “rock blot”.
FIG. 2 shows a comparison of UW 96 well assay with fire assay using core split chips.
FIG. 3A shows a film analysis of 96 well plate assay where the exposure to film was a 10 second exposure.
FIG. 3B shows a film analysis of the same 96 well plate assay where the exposure to film was a 10 minute exposure.
FIG. 4A displays the results of each 96 well plate assay specificity sample along with a high and low ore standard. The “trp” and “adj” labels represent the signal from the trypsinized sample and then a background adjusted result.
FIG. 4B displays the results of a 50/50 mix of the specificity sample and the high (7.59 g/t) ore standard.
FIG. 5 show the results of the film analysis in a graphical form.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is directed to the use of non-naturally occurring specific gold-binding proteins or peptides in all areas of the mining industry including prospecting, exploration and development, actual mining, such as surface mining and underground mining, sustainable mining, sampling, concentration, beneficiation, and environmental remediation. In particular embodiments of the invention, uses include locating gold in field samples with intact or proteolyzed proteins, recovering gold with a magnetic gold-binding protein, and recovering gold via flotation with a gold-binding protein suitable as a flotation reagent. A magnetic gold-binding protein can be generated by techniques known to those skilled in the art, for example, by derivatizing magnetic beads with the gold-binding protein. Further embodiments include recovering gold using chemotactically sensitive microbes producing gold-binding protein and methods for determining the source of metal ions in streams, rivers, and drainage basins by using immobilized gold-binding proteins in these locations.
The gold binding proteins of the present invention are proteins that have a high specificity and affinity for gold. The preferred gold-binding proteins of the present invention are those identified as described by the methods in Brown, Nat. Biotech. 199715:269-72, and most preferably are the proteins set forth in Brown. However, the present invention is not limited to such proteins and specifically includes any gold-specific binding protein defined as a having high specificity and affinity for gold, obtained by any method. For example, the present invention includes monoclonal antibodies specific for metal ions including gold ions that are described in U.S. Pat. No. 5,503,987 to Wagner, et al, incorporated by reference herein in its entirety. In fact the present invention also extends to any other gold-specific binding, non-naturally occurring ligand to gold, be it a protein, polypeptide, peptide, protein fragment, oligonucleotide, carbohydrate, antibody, chelating agent, magnetic agent, hydrophobic agent, or combination thereof, that can be used in the methods of the present invention. As an example, in one embodiment of the invention, gold-binding protein is associated with magnetic beads to generate a magnetic gold-binding protein reagent. In another embodiments, a gold-binding protein is modified with hydrophobic tails to generate a hydrophobic gold-binding protein suitable as a flotation reagent. Additionally, methods of the present invention include the use of other proteins, such as the monoclonal antibodies specific for metal chelates as are described in Meares, et al., U.S. Pat. No. 4,722,892, incorporated by reference herein in its entirety.
I. Field System for Mineral Exploration (“Rock Blot”)
The present invention is directed toward a method for locating gold in field samples with a protein having high specificity and affinity for gold. As used herein, Au-specific protein or gold-specific protein refers to a protein having high specificity and affinity for gold. In one embodiment, the method is useful in characterizing the distribution of gold within deposits. Samples are first treated with blocking reagents well known in the art (e.g., protein, detergents) to prevent the Au-specific protein from binding to sites that have general affinity for protein. The sample is then exposed to an Au-specific protein. In a preferred embodiment, the Au-specific protein is alkaline phosphatase (AP) engineered with a Au-binding domain, or AP Au . AP Au is also referred to as GBP (gold-binding protein). The sample is washed and the location of the bound AP Au is determined by using a detectable substrate for alkaline phosphatase, for example, using standard ELISA techniques. In a preferred embodiment, the substrate is a luminescent substrate, detected by exposing overlaid film to light generated by the AP Au and a substrate that generates light when hydrolyzed by AP Au . Other suitable substrates are well-known to those skilled in the art. Examples of suitable substrates include 5-bromo-4-chloro-3 indolyl phosphate (BCIP), utilized in U.S. Pat. No. 5,354,658, and p-nitrophenyl phosphate, a water-soluble substrate. Indirect detection methods are also useful in the present invention, for example, a sandwich ELISA.
FIG. 1 shows the results of a typical assay. This assay has been termed a “rock blot” by the inventors. A rock section with visible Au was provided to serve as both a sample and control. The exposed areas of the film clearly line up over the Au deposits in the sample. The details of the protocol are included in Example 1.
II. High-throughput Gold Detection Protocol
The present invention also provides methods to quantify the surface area of Au exposed on ore samples in a high-throughput assay. The basic method is similar to the “rock blot,” but incorporates additional steps to reduce background signal generated by the reaction of the mineral matrix with the preferred luminescent substrate. In this assay, GBP was allowed to bind to a milled ore sample. The AP domains bound to the areas of the ore matrix that bound protein nonspecifically, while the Au-binding domain more specifically binds Au. Following this initial binding, the samples were treated briefly with a proteolytic agent cleaving the protein, and releasing into the supernatant any GBP bound only through its Au-binding domain. As used herein, proteolytic agent refers to a reagent that is capable of chemically or otherwise splitting proteins into smaller peptide fractions and amino acids. Proteolytic agents useful in the present invention include proteolytic enzymes such as proteases, peptidases, and proteinases. Examples of proteolytic enzymes are Lys C, Arg C, Asp N, Glu C, trypsin, chymotrypsin, pepsin, thermolysin, and proteinase K Non-enzymatic proteolytic agents include cyanogen bromide (CNBr) and formic acid (COOH). In a preferred embodiment, the proteolytic agent is trypsin. The alkaline phosphatase cleaved from the Au-binding domain and released into the supernatant was removed from the matrix-containing reaction and was quantified by measuring the activity of the alkaline phosphatase. A very sensitive assay for alkaline phosphatase involves cleavage of the substrate LUMI-PHOS® Plus (Lumigen, Inc., Southfield, Mich.) to produce light, which is quantified in a luminometer.
Experiments with milled ore samples containing high or low levels of Au led to the development of incubation and wash conditions that differentiated high Au containing samples from samples with low levels of Au.
The need to examine high numbers of samples required the development of a high-throughput analysis (96 well plate assay). “Saw chips” from a core-split were used to compare the plate assay with a standard fire assays of one-half of the core.
The fire assay is a potentially highly precise and accurate method for the total determination of Au and other precious metals in samples. It is typically used on ore-grade samples. The fusion, or “melt” is done in a furnace at high temperatures; hence the term “fire” assay. Samples are mixed with fluxes including lead-oxide, fused at 1050° C., cupeled to recover a dore bead, nitric acid parted to separate the precious metal then analyzed by either gravimetric, atomic absorption, or other analytical method. The fire assay does have drawbacks, however. First, the sample size is relatively large, requiring about one “assay ton” of pulverized sample, i.e. 29.84 grams of material. Second, certain types of ore contain elements that may interfere with the result. A good fire assayer knows how to modify the composition of the flux to avoid these problems, thus highly skilled and experienced assayers are necessary to achieve high quality results in a fire assay for gold.
FIG. 2 shows the results of a comparison of the fire assay with the GBP assay (average of three replicates) using a three point sample average smoothing. Overall, there was an excellent agreement between the results of the fire assay and the plate assay, particularly for samples from the upper region of the core. Application of the 96-well plate assay shows that replicate assays had small variance between replicates and differentiates between milled samples with high or low Au content.
In another embodiment, suitable for use in the field, the 96 well plate is exposed to film, as it would be much more convenient to analyze film in the field than carry out luminometer determinations. A POLAROID® film result can be scanned with a simple PC scanner device and the results quantified. Normal film can be scanned by a simple densitometer. In another embodiment, normal film or X-ray film is used, and, once exposed and developed, is taped the bottom of a 96 well plate and analyzed in a plate reader at 500 nM. The results of a sample quantitation are shown in Table 1 below and in FIG. 3 . In the sample plate, eight replicate well sets were used, and enzyme concentration was reduced by one-half for twelve steps. FIG. 3A shows a film exposed for 10 seconds, and FIG. 3B shows the same experiment with a film exposure of 10 minutes. These procedures are detailed in Example 2.
TABLE 1
Absorbance Values from Molecular Devices Plate Reader for 96-Well Plate
(10 second exposure)
1
2
3
4
5
6
7
8
9
10
11
12
A
2.105
2.538
2.802
1.202
0.708
0.409
0.272
0.218
0.206
0.202
0.193
0.190
B
1.306
2.615
2.226
1.204
0.713
0.390
0.261
0.206
.202
.194
0.195
0.189
C
1.893
2.737
2.261
1.326
.767
0.412
0.272
0.209
0.197
0.192
0.190
0.191
D
0.291
2.618
2.164
1.237
0.703
0.362
0.249
0.199
0.193
0.184
0.186
0.192
E
2.107
2.571
2.254
1.307
0.722
0.399
0.264
0.214
0.195
0.182
0.186
0.187
F
1.674
2.632
2.196
1.257
0.700
0.390
0.257
0.203
0.2
0.188
0.188
0.179
G
2.036
2.552
2.118
1.173
0.729
0.422
0.270
0.209
0.195
0.190
0.187
0.181
H
2.209
2.572
2.214
1.333
0.728
0.401
0.278
0.222
0.193
0.188
0.183
0.182
(10 minute exposure)
1
2
3
4
5
6
7
8
9
10
11
12
A
3.858
3.846
3.724
3.620
3.651
3.505
3.332
2.850
2.120
1.119
0.469
0.279
B
3.527
3.560
3.575
3.494
3.416
3.374
3.186
2.614
1.794
0.915
0.351
0.255
C
3.477
3.522
3.457
3.495
3.376
3.408
3.185
2.708
1.709
0.858
0.307
0.242
D
3.669
3.648
3.592
3.595
3.527
3.340
3.219
2.530
1.560
0.725
0.309
0.237
E
3.824
3.754
3.702
3.712
3.641
3.520
3.299
2.889
1.603
0.773
0.323
0.232
F
3.719
3.826
3.798
3.693
3.652
3.516
3.378
2.765
1.898
0.943
0.387
0.258
G
3.661
3.732
3.651
3.602
3.554
3.476
3.37
2.846
1.657
1.024
0.384
0.275
H
3.791
3.823
3.841
3.880
3.733
3.653
3.414
3.065
2.066
1.048
0.521
0.307
A number of different mineral samples were tested using the plate assay to determine the levels of nonspecific binding. Table 2 contains the raw data. FIG. 4 depicts the averages listed on the table in graphical form. FIG. 4A displays the results of each specificity sample along with a high and low ore standard. The “trp” and “adj” labels represent the signal from the trypsinized sample and then a background adjusted result. FIG. 4B displays the results of a 50/50 mix of the specificity sample and the high (7.59 g/t) ore standard.
TABLE 2
Raw data from specificity assay:
Sample only
trp
ave
trp-
ave
adjusted
Calcopyrite
3954
3710
3832
3538
3409
3474
359
Pyrite
0.75
0.91
1
1.53
1.48
2
−1
Arsenopyrite
2402
2444
2423
2900
2727
2814
−391
Aresenic I-Not
229
262
246
31.3
69.9
51
195
canada
Silicon Dioxide
1068
913
991
1078
596
837
154
Calcite
34.6
96
65
157
165
161
−95
Soda Feldspar
441
582
511
381
280
330
181
Calcopyrite on Dol
162
163
162
149
192
170
−8
Feldspar
380
386
383
245
203
224
160
Sericite I
Pseudomorph
3153
2680
2917
665
661
663
2254
Cerussite
0.62
12
6
5.36
5.54
5
1
Low
286
224
255
155
253
204
52
Hi
7990
8104
8047
565
206
385
7662
Sample spiked with
50% high Au ore
trp
ave
trp-
ave
adjusted
Calcopyrite
5229
5244
5237
1279
1402
1341
3896
Pyrite
265
132
198
110
80.3
95
103
Arsenopyrite
4315
4966
4641
2308
1514
1911
2730
Aresenic I-Not
2388
2473
2431
320
302
311
2119
canada
Silicon Dioxide
3285
3040
3163
673
1070
872
2291
Calcite
1496
1323
1410
195
320
258
1152
Soda Feldspar
3082
2940
3011
610
543
576
2435
Calcopyrite on Dol
321
601
461
330
76.3
203
258
Feldspar
2406
2613
2510
414
206
310
2199
Sericite I
Pseudomorph
4992
5528
5260
985
965
975
4285
Cerussite
135
148
142
166
132
149
−7
Low
286
224
255
155
253
204
52
Hi
7990
8104
8047
565
206
385
7662
III. Gold Recovery System (Magnetic Separation).
It is a further object of this invention to provide a method for the recovery of gold from a liquid containing a magnetic mineral. In this method, a magnetic mineral binding reagent including a gold-specific protein is added to the sample to form a complex of magnetic mineral and gold. When a magnetic field is applied to the sample, the complex is removed from the rest of the solution, allowing the recovery of the gold. The magnetic mineral binding reagent and the gold-specific protein may be associated by covalent or non-covalent means.
In a preferred embodiment, the liquid is a slurry containing magnetite and fine gold. Magnetite, sometimes called magnetic iron, is an oxide of iron (Fe 3 O 4 ) occurring in isometric crystals, also massive, of a black color and metallic luster. It is readily attracted by a magnet and sometimes possesses polarity, in which case it is called lodestone. As there is often a significant quantity of magnetite in the gold-processing stream, and a substantial amount of fine Au is lost during processing, this method provides a solution to the problem of this lost Au. In the case of ores with low magnetite, the method may be used upon addition of magnetite to the slurry.
In order to test the concept, Au beads (≈3 μm diameter) were coated with GBP and rabbit anti-alkaline phosphatase antibodies. The coated beads were in turn bound to magnetic beads coated with goat anti-rabbit antibodies. The complex was readily pulled to the wall of a micro-centrifuge tube in the presence of a magnetic field, while the controls stayed suspended and gradually settled to the bottom of the tube.
In one embodiment, a reagent with both gold-and magnetite-binding domains is added to bind gold and the natural magnetite, then the complex is extracted using magnetic means.
In another embodiment, a GBP bound to a magnetic particle is used. Methods for generating protein-bound magnetic particles are described in U.S. Pat. No. 6,033,878, herein incorporated by reference in its entirety.
In another embodiment, magnetic mineral binding reagent is a microbial cell expressing two different metal binding domains on its surface, one for gold and one for magnetite. In another embodiment, different cells, each expressing a different domain can be cross-linked to provide the reagent. Another way to achieve this aim is to make a fusion protein with both binding domains.
IV. Gold Flotation
In another embodiment, the present invention provides a gold flotation reagent. In one embodiment, the gold flotation reagent is a hydrophobic reagent comprising a gold-specific protein. As used herein, hydrophobic moiety refers to a substance that repels or is insoluble in water. The hydrophobic moiety may be any hydrophobic moiety. Simple hydrophobic moieties such as a C 5 tail are suitable, as well as larger and more complex hydrophobic groups. Suitable hydrophobic groups include those derived from the organic acids butanoic acid, maleic acid, valeric acid, hexanoic acid, phenolic acid, cyclopentanecarboxylic acid, benzoic acid, and the like. Other suitable hyrdrophobic moieties include protein domains consisting of the hydrophobic amino acids alanine, valine, leucine, isoleucine, phenylalanine, tyrosine, and tryptophan. Naturally-occurring proteins with such hydrophobic tails or domains are known to those skilled in the art, as are methods for the creation of fusion proteins with such hydrophobic domains.
The ability of a gold-specific protein to act as a flotation reagent is evidenced by an experiment with a modified gold-specific protein. GBP was modified with valeric anhydride to create a GPB with C 5 hydrophobic tails (C 5 -GPB). After binding to gold particles, valeric anhydride was added to acylate the bound GBP. Mineral oil was then added. After mixing, followed by separation of the oil and water layers, it was found that the C 5 -GBP bound to gold resided at the oil water interface. The experiment shows that gold bound to C 5 -GBP possesses sufficient hydrophobic character to be used in a flotation process.
V. Use of Microbes to Extract and Deliver Metals from Ores.
In another embodiment, the present invention provides a method to recover very small gold from crushed samples or from samples with free particles of sub micron to micron size gold. In one embodiment, the method utilizes microbial strains that express gold binding domains on their surfaces. The cells are directed to deliver the bound Au to the destination by taking advantage of their ability to swim up a concentration gradient of attractant (chemotaxis). Microbial cells have very efficient chemotaxis systems. Use of two phase aqueous systems should be useful for such separations. For example, an E. coli cell that expresses an extracellular gold binding protein domain will bind small particles of gold. The cell will then follow a chemical gradient (e.g., a gradient of the sugar ribose or amino acid aspartate or other chemoattractants) to the collection destination.
VI. Use of High Affinity Binding Proteins for Mineral Exploration.
The present invention also provides a method for determining the source of metal ions in streams, rivers, and drainage basins. In general, streams, rivers, and drainage basins are monitored for the presence of metal ions of interest. Determining the location of metal ions in various locations will allow one to track the course of the ion from its destination in a drainage basin backwards to its source. The approach involves placement of small dialysis sacs, immobilized proteins or similar devices in streams and rivers of a drainage basin for fixed times. The sacs containing proteins that bind metal ions with very high affinities are removed and analyzed for content of mineral ion.
EXAMPLES
Example 1
Field System for Mineral Exploration (“Rock Blot”)
A sample (rock) suspected of containing gold was obtained. The surface of the rock was blocked with a 50 μg/ml solution of alkaline phosphatase (P2991) diluted in TTBS (100 mM Tris pH 7.4, 0.5 M NaCl, 0.1% TWEEN® 20 (Polyoxyethylenesorbitan monolaurate)), mixing gently for four hours. The rock was then washed with TTBS buffer, 3×. FITC-GBPAP (Fluoresceinated Gold Binding Protein, 11 μg/ml in PBS) at a concentration of 0.18 μg/ml was added, and incubated for six hours with a rocking mixer. After incubation, the rock was rinsed three times with 6 ml TTBS. The rock was blocked by incubating in dry milk solution in (10% w/v in TTBS) for 30 minutes, followed by three washes with 10 ml TTBS each. Primary antibody (Anti-Fluorescein IgG, Monoclonal, 15 μg/ml in TTBS, Mouse anti-F, {fraction (1/10)} Dilution of stock) was added, and the rock was incubated at room temperature overnight with gentle shaking. A VECTASTAIN® kit (Vector Laboratories, Inc., Burlingame, Calif.) was used to bind biotinylated secondary antibody (horse anti-mouse) and avidin-labeled alkaline phosphatase.
Substrate solution was prepared in glass containers by dissolving 5 mg of 4-iodophenol and 20 mg of luminol (5-amino-2,3-dihydro-1,4-pthalazinedione) into 0.5 ml DMSO and adding solution of 0.5 ml 1 M Tris HCl pH 8.5, 21.5 ml ddH 2 O (double glass distilled H 2 O), and 2.5 ml 5 M NaCl. 62.5 μl of H 2 O 2 was placed in a separate glass tube.
The detection reaction was initiated in a darkroom. The rock was placed into the into the tris/salt solution face up without shaking. Luminol solution was added to the H 2 O 2 solution, mixed, and them immediately added to the petri dish. After two minutes, the solution were drained away from the rock. The rock surface was covered with plastic wrap and then exposed to Polaroid Type 57 high speed film for 1, 2, 4, 8, 16, 30, and 60 seconds. The film was developed to observe results of the blot.
Example 2
High-Throughput Analysis Protocol (96 Well Plate Assay)
A. Ore samples were puck milled (or powdered by another fashion to the extent of puck milling). Using a 5 mg scoop, samples were transferred into the wells of the 96 well filtration plate (MULTISCREEN® 96-well filtration and assay plate (Millipore, #MAHVN4510). 100 μl of gold binding solution (GBP in Buffer T (50 mM Tris, pH=8, 10 mM CaCl 2 , 40 mM NaCl, 1% TRITON® X-100 (t-octylphenoxypolyethoxyethanol)), standardized according to EXAMPLE 2B) was added to each well with a multipipettor. The plates were covered with sealing tape (Fisher Scientific #MATAHCL00) and vortexed for 30 mm in a Vortex Mixer with 96 well plate attachment (Fisher Scientific #12-812, 96-attachment is #12-812D). The plate was washed with 200 μl Buffer T fifteen times on a Vacuum Manifold for MULTISCREEN® plates (Millipore Corp.). 100 μl of trypsin (Sigma Chemicals #T8642, TPCK treated) solution (100 μl/ml, in buffer T) was added to each well with a multipipettor. The plate was covered again, and vortexed for 5 mm. The cover was then removed and blotted with a paper towel to remove excess moisture. 25 μl of trypsin inhibitor (Sigma Chemicals #T9003, from soybean) solution (1 mg/ml in buffer T) was added to each well to stop the reaction, and mixed briefly on the lowest setting (uncovered) on the vortex mixer. The entire volume of each well was transferred to a new filter bottom plate (using a 96 well syringe pipettor from Midwest Scientific, St. Louis, Mo.). A standard 96 well plate was placed into the chamber of the vacuum manifold, and the contents of the filter plate were vacuumed through to the top filter plate and into the receiver plate.
For a direct luminescent measurement, five μl of the filtrate is transferred to a 0.5 ml EPPENDORF® tube containing 95 μl of LUMI-PHOS® Plus (luminescent alkaline phosphatase substrate) (Lumigen, Inc., Southfield, Mich. #P-701). The solutions are mixed well and incubated for 1 hour. After 1 hour the tubes are read individually in the luminometer with an adaptor for 0.7 ml Eppendorf tubes. (Turner Designs TD-20/20).
The reaction may also be detected by film. In this case, 95 μl of LUMI-PHOS® Plus is added to each well of an opaque 96 well plate. Five μl of the sample in the standard (clear) 96-well plate is transferred to its corresponding location on the opaque plate and mixed with the vortex mixer on the lowest setting for a few seconds. The plate is incubated at room temperature for one hour and then exposed to Polaroid Type 57 high speed film for several time intervals.
B Standards Assay
To test a new preparation of GBP for efficacy, test several concentrations of GBP with the low gold fire assayed standard (0.02 g/ton) and high gold fire assayed standard (7.59 g/ton) from PD and pick the GBP concentration, that provides the best signal to noise between the two samples. The GBP concentrations were varied between 0.001 and 0.01 mg/ml to start. Optimal protein concentration is determined by maximizing the signal with the high concentration gold sample while keeping the non-specific signal from the low gold concentration ore at a low value.
C. Specificity Assay
The procedure for this assay was the same as that in Example 2A, with the following changes. The Gold Binding Protein Solution is in PKT(50) buffer (10 mM KH 2 PO 4 , 50 mM KCl, 1% Triton X-100, pH≅3.95 (Unadjusted)) instead of Buffer T. The concentration of the GBP was at 200 μg/ml. The samples were covered in sealing tape and vortexed on high for 10 mm. After the vortex step the wells were washed with Tris Calcium Buffer (1 mM CaCl 2 , 11 mM Tris pH 8.0, pH=8.2 Unadjusted) rather than Buffer T (using the 8-pipettor, 10 washes of 200 μl). Trypsin volume was changed from 100 μl to 200 μl. Concentration remained same at 100 μl/ml. The plate was covered and vortexed for 4 mm. The transfer step was eliminated; and the contents were vacuumed through into the receiver plate. Luminometer incubation volume and time were slightly adjusted. 5 μl of filtrate sample was added to 100 μl of Lumi-Phos Plus and incubation time was shortened to 40 mm.
Example 3
Gold Recovery System (Magnetic Separation)
DYNABEADS® M-280 Tosyl-activated (Dynal A. S., Oslo, Norway, Prod. No. 142.04) (200 μl, 2 mg) are uniform, superparamagnetic, polystyrene beads coated with a polyurethane layer. The polyurethane surface is activated by p-toluenesulphonyl chloride to provide reactive groups for covalent binding of proteins (e.g. antibodies) or other ligands containing primary amino or thiol groups. The beads are washed with 1 ml 0.1 M Na Borate, pH 9.5. 40 μl goat-anti-rabbit IgG (1 μg/μl) were added to 200 μl 0.1 M Na Borate containing 2 mg beads. The beads and the antibody were incubated at room temperature on a rotating shaker overnight. A control reaction contained control beads but no antibody. The beads were washed once with 1 ml Buffer D (PBS+0.1% BSA) then once with 0.5 ml Buffer D. The mixture was blocked overnight in buffer E (0.2 M Tris pH=8.5+0.1% BSA). Wash with 1 ml PKT Buffer (10 mM KH 2 PO 4 , pH 7.0, 10 mM KCl, 1% Triton X-100). Gold beads (20 μl of a 1 mg/ml suspension, 1.5-3.0 micron, Aldrich Chemical Co. #32658-5), were mixed with 30 μl PKT and 50 μl 1.11 mg/ml GBP in 50 mM Tris pH=8.0, (final concentration is 0.5×PKT (10 mm KCl)) and incubated overnight at room temperature on a rotating shaker. The overnight incubation ensures maximum bead coverage. The beads were washed 4 times with 1 ml PKT buffer.
Anti Alkaline Phosphatase Antibody (polyclonal, Harlan Sera-Lab #ENZ-020) (1.2 mg in 120 μl PKT) was added to the GBP-Au bead solution and incubated with gentle mixing for four hours. After incubation, the beads were washed twice with 1 ml PKT buffer. Twenty μg of the resulting beads (Au plus GBP plus anti AP) were mixed with the Dynabeads and incubated with rotation for one hour. After mixing the solutions, a magnetic field is applied with a Dynal MPC-P-12 Magnetic particle concentrator for 0.5 ml Eppendorf Tubes (Prod. No: 120.10). Gold beads without GBP attached were used as a control.
Example 4
Gold Flotation
Colloidal gold (1 ml, Sigma, #G1402, 5 nM,) was added to three 1.5 ml Eppendorf tube and the tubes centrifuged for fifteen minutes in a microcentrifuge at 12,000 rpm. The supernatant was removed and one tube of the colloid was resuspended in a solution of GBP (0.333 mg/ml in 50 mM Tris pH=8.0). Two other control tubes were resuspended in ddH 2 O only. The tubes were incubated on a rotating mixer overnight to allow binding to occur. The tubes were centrifuged for fifteen minutes in a microcentrifuge at 12,000 rpm to remove excess GBP, and the colloid was resuspended in 1 ml phosphate buffer (pH=6)(43.85 ml 0.2 M NaH 2 PO 4 , 6.15 ml 0.2 M Na 2 HPO 4 ) three to four times. Valeric anhydride (2 μl, Sigma #V-6127) was added to the tube with GBP and to one of the control tubes. Mineral oil (100 μl) was added to each tube and the tubes vortexed for 2-3 minutes. The tubes were allowed to settle and the oil and water to separate.
Example 5
GBP Binding Using 1.5-3.0 Micron Spherical Au Particles
A. Preparation of Gold Beads. 10 mg of 1.5-3.0 micron Au powder (Aldrich Chemical #32.658-5) was suspended in 1 ml of 10% Hydrofluoric acid (HF) and incubated on a rotating mixer at room temperature overnight (to clean any organic debris from the beads). The beads were washed by spinning at 10,000 RPM in a microfuge for 1 minute. The supernatant was decanted and the gold beads resuspended in 1 ml PKT(50) at pH=7.0. The wash procedure was repeated four times, with the beads in a final volume of 1 ml. The beads were vortexed vigorously and 10 μl of this suspension was immediately pipetted to another 1.5 ml Eppendorf tube, yielding 100 μg of Au beads per tube.
B. Gold bead assay. 500 μl of GBP solution at 10 μg/ml in PKT(50) buffer, pH=7.0 was added to the gold containing tube and incubated for 30 minutes at room temperature on a rotating mixer (the tube was rotated end over end because the beads settle rapidly). After 30 minutes, the beads were washed three times as described above in EXAMPLE 3A.
C. Trypsinization. The final pellet was resuspended in 200 μl trypsin solution (10 μg/ml trypsin (Sigma Chemicals #T8642, TPCK treated) in trypsin buffer (10 mM Tris pH=8.0, 10 mM CaCl 2 )). After five minutes on the mixer, the Au beads were spun down again. The supernatant was assayed for AP activity by adding 5 μl of the supernatant to 100 μl Lumi-Phos® Plus and then reading in the luminometer after a 30 minute incubation.
Example 6
GBP Binding Using Gold-Coated Slides
This procedure is an improvement on the Au bead assay for determination of GBP binding ability. Using a gold-coated slide in place of the Au beads greatly reduces the variability that was previously observed, most likely due to a much more uniform and reproducible surface.
A. PNPP assay. For determination of GBP-AP alkaline phosphatase activity, 10 μl of GBP solution was added to 1 ml of the PNPP (p-Nitrophenyl Phosphate, Sigma #104-0, 52 mg in 50 ml 50 mM Tris pH 8.0). The change in absorbance was measured at an O.D. of 600 nM. Slope was multiplied by 100 to yield PNPP units per ml.
B. Gold slide assay. A glass slide (15×4 mm) was incubated in a 1.5 ml Eppendorf tube containing 1 ml of GBP solution. The concentration of GBP was around 10 μg/ml in PKT(50) buffer. The incubation was at room temperature on a shaking incubator for 30 minutes. The slide was removed and rinsed with ddH 2 O. The slide was placed into a 1.5 ml Eppendorf tube containing 1 ml Lumi-Phos® Plus and incubated on shaking incubator for 30 min. 100-500 μl samples were analyzed in a Turner TD 20—20 Luminometer.
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Methods for detecting gold and quantitating gold in ore samples utilizing a gold-specific protein are provided, including methods for multiple sample handling. Also provided are methods for extracting gold from mineral suspensions utilizing a magnetic mineral binding reagent and gold-specific protein, or hydrophobic reagent and gold-specific protein in conjunction with a flotation reagent.
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BACKGROUND OF THE INVENTION
The purpose of this invention is to construct a unique combination of elements in a gas turbine engine in order to maximize fuel economy, part power performance, and ease of maintenance. Gas turbine engines are most economical when they are run at full power and, therefore, maximum inlet temperature. Problems in economy arise, however, when a gas turbine engine must be run at less than the full power condition. This problem is most significant when the engine is used in a land vehicle as opposed to an aircraft. Fuel economy can be enhanced during the part power operation through the use of an exhaust gas regenerator to preheat the airflow entering the combustor. It is, therefore, an object of this invention to utilize an exhaust gas regenerator in as simple a manner as possible.
Pollution reduction and economy is promoted by accurate control of the fuel to air ratio in the combustor. This can best be accomplished by the use of a can-type combustor, and it is, therefore, an object of this invention to utilize this type of combustor.
To further increase the part power performance and, also, fuel economy, the power output of the engine is taken through a differential gear assembly.
Ease of maintenance is obtained through the use of substantially axial symmetrical elements and the use of a simple can-type combustor. Maintenance is further facilitated by taking the power output from the front of the engine. This tends to isolate the high temperature portions of the engine from the transmission and accessory drive elements. The engine of this invention is also constructed to eliminate heavy containment rings which are generally needed to prevent injury caused by a malfunction in the turbine compartment. In addition, this unique engine will have unlimited flexibility with respect to size both in diameter and length.
It is, therefore, the object of this invention to assemble the most desirable components of a gas turbine engine from the standpoint of fuel economy and performance while arranging and packaging these components to provide simplicity of manufacture and ease of maintenance.
SUMMARY OF THE INVENTION
The gas turbine engine of this invention is provided with a duct which directs airflow from the forward inlet to a compressor from which the pressurized air is radially diffused into an annular regenerator. The airflow is directed rearward where it is preheated in the regenerator through the transfer of heat from the exhaust of the engine. The duct is constructed to take the rearward flowing preheated air and turn it into a forward extending can-type combustor where the air is mixed with fuel and burned to produce a high energy gas stream. The high energy gas from the combustor is directed in the forward direction, first, through a power turbine and then through a gasifier turbine where work is performed and the gasflow drops in pressure and temperature. The gasflow is then exhausted from the turbine compartment over the regenerator duct to provide heat thereto. It is then discharged into the atmosphere. The combustor and turbine compartments are located within the annular regenerator.
Power from the gasifier turbine shaft is transmitted through a spline to the compressor drive shaft. These shafts are constructed with an interior concentric passage through which the power turbine shaft may pass to the front of the engine where it is connected to the differential gear assembly.
DESCRIPTION OF THE DRAWING
This invention is described in more detail below with reference to the attached drawing and in said drawing:
FIG. 1 is a longitudinal view of a gas turbine engine partly in section;
FIG. 2 is a sectional view along the section line 2--2 of FIG. 1; and
FIG. 3 is a sectional view along the section line 3--3 of FIG. 2 with the horizontal portion of section line 3--3 rotated into a vertical position.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawing, there is shown a gas turbine engine 10 of the turboshaft type. Airflow (indicated by small arrows 12 throughout the engine) enters the engine duct 14 at inlet 14a and is distributed to a compressor 16 rotatably mounted in duct 14 on shaft 32. Compressor 16, as shown, consists of an axial flow impeller 18, and a centrifugal flow impeller 20 which directs the airflow 12 radially into the diffuser section 22 of duct 14.
The portion of duct 14 in which compressor 16 is mounted includes a forward compressor housing 24 and a compressor frame 26. The latter carries the bearings 28 and 30 which journal the hollow compressor drive shaft 32 upon which the compressor impellers are commonly mounted. The attitude of the guide vanes 34 and 36 which are mounted on the forward compressor housing 24 at the inlet of each stage of the axial flow rotor 18 are variable to maintain efficient compressor operation over the entire flow range. Mounted on top of the compressor frame 26 is the accessory drive gear box 38 which has an input shaft 40 driven by a bevel gear 42 fixed on the compressor shaft 32. Mounted at the bottom of the compressor frame 26 is the reservoir 44 for engine oil.
The compressed and diffused airflow is next preheated in a regenerator portion 46 of duct 14 which is a heat exchanger of the fixed-boundary type, i.e., a recuperator. Upon leaving the diffuser portion 22 of duct 14, the air enters the front header 48 to flow in the channels 50 which distribute the airflow to the forward end of the annular recuperator core 52. The recuperator core 52 is supported between the front header 48 and the rear header 54 which are structurally joined by the U-shaped shell 56 as shown in FIG. 2 surrounding the core 52.
From the recuperator 52 the preheated air next flows in duct 14 to the combustor section 58 which is supported from the rear header 54. The duct 14 in rear header 54 directs the preheated air to the channels 60 in the rear frame 62 formed by joining front wall 64 and rear wall 66 by webs 68. A central opening in the front wall 64 supports a cylindrical combustor housing 70 which defines the combustor section 58 of duct 14. A similar opening in the rear wall 66 is closed by a rear cover plate 72.
A cylindrical combustor liner 74 within which air and fuel are burned is concentrically spaced in the combustor housing 70 by local supports 76 and 78. A fuel nozzle 80 carried by the rear cover plate 72 protrudes into the frusto-conical end 82 of the liner 74. Preheated, compressed air flows from the annular passage 84 around the liner 74 into the liner interior through the liner end 82 and through openings (not shown) in the liner walls thereby providing air for burning the fuel, mixing the resulting hot gas (indicated throughout by larger arrows 86) and cooling the walls of liner 74. The combustor 58 described is well known in the art as the single can type. The discharge end of the liner 74 slip fits into an outer gas guide shell 88 which is connected by hollow struts 90 to a parabolic deflector 92 in which a passage is constructed. The deflector 92 and the shell 88 define a section of duct 14 which directs the airflow 12 to the power turbine nozzle 100 formed by the outer shroud 96 and inner shroud 98.
The gas turning vanes 102 are mounted in the nozzle 100 to direct the airflow to the blades of turbine rotor 114 and have internal passages (not shown) communicating with passages (not shown) in the inner shroud 98 for receiving cooling air. The internal vane passages discharge to the outer surfaces of the vanes 102 providing film cooling as well as convective cooling as is known in the art. The cooling air flows from the annular passage 84 through the struts 90 into the passage of the parabolic deflector 92, through the inner shroud 98 and into the vane passages.
The section of duct 14 immediately following the turbine nozzle 100 is defined by the interturbine frame 106. The power turbine nozzle 100 is supported by bolting not shown its outer shroud 96 to the outer wall 104 of the interturbine frame 106. The outer wall 104 is provided with a sliding seal 108 to the combustor housing 70. The interturbine frame 106 additionally comprises an inwardly extending flange 110 integrally joined to the outer wall 104 by interturbine struts 112.
The bladed power turbine disk 114 is integrally mounted on a shaft 116 which is supported for rotation in the flange 110 of interturbine frame 106 by bearings 118. A two-stage gasifier turbine 120 is mounted for rotation downstream from the power turbine 114 in a section of duct 14 formed by a support sleeve 122. Support sleeve 122 is bolted between the front header 48 and the interturbine frame 106. Vaned nozzles 124 and 126 and a vaned discharge flow straightener 128 are mounted in duct 14 within sleeve 122. The gasifier turbine rotor 126 is fixed on a hollow shaft 132 journaled by bearings 134 retained by the interturbine frame 106. The gasifier turbine shaft 132 is splined to the compressor drive shaft 32 forming a compressor spool. The gas exhausting from the gasifier turbine 120 is turned by a deflector 136 into a passage 138 in the front header 48, which has several angularly spaced webs 139. The gas is then directed by a cylindrical gas guide 140 to the recuperator core 52 while passing over the recuperator core 52, the gas flows between the core 52 and its U-shaped shell 56 and then exhausts at the top into the atmosphere, or, as could be provided into a connecting exhaust duct (not shown).
At the inlet end of duct 14 a central cavity is formed in which a differential gearing 142 is supported. The differential gearing 142 has a sungear 144 with an integral shaft 146 providing a high-speed power takeoff for the engine 10. The sungear 144 meshes with planetary pinions 148 journaled in rotatable fore and aft carriers 150 and 152. The aft carrier 152 has an integral shaft 154 which is splined to the power turbine shaft 116 forming a power spool. The planetary pinions 148 mesh with an internal ring gear 156 having an integral hollow shaft 158 splined to the compressor shaft 32.
An intershaft bearing 160 may be provided to allow the power turbine shaft 116 and the concentric compressor shaft 32 to mutually support each other. These concentric shafts corotate in the particular arrangement described for the differential gearing 142, thereby minimizing the relative speed between the inner and outer races of the intershaft bearing 160 and allowing the bearing 160 to have long operating life. If required, a bumper bearing (not shown) could be utilized between the shafts 116 and 32 because of their low relative speed to limit deflections during critical speed operation.
For maximum braking, if desired, the corotation also permits a clutch (not shown) to be installed to lock the power turbine shaft 116 to the compressor shaft 32 so that the load would drive the compressor 16. During braking, the compressed air would be vented to atmosphere at the compressor exit.
Cooling of the turbines is commonly accomplished with a small flow of compressed air bled from the main engine airflow after the last or an intermediate stage of the compressor. In this engine, for improved performance, the consumption of compressed air for cooling of the bladed rotor in the first stage turbine is kept small by precooling the cooling air and by drawing cooling air only when the turbines are running hottest, which is at high engine power.
Turbine cooling air flows from the compressor diffuser 22, through a control valve 162, to the compressed air side of a cooler 164. External piping 165 directs the cooling air to a passage 166 in front header 48 formed through a solid portion of the air diffuser 22 and then into a passage 167 within one of the several front header webs 139. The cooling air then flows through piping 168 retained in the gasifier turbine support sleeve 122, through a channel 169 in the outer wall 104 of the interturbine frame 106, through passage 170 in one of the interturbine struts 112 and into a channel 172 within the interturbine flange 110. The channel 172 opens to a series of parallel nozzles 174 which discharge cooling air to ventilate the downstream interturbine cavity 176. The channel 172 also feeds a series of swirl nozzles 178 which direct cooling air jets toward a series of apertures 180 in the downstream face of the power turbine disk 114. The apertures 180 are the openings to parallel passages 182 in the disk 114 for ducting cooling air to cooling passages 184 within the blades 186. These blade cooling passages 184 discharge cooling air along the blade surfaces and into the gas stream. The swirl nozzles 178 are oriented at and in the direction of rotation of the apertures 180 in the turbine disk 114 in order to minimize the relative velocity between the issuing jets and the disk 106 so that most of the temperature drop experienced by the cooling airflow during acceleration in the nozzles 178 is preserved upon impinging the disk 114. A small portion of the airflow from the swirl nozzles 178 does not enter the disk passages 182, but ventilates interturbine cavity 188.
The turbine cooling air rejects heat to atmospheric air induced into the involuted duct 190 and propelled through the atmospheric air side of the cooler 164 by a fan 192 which operates only at high engine power when its electromagnetic clutch (not shown) is engaged to an output shaft (not shown) of the accessory gear box 38. The electromagnetic clutch may be controlled by signal from an element sensing one of many possible engine variables, for example, gasifier turbine discharge temperature, power turbine discharge temperature, compressor discharge temperature, compressor speed or fuel flow.
Locating the combustor at one end of an engine allows a single can combustor to be placed with its flow axis in line with that of the turbines. This preserves the inherent capability of a single can combustor to generate hot gas without large local hot spots which are very detrimental to the turbine nozzle vanes downstream. This capability results from several factors: A liner in a single can combustor, having less surface for a given volume than an annular combustor or a multiple can combustor, requires less air for cooling of its surfaces making more air available for mixing of the gas. Only one fuel nozzle need be used, and its spray pattern can be accurately regulated to avoid local overconcentrations of fuel. Moreover, the spray obtainable from the single nozzle can be tailored to produce a desirable temperature pattern such as a hot annular zone in the gas within the combustor. The pattern will persist in the annular turbine channel as a radial gradient with higher temperatures near the center of the channel and cooler temperatures near the walls thereby obviating heavy cooling of the turbine channel walls. Consequently, the turbine cylinders experience lesser and fewer thermal gradients and smaller distortions allowing tight turbine clearances to be maintained for good performance. Finally, the fuel passages in the single nozzle are large and not susceptible to plugging so that heavy (viscous) fuels can be burned as well as light fuels.
In this engine 10, the construction of the compressor 16 when examined in detail reveals a number of advantageous features. The compressor frame 26 is a large structural member which defines most of the compressor sections of the duct 14 comprising an outer wall 194 and an inner wall 196 connected by the intercompressor struts 198. The inner race of the compressor aft bearing 30 is clamped on the compressor shaft 32 between a bevel gear 42 which butts against a shoulder 199 on the shaft 32 and a seal ring 201 which is axially loaded by the centrifugal impeller 20 which in turn is axially loaded by the rearward compressor shaft nut 204. The outer race of the compressor aft bearing 30 is fixed in the inner wall 196 very near the centrifugal impeller 20 and carries both thrust and radial loads. The compressor fore bearing 28 is mounted within the axial flow impeller 18 in a conical extension 200 of the inner wall 196; thus, distributing the support of the compressor drive shaft 32 forward and rearward of the center of a large structural member 26, which also forms the outer wall 194 that shrouds the centrifugal impeller 20 and most of the axial impeller 18, minimizes deflections and thermal distortions which vary the clearances between the impellers and their shrouding walls. This arrangement allows close clearances to be set and maintained for efficient compressor performance.
In the engine 10 described above, the arrangement of the major components, the design of their housings and the grouping of parts into unitary subassemblies permits access to major components without total engine disassembly. Since the main structural elements of the engine are secured by bolts removal of one or two components or subassemblies exposes any of the major components as shown by the following examples: Unbolting the rear cover plate 72 from the rear frame 62 allows removal of the combustor liner 74. Separating the rear frame 62 from the rear header 54 allows the combustor 58 as a unitary subassembly to be withdrawn rearward. Subsequently, unbolting the gasifier turbine cylinder 122 from the front header 48 allows the turbines 94 and 120 to be withdrawn rearward as a unitary subassembly. The differential gearing 142 is accessible from the front of the engine 10. The housing of duct 14 is unbolted from the forward compressor housing 24 to expose the rear of the differential gearing 142 and the forward compressor shaft nut 202. Removal of this nut 202 allows withdrawal of the axial impeller 18. Alternatively, separating the compressor frame 26 from the front header 48 at 208 allows the rearward compressor shaft nut 204 to be removed and the centrifugal impeller 20 to be withdrawn.
The engine 10 has no major longitudinal joints in its outside housings and only a few radial joints, which are more readily sealable, minimizing, thereby, the potential leakage of compressed air or gas and the resulting detriment to engine performance. Most of the major engine parts are axially symmetric which is conducive to low cost fabrication by casting and spinning. The engine differential gearing 142, the accessory gear box 38 and the oil reservoir 44 are located at the front of the engine 10 minimizing adverse exposure to hot parts which are segregated to the rear. Any required transmission (not shown) could be conveniently located adjacent to the engine power takeoff shaft 146 at the front of the engine 10 and desirably remote from the rearward hot section.
In addition, the recuperator core 52 surrounding the turbines 94 and 120 will retain flying fragments should a turbine rotor burst from centrifugal forces. Consequently, no additional precautionary shielding is needed for containment of the hot, rotating section of the engine.
Yet another advantage of this engine 10 is that its arrangement does not restrict enlarging the radial or longitudinal size of any of the major components, namely the compressor 16, the turbines 94 and 120, the combustor 58 or the recuperator 52. The lengths of the compressor drive shaft 32 and the power turbine shaft 116 are not limited by critical speed considerations because of the intershaft bearing 160 and the feasibility of employing bumper bearings as already described.
The oil supplied throughout the accessory gear box 38 for lubrication drains directly into the engine oil reservoir 44 below so that a separate scavenge pump and sump for the gear box are obviated. The accessory gear box 38 contains the oil supply pump 210 which draws from the reservoir 44 through a suction pipe 212 and discharges through piping (not shown) for distributing oil throughout the gear box 38 and through a supply pipe 214 leading to the turbine bearings 134 and 118. The supply pipe 214 connects with an oil passage 216 formed through a solid portion of the air diffuser 22. Continuing from the diffuser oil passage 216, connected in series are a passage 218 through one of the several front header webs 139, piping 220 retained by the gasifier turbine cylinder 122, and a passage 222 through one of the several interturbine struts 112. From the latter passage 222, oil is distributed to the turbine bearings 134 and 118.
The resulting oil froth is withdrawn from the bottom of the scavenge chamber 222 by a series of scavenge passages 224 communicating with a scavenge pump 226 in the accessory gear box. The scavenge passages 224 are contained in the lower portion of the engine 10, but follow a similar route as that already described for the oil supply passages. They are of larger diameter than the oil supply passages to accommodate the larger volumetric flow of oil froth. The froth is discharged through a short pipe 228 into the reservoir 44 where the oil settles out from the entrained air.
The turbine cooling air supply passages, the oil supply passages and the oil scavenge passages are preferably inexpensively provided in the engine housings and casings by casting the housing and casing walls with the passages in situ. Alternatively these auxiliary passages can be machined into the walls. Containing the auxiliary passages within the housing and casing walls obviates the use of external piping which is vulnerable to external damage and adds excess bulk and weight to an engine.
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A gas turbine engine is constructed having a forward differentially geared power output with an adjacent inlet for the introduction of airflow to the engine. After the airflow is compressed, it is discharged into an annular regenerator which is heated by exhaust gases. A reverse flow can-type combustor is located within the annular regenerator and receives the preheated air therefrom. The exhaust gas from the combustor is directed forward, first, to the power turbine and then to the gasifier turbine, after which it is exhausted through the regenerator.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to semiconductor integrated circuit (IC) chips which can be tailored to include a fuse. The invention further relates to a method of making the improved circuit.
[0003] 2. Related Art
[0004] Laser deletion of thick metal fuses is difficult due to the mass of metal that must be removed without damage to surrounding and underlying structures.
[0005] In the manufacture of semiconductor integrated circuits, wiring layers are deposited and defined and interconnected with conductive vias through a series of well known photolithography and metal etching steps. Each such wiring level is coated with a layer of a glassy protective material, known as a passivation layer, which protects and insulates the wiring of each layer. The creation of integrated circuits with such multiple wiring layers is well known to the semiconductor art.
[0006] In some circuits, such as CMOS logic circuits, the fuses designed in the circuit are often formed in regular arrays in the upper most layers of wiring and in a position such that other wiring is not placed immediately over or under the fuses. In such arrays the fuses are often aligned in parallel rows and placed as closely together as is possible. By opening selected ones of these fuses the logic elements of the circuits can be arranged in different combinations to perform different logic functions or correct manufacturing defects.
[0007] These fuses are typically opened by applying a laser pulse of sufficient size, duration and power as to superheat and vaporize the metal forming the fuse. This superheating of the fuse and its vaporization fractures and blows away a portion of the overlying glassy protective layer creating a saucer shaped crater in the protective layer. When the protective layer ruptures, cracks can radiate outwardly causing additional damage such as breakage of, or the uncovering of, adjacent fuse elements. Such uncovering of the adjacent elements can cause subsequent corrosion and premature failure of the circuit. While fuses are typically opened using a laser, they may also be opened by passage of electrical current or exposure to an ion beam which ablates (or removes or sputters) away the fuse The described invention is also useful for these methods of fusing.
[0008] The reader is referred to the following patents related to fuses including “Array Protection Devices and Fabrication Method,” U.S. Pat. No. 5,523,253, and “Array Fuse Damage Protection Devices and Fabrication Method,” U.S. Pat. No. 5,420,455, both to Richard A. Gilmour, et al. and of common assignee to this invention, the contents of which are incorporated herein by reference in their entireties.
[0009] Fuses are used in semiconductor chips to provide redundancy, electrical chip identification and customization of function. For designs having three (or more) layers of wiring, the fuses are typically formed from a segment of one of the wiring layers, e.g., the “last metal” (LM) or “last metal minus one” (LM−1) wiring layer. Fusing, i.e., the deletion of a segment of metal fuse line, is accomplished by exposing the segment of metal fuse line to a short, high intensity pulse of “light” from an infra-red (IR) laser. The metal line absorbs energy, melts and expands, and ruptures any overlain passivation. The molten metal then boils or vaporizes out of its oxide surroundings, disrupting line continuity and causing high electrical resistance. A “sensing” circuit is used to detect fuse segment resistance.
[0010] Laser deletion of thick metal fuses is difficult due to the mass of metal that must be removed without damage to surrounding structures. As the mass of the fuse link increases or the melting temperature of the fuse link metal increases, higher laser energies and longer (or multiple) laser pulses are required to accomplish deletion. Higher energies and longer pulses provide sufficient energy to adjacent and underlying structures, e.g., silicon under the fuse area, to cause severe damage to the interlayer dielectric (ILD) oxide and adjacent fuse wiring. What is needed is a way to eliminate the need to use high laser energies.
SUMMARY OF THE INVENTION
[0011] The present invention includes a method for forming a thin pedestal fuse segment in a thick last metal (LM) wiring line, including the steps of forming a last metal minus 1 (LM−1) wiring layer and an overlaying oxide inter layer dielectric (ILD) using conventional techniques, depositing a layer of nitride using conventional techniques, wherein a thickness of the nitride layer is an approximate- thickness desired for the thin pedestal fuse segment, defining with a resist layer and mask the LM wiring line that will contain a fuse link, wherein the fuse link is not yet imaged, etching the nitride layer and the oxide ILD, forming a thick line trench, stripping the resist, applying a new layer of resist and opening an image, defining the fuse link overlapping adjacent ends of an interrupted LM trench, etching the nitride layer using an etchant, stripping the new layer of resist, applying another layer of resist and imaging and etching via contacts, wherein the via contacts will connect the LM to the LM−1 wiring layers, stripping the another layer of resist, filling the wiring trench with at least one metal, and polishing to remove unwanted and excess metal, forming a LM damascene fuse line having the thin pedestal fuse segment.
[0012] In one embodiment of the invention, the oxide layer includes silicon dioxide. In another, the nitride layer includes silicon nitride. In yet another embodiment, the deposition steps can include chemical vapor deposition (CVD)and physical vapor deposition (PVD) techniques.
[0013] In one embodiment of the invention, the etching step includes using an etchant that is relatively selective to the nitride. In another embodiment, if the nitride layer is thin, selectivity is not required.
[0014] In another embodiment of the invention, the wiring trench can be filled with copper.
[0015] In an embodiment of the invention, the polishing step can include using at least one of a chemical and a mechanical polishing technique.
[0016] In another embodiment of the invention, a method for forming a thin pedestal fuse segment in a last metal (LM) wiring line includes the steps of forming a last metal minus 1 (LM−1) wiring layer and an overlaying oxide inter layer dielectric (ILD) layer using conventional techniques, depositing a layer of nitride using conventional techniques, wherein a thickness of the nitride layer is an approximate thickness desired for the thin pedestal fuse segment, defining with a resist layer and mask the LM wiring line that will contain a fuse link, wherein the fuse link is not yet imaged, etching the nitride layer and the underlying oxide ILD, forming a thick wiring line trench, stripping the resist layer, applying a new layer of resist and opening an image over an interrupted segment, etching selectively the oxide to form vias using an etch selective to the oxide, leaving exposed a nitride pedestal cap, etching selectively the nitride pedestal cap using an etch selective to the nitride, stripping the new layer of resist, filling the wiring line trench with at least one metal, and polishing to remove unwanted and excess metal, forming LM damascene fuse line having the thin pedestal fuse segment.
[0017] In an embodiment of the invention, the first etching step includes using an etchant that is relatively selective to the nitride.
[0018] In another embodiment, the second etching step includes using an etchant, wherein if the nitride layer is thin, selectivity is not required.
[0019] In yet another embodiment, the invention includes filling the wiring line trench. with copper metal. In another embodiment, the polishing step includes using a chemical or a mechanical polishing technique.
[0020] In another embodiment of the invention, a metallization structure formed on a semiconductor substrate, includes an insulator structure formed on the substrate, the insulator structure having an upper layer and a lower layer, the upper layer being thinner than the lower layer, the insulator structure having a plurality of openings therein of varying depth, and a metal structure inlaid -in the insulator structure the metal structure having first and second portions and a third portion there between that is substantially more resistive than the first and second portions, the third portion having a thickness that is substantially similar to the thickness of the upper layer of the insulator structure. In an embodiment of the invention, the upper layer includes a nitride layer and the lower layer includes an oxide layer. In another embodiment of the invention, the metal structure includes copper.
[0021] An advantage of the present invention is that the claimed fuse structure allows formation of “easy to delete” thin metal fuses within segments of thick metal lines. The claimed structure is particularly applicable to wiring layers formed from “high” melting temperature metals and those defined using a damascene process.
[0022] The present invention provides an integrated path to achieve high yield fusing for technologies that use thick wiring layers or wiring layers comprised of high melting temperature metals. The structure of the present invention separates the thickness of the fuse segment from the remainder of the wiring line. The structure is compatible with thick (such as, e.g., 0.8μ), very thick (such as, e.g., greater than 1.2μ wiring) and very thin (such as, e.g., less than 0.5μ fuses). The present invention is particularly valuable for technologies using damascene to define wiring levels. One example of applicable technology is in development of central processing unit (CPU) chip sets for CMOS semiconductor integrated circuit chips.
[0023] Further features and advantages of the invention, as well as the structure and operation of various embodiments of the invention, are described in detail below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The foregoing and other features and advantages of the invention will be described with reference to the accompanying drawings. In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements. Also in the figures, the left most digit of each reference number corresponds to the figure in which the reference number is first used.
[0025] [0025]FIGS. 1A through 1G depict a cross-section of an integrated circuit during fabrication of the fuse of the present invention;
[0026] [0026]FIG. 2 depicts a f low diagram of the steps of an example process of this invention;
[0027] [0027]FIGS. 3A through 3F depict a cross-section of an integrated circuit during an alternative fabrication technique embodiment of the fuse of the present invention;
[0028] [0028]FIG. 4 depicts a flowchart illustrating an example technique of fabricating the structure of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The preferred embodiment of the invention is discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the spirit and scope of the claimed invention.
[0030] Overview of Present Invention
[0031] Laser delete of metal fuses becomes more difficult as the thickness of the metal fuse increases. A section of last metal (LM) line is formed which is left intact in an unblown fuse and is removed in a blown fuse, in order to provide a high resistance. A fuse is blown by shining an infrared (IR) laser on the metal line. To make the line high resistance, all the metal of the fuse must be removed. This becomes difficult as the fuse gets thick, i.e., becomes deeper and deeper, requiring a higher energy IR laser. After sufficient depth, the metal line can not be removed without seriously damaging surrounding and underlaying structures. This invention provides a structure which creates a locally, thin, easy-to-delete line section and provides for the use of very thick wiring everywhere else on the circuit, chip or wafer. The present invention enables the use of very thick wiring to carry large amounts of current about the chip from one area to another, while still providing functional fuses, i.e. functional at low laser energies, such that no damage is sustained by surrounding circuitry.
[0032] Two exemplary fabrication sequences are described herein, both of which result in a thin fuse embedded in a thick wiring layer. The present invention advantageously permits the thickness of a fuse to be controlled, decoupled from the surrounding metallic wire line by varying the thickness of an upper nitride layer.
[0033] The invention includes a metal wiring line containing a fuse link segment where the fuse link segment is thinner than the adjacent fixed wiring line of which it is a part. The thickness of the fuse link segment can be adjusted independent of the remainder of the wiring line. Fuse link horizontal dimensions can be adjusted independently of the wiring line dimensions if desired. The present invention is particularly useful for back end of line (BEOL) wiring structures, where a “thick” wire option is employed.
[0034] It will be apparent to those skilled in the art, that the present invention is not restricted to LM or LM−1 wiring layers, but can be used at any wiring layer.
[0035] An example embodiment of the structure of the present invention can be formed using a technique including the following steps of:
[0036] 1. forming an LM−1 wiring layer and its overlaying dielectric layer using conventional techniques;
[0037] 2. depositing a layer of silicon nitride (i.e. referred to as the “nitride layer”) using conventional techniques, such as, e.g., chemical vapor deposition (CVD), wherein the thickness of the silicon nitride layer is the approximate thickness desired for the “thin” fuse segment that will be formed in the last metal (LM) wiring line, e.g. less than or equal to 0.5μ;
[0038] 3. defining the LM wiring line that will contain the fuse link, but not imaging the fuse link, at this time;
[0039] 4. etching the nitride and an underlying interlayer dielectric (ILD) (such as, e.g., silicon dioxide) (i.e. referred to as “the oxide layer”) to form a thick line trench, typically of greater than or equal to (>=) 0.8μ; stripping the resist;
[0040] 5. applying a new layer of resist and opening an image to define the fuse link that overlaps adjacent ends of the interrupted LM trench;
[0041] 6. etching the silicon nitride using an etchant that is relatively selective to the silicon nitride, wherein if the silicon nitride is thin, selectivity is not required; stripping the resist;
[0042] 7. applying a new layer of resist and image and etching the via contacts that will connect LM to LM−1 wiring layers; stripping the new layer of resist; and
[0043] 8. filling the wiring trench with the metal or metals of choice and chemically and/or mechanically polishing (stopping on the nitride), removing unwanted and/or excess metal. The preceding process is described further with respect to FIGS. 1 A- 1 G and FIG. 2, below.
[0044] In an alternative embodiment, after defining the trench which will hold the conductor line (i.e., step 4 above), applying a new layer of resist (step 5) and opening images defining the vias and fuse link. Specifically, using an etch selective to oxide the technique first etches the vias, then using an etch selective to nitride the tehnique creates the shallow trench for the fuse link. The resist can then be stripped and the wiring trench can then be filled with one or more metals. The preceding alternative process is described further with reference to FIGS. 3 A-F and 4 .
[0045] Example Detailed Implementation of Specific Embodiments of the Present Invention
[0046] [0046]FIGS. 1A through 1G depict a cross-section of an integrated circuit during fabrication of the fuse of the present invention. FIG. 2 depicts a flowchart 200 illustrating an example technique of fabricating the structure depicted in FIGS. 1A through 1G.
[0047] [0047]FIG. 2 begins with step 202 which can continue immediately with step 204 . In step 204 , an interrupted fuse line is formed including a resist layer, a nitride layer, an oxide layer and a last metal minus one (LM−1) layer. Specifically, interrupted fuse line is formed by placing a resist layer over the previously deposited nitride layer. The nitride layer can include a material such as, e.g., silicon nitride, deposited using conventional methods such as, e.g., chemical vapor deposition (CVD), over the previously deposited oxide layer. The oxide layer can include a material such as, e.g., silicon dioxide, deposited using a conventional method such as, e.g., chemical vapor deposition(CVD) on the previously deposited LM−1 layer. The thickness of the silicon nitride layer can be selected according to the approximate thickness desired for the resulting “thin” fuse segment (see FIG. 1G, below) which is to be formed in the last metal (LM) wiring line. In one embodiment, the desired thickness of the “thin” fuse segment can be, e.g., 0.5μ or less. In another embodiment, the desired fuse segment can be, e.g., 0.8μ or less. In yet another embodiment, the desired fuse segment can be, e.g., 0.3μ or less. Fuse thicknesses can be adjusted to provide advantageous chip yields. Table 1, below, illustrates exemplary fuse thicknesses and some observed fuse yields associated with certain example fuse segment thicknesses. An example of the structure formed by step 204 is depicted in FIG. 1A.
TABLE 1 Fuse Metal Thickness Fuse Fuse Structure Material of fuse Fusing Parameter Yield Thick LM Copper 1.2 μ Single Pass 71.9% Thin LM Copper 0.5 μ Single Pass 99.9%
[0048] [0048]FIG. 1A illustrates a semiconductor structure including resist segments 102 a , 102 b and 102 c formed on a thin upper nitride layer 104 which overlays an inter layer dielectric (ILD) oxide layer 106 which in turn overlays last metal minus 1 (LM−1) layer segments 108 a and 108 b.
[0049] From step 204 , flowchart 200 can continue with step 206 . In step 206 , the nitride layer and oxide layer can be etched to create a “line” trench, and the resist layer can be stripped. The structure formed by step 206 is depicted in FIG. 1B.
[0050] [0050]FIG. 1B illustrates the semiconductor structure of FIG. 1A following etching of the nitride and oxide layers 104 and 106 , yielding oxide layer 106 a including exemplary line trenches and pedestals. Nitride 104 is etched leaving nitride segments 104 a , 104 b and 104 c remaining capping the pedestals of oxide layer 106 a , formed by stripped resist segments 102 a , 102 b and 102 c . LM−1 segments 108 a and 108 b remain overlaid by the oxide ILD layer 106 a.
[0051] From step 206 , flowchart 200 can continue with step 208 . In step 208 , resist can be applied and an image can be opened using a mask or reticle over resist segments and interrupted center pedestal oxide segment, leaving uncovered the interrupted center pedestal oxide segment and covering the other oxide pedestal portions where the nitride layer will be retained. The resulting structure of the material is illustrated in FIG. 1C.
[0052] [0052]FIG. 1C illustrates the semiconductor structure of FIG. 1B following application of resist segments 110 a and 110 b and opening an image mask over interrupted center oxide segment of oxide 106 a having nitride segment cap 104 b , leaving resist segments 110 a and 110 b , protecting nitride segment caps 104 a and 104 c , respectively. LM−1 segments 108 a and 108 b remain overlaid by the oxide ILD layer 106 a.
[0053] Photoresist can be dispensed with a wafer structure stationary or rotating. A uniform resist thickness is preferred.
[0054] After resist coating is complete, the wafer can be transported to a softbake station which can bake by direct conduction at a specified temperature and time.
[0055] The resist film is sensitive to specific wavelengths of ultraviolet light (UV). The wafer/resist combination can be inserted into a mask aligner, which can contain optics, a UV light source, and the circuit layer image contained on a mask or reticle, which is to be transferred to the resist film.
[0056] A development step can form the mask image by selectively removing exposed (or unexposed) regions in the positive (or negative) photoresist film. Wafers can be cassette loaded onto a developer/hardbake track and can be sent to a developer station. Developer solution can be dispensed to flood the wafer, and the wafer can remain idle while development proceeds for a time, and then a spin/rinse cycle or cycles can complete the process. An alternate technique can employ a temperature controlled bath where wafers are batch developed using agitation.
[0057] From step 208 , flowchart 200 can continue with step 210 . In step 210 , the center nitride cap segment over center interrupt pedestal can be selectively etched away and the resist layer can then be stripped away. The center nitride cap segment, if sufficiently thin, can be etched without a selective etchant. It will be apparent to those skilled in the art that part of the oxide layer adjacent to the center pedestal can be removed during this etching process, if not covered by resist segments 110 a and 110 b , as shown in FIG. 1D. The resulting structure formed by step 210 is illustrated in FIG. 1D.
[0058] The patterned photoresist can expose the underlying material to be etched. The photoresist can be robust enough to withstand wet (acidic) and dry (plasma or reactive ion etching (RIE)) etching environments with good adhesion and image continuity, as well as the force of an implanter beam when used as an implantation mask.
[0059] Resist stripping can include complete removal of the photoresist after the masking process to prevent contamination in subsequent processes. There are many photoresist solvent (premixed) strippers available that will remove positive and negative photoresist (+PR and −PR) without adversely affecting the underlying material. A temperature controlled bath can be used for batch stripping of photoresist followed by appropriate rinsing. Ozone plasma(O 3 ) can also be effective in removing photoresist.
[0060] [0060]FIG. 1D illustrates the semiconductor structure of FIG. 1C following etching of interrupted nitride cap segment 104 b of oxide 106 a , and stripping of resist segments 110 a and 110 b , leaving exposed the center pedestal portion of oxide 106 a and nitride caps 104 a and 104 c . LM−1 segments 108 a and 108 b remain overlaid by the oxide ILD layer 106 a.
[0061] From step 210 , flowchart 200 can continue with step 212 . In step 212 , resist can be applied and an image can be opened using a mask for defining vias to the LM−1 layer forming resist segments leaving uncovered the intended locations of the vias and covering the center pedestal portion of the oxide and the two nitride capped pedestals. The resulting structure formed by step 212 is illustrated in FIG. 1E.
[0062] [0062]FIG. 1E illustrates the semiconductor structure of FIG. 1D following application of resist segments 112 a , 112 b and 112 c over pedestals portions of oxide 106 b including nitride cap segments 104 a and 104 c and opening an image mask so as to leave uncovered by resist portions of oxide 106 a intended as locations of vias to LM−1 segments 108 a and 108 b . LM−1 segments 108 a and 108 b remain overlaid by the oxide ILD layer 106 a.
[0063] From step 212 , flowchart 200 can continue with step 214 . In step 214 , the oxide segments intended as locations of vias to LM−1 can be selectively etched away and the resist segments can then be stripped away, leaving a structure include vias and line trenches ready for a damascene metallization fill. Various etching techniques can be used including, e.g., wet etching and dry etching. Wet etching can use various mixtures of hydrofluoric acid and water (e.g., 10:1, 6:1, 100:1), and can include a buffering agent such as ammonium fluoride for a slower, more controlled etch rate. Although relatively inexpensive, wet etching can also lead to severe undercutting since it is an isotropic process, i.e. proceeding at nearly equal rates in all directions, which can make it impractical. To avoid encroachment, dry, or plasma etch technology, using, e.g., a glow discharge to ionize an inert gas (i.e. reactive ion etching (RIE)physical sputtering) can be used to set up very anisotropically (i.e. directional) etched features, providing for higher circuit densities. When multiple layers are involved in dry etching process, such as silicon nitride over silicon dioxide, it is important to know the relative etch rates of the two materials in the available etchants. This “selectivity” will determine if significant etching of underlying layers will occur. Plasma etch processes, since they are basically chemical by nature exhibit better selectivity as compared to RIE physical sputtering processes. To etch the oxide layer using plasma etch CF 4 , CHF 3 and NF 3 gases can be used, for example, with an etch rate of greater than 5000 angstrom per minute. The resulting structure formed by step 214 is illustrated in FIG. 1F.
[0064] [0064]FIG. 1F illustrates the semiconductor structure of FIG. 1E following etching of oxide 106 b to form vias therein. FIG. 1F depicts oxide 106 b with etched vias yielding oxide portions 106 c , 106 d and 106 e . Oxide portions 106 c and 106 e have nitride segments 104 a and 104 c capping them, respectively. And center pedestal 106 d is now ready for damascene fill to form a thin line fuse of thickness approximately equal to original nitride segment 104 b . The vias formed by etching in-step 214 of oxide 106 b provide access to LM−1 segments 108 a and 108 b as shown.
[0065] From step 214 , flowchart 200 can continue with step 216 . In step 216 , the trench formed by the preceding steps can be filled with one or more layers of metal or barrier layers followed by metal and can be polished using a chemical, mechanical polishing process to form a last metal (LM) damascene fuse line link having a thin region of thickness approximately equal to the nitride layer thickness. Metal is used in semiconductor processing for creating low resistance paths. Barrier layers are used to prevent metal interaction with the surrounding dielectric. Metal and barrier layers can be put down by, e.g., the chemical vapor deposition(CVD) process, physical vapor deposition (PVD) sputtering process, evaporation, and plating. For example, using CVD, WF 6 can be used to deposit tungsten (W). Copper can be deposited using a sputtering process or plating. Physical vapor deposition can be done by an evaporation metallization process and a sputtering deposition process. Copper deposition can include depositing Ta or TaN as a liner or barrier layer between Cu and Si. The resulting structure formed by step 216 is illustrated in FIG. 1G. From step 216 , flowchart can immediately end with step 218 .
[0066] [0066]FIG. 1G illustrates the semiconductor structure of FIG. 1E following filling of the trench formed in FIGS. 1 A- 1 F with metal forming thin fuse link segment 114 b , and thick wire lines 114 a and 114 c , adjacent to segment 114 b . Following filling of the metal by damascene process, the top surface of the structure can be polished. Chemical mechanical polishing can be used to form the last metal (LM) damascene fuse line 114 having thin region 114 b . Polishing is the process of grinding flat, microsanding and/or planarizing the resulting surface to obtain a structure of uniform thickness. Polishing can include chemically removing variations left after grinding including chemical etching using acid formulations, and can include a chemical/mechanical process to produce a polished, highly reflective, damage free surface. The damascene process includes the process of filling in with metal and polishing the resulting -surface of the structure. Resulting thin fuse link segment 114 b is approximately the same thickness as nitride cap segment 104 b of FIG. 1B.
[0067] [0067]FIGS. 3A through 3F depict a cross-section of an integrated circuit during an alternative fabrication technique embodiment of the fuse of the present invention. FIG. 4 depicts a flowchart 400 illustrating an example technique of fabricating the structure depicted in FIGS. 3A through 3F.
[0068] [0068]FIG. 4 begins with step 402 which can continue immediately with step 404 . In step 404 , an interrupted fuse line is formed including a resist layer, a nitride layer, an oxide layer and a last metal minus one (LM−1) layer. Specifically, interrupted fuse line is formed by placing a resist layer over the previously deposited nitride layer. The nitride layer can include a material such as, e.g., silicon nitride, deposited using conventional methods such as, e.g., chemical vapor deposition (CVD), over the previously deposited oxide layer. The oxide layer can include a material such as, e.g., silicon dioxide, deposited using a conventional method such as, e.g., chemical vapor deposition(CVD) on the previously deposited LM−1 layer. The thickness of the silicon nitride layer can be selected according to the approximate thickness desired for the resulting “thin” fuse segment (see FIG. 3F, below) which is to be formed in the last metal (LM) wiring line. In one embodiment, the desired thickness of the “thin” fuse segment can be, e.g., 0.5μ or less. In another embodiment, the desired fuse segment can be, e.g., 0.8μ or less. In yet another embodiment, the desired fuse segment can be, e.g., 0.3μ or less. Certain thicknesses can provide advantageous chip yields. Table 1, above, illustrates exemplary fuse thicknesses and some observed fuse yields associated with certain example fuse segment thicknesses. An example of the structure formed by step 404 is depicted in FIG. 3A.
[0069] [0069]FIG. 3A illustrates a semiconductor structure including resist segments 302 a , 302 b and 302 c formed on a thin upper nitride layer 304 which overlays an inter layer dielectric (ILD) oxide layer 306 which in turn overlays last metal minus 1 (LM−1) layer segments 308 a and 308 b.
[0070] From step 404 , flowchart 400 can continue with step 406 . In step 406 , the nitride layer and oxide layer can be etched to create a “line” trench, and the resist layer can be stripped. The structure formed by step 406 is depicted in FIG. 3B.
[0071] [0071]FIG. 3B illustrates the semiconductor structure of FIG. 3A following etching of the nitride and oxide layers 304 and 306 , yielding oxide layer 306 a including exemplary line trenches and pedestals. Nitride 304 is etched leaving nitride segments 304 a , 304 b and 304 c remaining capping the pedestals of oxide layer 306 a , formed by stripped resist segments 302 a , 302 b and 302 c . LM−1 segments 308 a and 308 b remain overlaid by the oxide ILD layer 306 a.
[0072] From step 406 , flowchart 400 can continue with step 408 . In step 408 , resist can be applied and an image can be opened using a mask or reticle over resist segments and interrupted center pedestal oxide segment, leaving uncovered the interrupted center pedestal oxide segment and covering the other oxide pedestal portions where the nitride layer will be retained. The resulting structure of the material is illustrated in FIG. 3C.
[0073] [0073]FIG. 3C illustrates the semiconductor structure of FIG. 3B following application of resist segments 310 a and 310 b and opening an image mask over interrupted center oxide segment of oxide 306 a having nitride segment cap 304 b , leaving resist segments 310 a and 310 b , protecting nitride segment caps 304 a and 304 c , respectively. LM−1 segments 308 a and 308 b remain overlaid by the oxide ILD layer 306 a.
[0074] From step 408 , flowchart 400 can continue with step 410 . In step 410 , the technique can selectively etch the exposed oxide layer forming vias to the LM−1 layer, leaving exposed the nitride cap segment protecting the center pedestal oxide segment, and leaving covered the two other pedestal portions of the oxide and their two nitride caps. The resulting structure formed by step 410 is illustrated in FIG. 3D.
[0075] [0075]FIG. 3D illustrates the semiconductor structure of FIG. 3C following selective etching of oxide 306 a forming vias to LM−1 segments 308 a and 308 b . Resist segments 310 a and 310 b protect pedestal portions of oxide 306 b and 306 d and nitride cap segments 304 a and 304 c , and LM−1 segments 308 a and 308 b are overlaid by the oxide ILD layer segments 306 b and 306 d.
[0076] From step 410 , flowchart 400 can continue with step 412 . In step 412 , the center nitride cap segment over the center interrupt oxide pedestal can be selectively etched away and the resist layer can then be stripped away. The center nitride cap segment, if sufficiently thin, can be etched without a selective etchant. It will be apparent to those skilled in the art that the oxide layer segments 306 b and 306 d could be etched if not covered by resist segments 310 a and 310 b , as shown in FIG. 3E. The resulting structure formed by step 412 is illustrated in FIG. 3E.
[0077] [0077]FIG. 3E illustrates the semiconductor structure of FIG. 3D following etching of interrupted nitride cap segment 304 b of center pedestal oxide 306 c . LM−1 segments 308 a and 308 b remain overlaid by the oxide ILD layer segments 306 b and 306 c.
[0078] From step 412 , flowchart 400 can continue with step 414 . In step 414 , the resist is stripped away, including resist segments 310 a and 310 b , leaving the structure ready for damascene fill. The resulting structure includes vias and line trenches ready for a damascene metallization fill. The resulting structure formed by step 414 after damascene filling is illustrated in FIG. 3F.
[0079] From step 414 , flowchart 400 can continue with step 416 . In step 416 , the trench formed by the preceding steps can be filled with metal and can be polished using a chemical, mechanical polishing process to form a last metal (LM) damascene fuse line link having a thin region of thickness approximately equal to the nitride layer thickness. The resulting structure formed by step 416 is illustrated in FIG. 3F. From step 416 , flowchart can immediately end with step 418 .
[0080] [0080]FIG. 3F illustrates the semiconductor structure of FIG. 3E following filling of the trench formed in FIGS. 3 A- 3 E with metal forming thin fuse link segment 312 b capping pedestal oxide portion 306 c , and thick wire lines 312 a and 312 c , adjacent to segment 312 b . Following filling of the trenches with the metal by damascene process, the top surface of the structure can be polished. Chemical mechanical polishing can be used to form the last metal (LM) damascene fuse line 312 having thin region 312 b . Resulting thin fuse link segment 312 b is approximately the same thickness as nitride cap segment 304 b of FIG. 3B.
[0081] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
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A structure and method of fabricating a metallization fuse line is disclosed. The structure can be formed on a semiconductor substrate, including an insulator structure formed on the substrate, the insulator structure having an upper layer and a lower layer, the upper being thinner than the lower, the insulator structure having a plurality of openings of varying depth, and a metal structure inlaid in the insulator structure, the metal structure having first and second portions and a third portion there between that is substantially more resistive than the first and second portions, the third portion having a thickness substantially- similar to the thickness of the upper layer of the insulator structure. The upper layer includes a nitride, the lower layer includes an oxide and the metal structure includes copper. The fuse structure allows formation of “easy to laser delete” thin metal fuses within segments of thick metal lines. This applies to wiring layers formed from “high” melting temperature metals and those defined using a damascene process. For example, copper back end of line (Cu BEOL) damascene wiring, as used with CMOS can use the invention. The technique achieves high yield fusing for technologies that use thick wiring layers. The structure separates the thickness of the fuse segment from the remainder of the wiring line. The structure can be used with very thick, e.g., >1.2μ wiring and very thin, e.g., <0.5μ fuses.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of analog-to-digital converters and more particularly to low-voltage drop reference generation circuit for A/D converters basically utilizing a resistor string, two transistors, and two amplifiers.
BACKGROUND ART
[0002] In interfacing between the analog and digital domain, the analog-to-digital (A/D) converter is a vitally important device. The A/D converter converts an analog signal such as a voltage or a current into a digital signal, which can be further processed, stored, and disseminated using digital processors. For example, A/D converters are used in communications, appliances, display, signal processing, computers, medical instrumentation, industries, and any other fields that require conversion of analog signals into digital forms.
[0003] The A/D converter encodes an analog input signal into a digital output signal of a predetermined bit length. The A/D converter basically includes a resistor string which is comprised of a plurality of resistors. The resistors form a resistor string and are coupled in series between two reference voltages: the most positive reference voltage and the most negative reference voltage. These reference voltages are then fed into several blocks such as comparators, digital-to-analog (D/A) subsection, preamplifiers, and interstage amplifiers.
[0004] Prior Art FIG. 1 illustrates a circuit diagram of a conventional reference generation circuit for A/D converter 100 . The conventional reference generation circuit for A/D converter shown in Prior Art FIG. 1 is comprised of a plurality of resistors and an amplifier 121 . The resistors form a resistor string and are coupled in series between two reference voltages: the most positive reference voltage, V REFT , and the most negative reference voltage, V REFB . It is noted that the negative input of the amplifier 121 is connected to its output node. Thus, it becomes voltage-follower configuration. This conventional circuit 100 generates a plurality of reference voltages characterized by voltage increments between the most positive reference voltage, V REFT , and the most negative reference voltage, V REFB .
[0005] Unfortunately, the conventional reference generation circuit for A/D converter 100 is inefficient to implement in integrated circuit (IC) chip. First, the power supply rejection with respect to negative power supply (or ground) rather than positive power supply is significantly degraded at node 104 . In reality, switches and analog blocks are connected to the nodes between the serially coupled resistors in Prior Art FIG. 1 . The regulation at the node 104 is much weaker than in the case of the node 101 whenever charge-injection error occurs at the node (i.e., whenever MOS switches (not shown), which connected to the nodes between the serially coupled resistors, turn off). Furthermore, voltage at the node 101 (i.e., V REFT ) becomes V REFTIN for V DROPB <V REFIN <V DD −V DROPT . Thus, voltage drop between power supply and the most positive reference voltage (i.e., V DD −V REFT ) is usually lager than average MOS device threshold voltage (i.e., thick oxide MOS device threshold voltage). Thus, the conventional reference generation circuit for A/D converter 100 has a major limitation on rail-to-rail A/D converters and will miss codes for large-swing analog input signal, as shown in Prior Art FIG. 1 . Thus, minimum performance of rail-to-rail A/D converters can not be achieved without low-voltage drop reference generation circuit for all types of A/D converters.
[0006] Thus, what is needed is cost-effective low-voltage drop reference generation circuits for A/D converter that can be easily designed and efficiently implemented along with maximizing the total reference voltage range and power supply rejection with respect to both positive power supply and negative power supply (or ground). The present invention satisfies these needs by providing two low-voltage drop reference generation circuits for A/D converter basically utilizing a resistor string, two transistors, and two amplifiers.
SUMMARY OF THE INVENTION
[0007] The present invention provides two cost-effective low-voltage drop reference generation circuits for A/D converter. The cost-effective low-voltage drop reference generation circuits for A/D converter of the present invention basically includes a resistor string, two transistors, two amplifiers (or operational amplifiers). The resistor string generates a plurality of reference voltages characterized by voltage increments between two fixed reference voltages. In this configuration, the two transistors are used as common-source amplifier and each amplifier receives a reference voltage at its negative input. The generated reference voltages are not only constant with respect to the fluctuations of positive power supply and negative power supply (or ground), but also greatly increases the total reference voltage range (i.e., increases voltage difference between the most positive reference voltage and the most negative reference voltage, increases V REFT −V REFB , maximizes the most positive reference voltage and minimizes the most negative reference voltage). The present invention achieves a drastic improvement in increasing the total reference voltage range with good power supply rejection with respect to positive power supply and negative power supply (or ground).
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention:
[0009] Prior Art FIG. 1 illustrates a circuit diagram of a conventional reference generation circuit for A/D converter.
[0010] FIG. 2 illustrates a circuit diagram of a low-voltage drop reference generation circuit for A/D converter in accordance with the present invention.
[0011] FIG. 3 illustrates a circuit diagram of a flexible low-voltage drop reference generation circuit for A/D converter according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] In the following detailed description of the present invention, two cost-effective low-voltage drop reference generation circuits for A/D converter, numerous specific details are set forth in order to provide a through understanding of the present invention. However, it will be obvious to one skilled in the art that 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.
[0013] FIG. 2 illustrates a low-voltage drop reference generation circuit for A/D converter in accordance with the present invention. The low-voltage drop reference generation circuit for A/D converter 200 is comprised of n resistors, a PMOS transistor 231 , an NMOS transistor 232 , and two amplifiers (or operational amplifiers) 221 and 222 . The amplifiers 221 and 222 are termed upper amplifier and lower amplifier, respectively. The resistor string generates n−1 spaced reference voltages between two reference voltages such as V REFT and V REFB . The dotted lines 213 represent m resistors where m is an integer greater than or equal to one. As shown in FIG. 2 , the two transistors are used as common-source amplifier and each amplifier (or operational amplifier) receives a reference voltage at its negative input. It is noted that the positive input of the amplifier 221 is connected to the drain node of the PMOS transistor 231 and its output is connected to the gate node of the PMOS transistor 231 . The amplifier 221 and PMOS transistor 231 are in negative feedback configuration. Likewise, the amplifier 222 and NMOS transistor 232 are in negative feedback configuration. Even though V REFTIN goes up close to positive power supply, voltage at a node 201 (i.e., V REFT ) still becomes equal to V REFTIN . Even though V REFBIN goes down close to negative power supply (or ground), voltage at a node 204 (i.e., V REFB ) still becomes equal to V REFBIN . In addition, as voltages at both positive power supply and negative power supply (or ground) change, the voltage at the node 204 will be much more constant than the case of Prior Art FIG. 1 (i.e., the voltage at the node 104 ). However, the regulation at all nodes 201 through 204 shown in FIG. 2 is much stronger than in the case of Prior Art FIG. 1 whenever charge-injection error occurs at the nodes (i.e., whenever MOS switches (not shown), which connected to the nodes between the serially coupled resistors, turn off). Thus, the low-voltage drop reference generation circuit for A/D converter 200 provides a strong basis for all types of rail-to-rail A/D converters, and can be efficiently implemented along with increasing the total reference voltage range and maintaining good power supply rejection with respect to both positive power supply and negative power supply (or ground). The present invention generates low-voltage drop reference voltages utilizing a resistor string, two amplifiers (or operational amplifiers), and two transistors. Amplifiers are well known circuits in the art and can be implemented using various well known devices such as transistors, capacitors, resistors, etc. In addition, the amplifiers (or operational amplifiers) 221 and 222 are differential-input single-ended output amplifiers and can have any number of gain stages with or without buffer stage (i.e., output stage).
[0014] FIG. 3 illustrates a circuit diagram of a flexible low-voltage drop reference generation circuit for A/D converter 300 according to the present invention. The flexible low-voltage drop reference generation circuit for A/D converter 300 is comprised of n resistors, a PMOS transistor 331 , an NMOS transistor 332 , two amplifiers (or operational amplifiers) 321 and 322 . The amplifiers 321 and 322 are termed upper amplifier and lower amplifier, respectively. The dotted lines 313 represent m resistors where m is an integer greater than or equal to one. The resistor string consists of an upper part 311 and 312 , a middle part 313 , and a lower part 316 and 317 . However, the middle part of the resistor string is excluded in either feedback loop.
[0015] In addition, it is also noted that the amplifier 321 , PMOS transistor 331 , and resistors 311 and 312 shown in FIG. 3 are in negative feedback configuration in the same fashion as the amplifier 221 and PMOS transistor 231 . However, a difference between FIG. 2 and FIG. 3 is that upper part 311 and 312 and lower part 316 and 317 shown in FIG. 3 are included in each feedback path. Thus, even though V REFUPIN is not close to V DD and V REFDNIN is not close to −V SS (or ground), voltage at node 301 (i.e., V REFT , the most positive reference voltage) and voltage at node 306 (i.e., V REFB , the most negative reference voltage) become a constant reference voltage closed to V DD and a constant reference voltage closed to −V SS (or ground), respectively. The flexible low-voltage drop reference generation circuit for A/D converter 300 is highly effective when V REFUPIN is not high enough and V REFDNIN is not low enough.
[0016] In summary, the low-voltage drop reference generation circuit for A/D converter 200 and the flexible low-voltage drop reference generation circuit for A/D converter 300 can also be implemented using additional capacitors attached to the nodes 201 through 204 and the nodes 301 through 306 , respectively. In addition, the two low-voltage drop reference generation circuits of the present invention are highly efficient to implement in integrated circuit (IC) and system-on-chip (SOC). The low-voltage drop reference generation circuit for A/D converter 200 of the present invention achieves a drastic improvement in the total reference voltage range and converting larger analog signal swing and power supply rejection. In addition to the strengths mentioned above, the flexible low-voltage drop reference generation circuit for A/D converter 300 of the present invention provides the most positive reference voltage higher than V REFUPIN and the most negative reference voltage lower V REFDNIN when high V REFUPIN and low V REFDNIN are not available. While the present invention has been described in particular embodiments, it should be appreciated that the present invention should not be construed as being limited by such embodiments, but rather construed according to the claims below.
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Two cost-effective low-voltage drop reference generation circuits for A/D converter of the present invention generates a plurality of reference voltages characterized by voltage increments between two fixed reference voltages, which are able to be close to positive rail and negative rail (or ground). These low-voltage drop generation circuits not only greatly increases the total reference voltage range (i.e., increases voltage difference between the most positive reference voltage and the most negative reference voltage, increases V REFT −V REFB , maximizes the most positive reference voltage and minimizes the most negative reference voltage), but also enables A/D converter to convert rail-to-rail analog input with maintaining good power supply rejection with respect to positive power and negative power (or ground).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to endoscopes which are widely used in the field of medicine and in particular to a compact endoscope having a fine diameter probe for use in hospitals and doctors' offices for outpatient procedures.
2. Description of the Related Art
Currently, orthopaedic surgeons perform the greatest number of arthroscopic in-hospital procedures, approximately half of which could be performed on an outpatient basis. Almost 2.5 million such procedures are undertaken annually. Of these, 510,000 are for shoulder injuries, 1.7 million are for knee injuries, and 200,000 are for such procedures as elbows, ankles and wrists. The future arthroscopic market is expected to be additionally enhanced by anticipated developments in the fields of synthetic bone and tissue transplantation.
Currently available endoscopes have the disadvantages of being bulky, expensive instruments which are typically found only in hospitals. Available endoscopes have relatively large diameter optical probes, requiring proportionately large incisions to permit their use. There is a need in the art for a compact, small diameter endoscope, which may be purchased and used by medical professionals in their offices to perform outpatient diagnostic and surgical procedures.
There are at least two major technical obstacles to the design of an endoscope having an outside diameter of less than 2 mm. The first obstacle is that of insufficient illumination. An endoscope must both provide light to the area within the body being viewed and collect sufficient reflected light to be detected by available sensor arrays. The narrow optical pathways available in a very small diameter endoscope have typically not been capable of transmitting or collecting sufficient light.
The quantity of light transmitted in any optical arrangement is principally determined by two factors: 1) the optical characteristics of the light receiving surface of the arrangement (surface area, curvature, etc.); and 2) the intensity of the light energy incident upon that surface. Reduction in either factor reduces the amount of light transmitted.
In conventional endoscopic systems, these transmission constraints restrict the ability to effectively reduce the diameter of the probe which delivers light into the cavity to be viewed and collects the reflected image. Light sources of conventional brightness are not compatible with optical transmission systems which employ a significant reduction in the surface area of the light transmission pathway. Accordingly, there is a need in the art for an endoscopic system which can deliver sufficiently intense light energy to an endoscope to permit reduction in the light transmission portion of an endoscope probe.
Collection of the reflected light which will form an image of the viewing area presents another set of technical difficulties. Prior art endoscopes typically focus the image on either a charge coupled device (CCD) sensor array or magnify the image into an eye piece that the surgeon or medical professional can view directly. Ideally, a single glass rod could be used to transmit image light from an object lens to the sensor array. Such a construction is employed in many larger diameter conventional endoscopes. However, as the diameter of such a glass rod is reduced, the rod becomes vulnerable to stress induced birefringence, which distorts the image being transmitted.
Conventional optical fibers, while they are thin enough to be flexible and avoid the problem of birefringence, have cross sectional surface areas which individually collect only limited amounts of light. No matter how many such fibers are used, the brightness of the transmitted image is not enhanced because the optical characteristics of the receiving or input face of each fiber do not change. Thus, there is also a need in the art for a fine diameter endoscope probe which uses a single optical pathway to collect and deliver image light to a suitable sensor array.
SUMMARY OF THE INVENTION
Briefly stated, the invention in a preferred form comprises a compact, office-based fine diameter endoscope system which employs a pulsed xenon light source and novel image delivery optics to provide an endoscope probe having a diameter which is reduced in comparison to comparable conventional probes. The micro-endoscope system (ME system) includes a service module, a combined optical and electronic service cable and a micro-endoscopic device (MED). The service module houses the system power supply, the pulsed xenon light source, the image processor and the control electronics as well as the display/monitor. The combined optical and electronic cable contains a fiber optic bundle to transmit light from the service module to the MED and conductors to communicate with the electronic portion of the MED.
The MED comprises a sensor head that contains a sensitive charge coupled device (CCD) sensor array, a light pulse transfer interface and image focus optics. Controls allow the user to control the focus and magnification functions. A removable, one-piece optical probe and ergonomic grip slides over the sensor head to mate with the light pulse transfer interface. The optical probe includes a light pipe to deliver light from the pulse transfer interface to the viewing area and an image path for collecting and guiding reflected light back to the image focus optics. The pulse transfer interface enhances the transfer of light from the fiber optic bundle to the light pipe. Light travels the length of the light pipe and is directed upon the area to be viewed. Light reflected from the viewing area is collected by an object lens and focused into the image path. The image path guides reflected light to the image focus optics in the sensor head where the image is focused on the CCD array. Image data from the CCD array is communicated to the service module electronics through the service cable.
To enhance the intensity of light incident on the optical components of the light path, the MED utilizes a pulsed xenon light source which emits short duration, very high-energy pulses of light. Each pulse of light may be in the energy range of 100,000 watts and have a duration of approximately 10 microseconds. The pulsed xenon light source is essentially a point source of light. The pulsed xenon light source is positioned so the emitted pulses of light pass directly into the input end of the fiber optic bundle. The highly concentrated light energy provides sufficient illumination of the viewing area while employing a smaller diameter light path.
Image path optics having a diameter of approximately 1 mm address the issue of birefringence by using an image guide comprised of glass rod segments. Short rod segments are not prone to the stresses which induce birefringence. The sections of the image guide are assembled to form an integrated guide having the length desired for the optical probe. An alternate embodiment of the image guide may be constructed of optical grade plastic, such as polyethylene.
An object of the present invention is to provide a new and improved fine diameter endoscope having an efficient and cost effective construction and which is adaptable for use in out-patient clinics and doctors' offices.
Another object of the present invention is to provide a new and improved fine diameter endoscope which employs novel image collection optics to enhance image quality.
A further object of the present invention is to provide a new and improved fine diameter endoscope which uses a novel pulsed xenon light source to increase the illumination of the viewing area.
A yet further object of the present invention is to provide a new and improved fine diameter endoscope which may be used as an inexpensive real-time diagnostic tool.
These and other objects, features, and advantages of the invention will become readily apparent to those skilled in the art from the specification and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a micro-endoscopic system (ME system) in accordance with the present invention;
FIG. 2 is a schematic block diagram of the light path for the ME system of FIG. 1;
FIG. 3 is a schematic block diagram of the image path for the ME system of FIG. 1;
FIG. 4 is an enlarged fragmentary side view of an image guide structure which may be employed in the optical probe of the MED in accordance with the present invention;
FIG. 5 is an enlarged fragmentary perspective side view of an optical probe of an MED in accordance with the present invention;
FIG. 6 is a side view of an MED in accordance with the present invention;
FIG. 7 is a side view, partly broken away, partly in section, and partly in schematic of the MED of FIG. 6;
FIG. 8 is a sectional view of the MED of FIG. 6 with the optical probe removed;
FIG. 9 is a sectional view of the optical probe of the MED of FIG. 6;
FIG. 10 is a fragmentary perspective side view of an alternative embodiment of the light pipe component of an optical probe for an MED in accordance with the present invention;
FIG. 11 is a side view, partially in phantom, of the optical probe of the MED of FIG. 6;
FIG. 12 is a side view, partially in phantom, of an alternative embodiment of an optical probe for use in conjunction with the MED of FIG. 6;
FIG. 13 is a side view, partially in phantom of an alternative embodiment of an optical probe for use in conjunction with the MED of FIG. 6; and
FIG. 14 is a schematic view showing the relationship of the pulsed xenon light source to the light transmitting fiber optic bundle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A micro-endoscopic system (ME system) incorporating a micro-endoscopic device (MED) 40 in accordance with the present invention is generally designated by the numeral 10 . With reference to FIG. 1, one embodiment of the ME system is comprised of a service module 20 , service cable 30 and a MED 40 . The service module 20 contains a video monitor 22 , a pulsed xenon light source 28 , system power supplies 26 and system processing and control electronics 24 .
A service cable 30 connects the service module 20 with the MED 40 . The service cable includes a fiber optic bundle 32 to transmit light from the light source 28 to the MED 40 . The service cable 30 also incorporates electrical conductors 34 to allow the service module 20 to communicate with the electronic portions of the MED 40 . Because of the compact size of the ME system 10 , the service cable may be as short as 2 meters. A short service cable 20 increases the amount of light reaching the viewing area by limiting the distance dependent losses associated with transmittal of light through long fiber optic cables. The service cable 20 may be permanently affixed to the service module 20 and MED 40 or may be equipped with couplings at one or both ends to allow removal from the service module 20 and/or the MED 40 . A permanent installation has the advantage of eliminating the light losses associated with fiber optic couplings.
The functional components of the MED 40 are illustrated in FIG. 1 . The MED 40 comprises an optical probe 50 , a sensor head 49 which contains a zoom/image focus optics package 42 , a CCD sensor array (which may also be referred to as a camera) 44 and a light pulse transfer interface 46 . With reference to FIG. 6, an MED housing 48 is a rigid structure which may be integrally connected to the optical probe 50 . In a preferred embodiment, an integrated optical probe 50 and housing 48 slidably mount over the sensor head 49 and lock in place. The housing 48 has a compact hand-held configuration which is exteriorly contoured to fit the hand of a user to facilitate dexterous and versatile usage.
The removable integrated optical probe 50 and MED housing 48 permit replacement of the entire exterior of the MED 40 . Once used, the integrated optical probe 50 and MED housing 48 may be replaced with a sterile unit. Probes having alternative magnifications and fields of view are also possible. A removable optical probe/housing allows the MED to be efficiently prepared for the next patient by simply replacing a used probe with a new probe/housing. An interchangeable probe/housing also allow the physician to easily alter the field of view.
As illustrated in FIG. 2, the ME system provides a light source 28 and light path 60 which enhance the illumination of the viewing area. The pulsed xenon light source 28 incorporates a flash tube 28 a which emits a pulse of light of great intensity and broad spectrum but extremely short duration. The duration of the light source pulses is preferably less than 15 micro-seconds. For example, the flash tube may emit a light pulse having the equivalent of 100,000 watts of light power, but last only 10 micro-seconds. A continuous source of light having this intensity would generate significant and unwanted quantities of heat. The short duration of the light pulses from the flash tube 28 a avoids any significant heat buildup. Light generated by the flash tube 28 a is focused on the light receiving face of the fiber optic bundle 32 by light focus optics 28 b . Light focus optics 28 b further enhance the intensity of light incident on the receiving face by gathering, directing and focusing the light.
FIG. 14 illustrates one embodiment of a light source 28 incorporating a point source xenon flash tube S, focus reflector M, ultra violet filter 27 and infra red filter 29 . The maximum fiber bundle acceptance angle θ of the fiber optic bundle 32 is calculated using the formula θ=sin −1 NA where NA is the numerical aperture of each fiber. Point source xenon flash tube S is positioned distance d and reflecting mirror M is positioned distance d M from the light-receiving end of the fiber optic bundle 32 . Distances d and d M are calculated with reference to the maximum fiber bundle acceptance angle θ so that most of the light emitted by point source xenon flash tube S directly incident upon or reflected by mirror M to be incident upon the light receiving end of the fiber optic bundle 32 at an angle of θ or less. This arrangement maximizes the light incident upon the light-receiving end, and ultimately transmitted by the fiber optic bundle 32 . Ultra violet filter 27 and infra red filter 29 exclude undesirable portions of the broad spectrum emitted by the flash tube S.
The internal components of the MED are illustrated in FIGS. 6-9. Within the MED 40 , the light path comprises the terminus of the fiber optic bundle 32 , a pulse transfer interface 46 and a light pipe 52 . Light pulses are delivered to the MED via the fiber optic bundle 32 in the service cable 30 . Upon entering the sensor head 49 , the fiber optic bundle 32 divides into a fiber optic annulus 33 . The fiber optic annulus 33 forms the light delivery side of the pulse transfer interface 46 . The ring-shape of the fiber optic annulus 33 is optically matched by the circular entrance to the light pipe 52 .
The light pipe 52 comprises a core light transmitting material 52 a having a high index of refraction surrounded by material having a low index of refraction 52 b , thereby creating a light tunnel in a manner similar to the methods used in fiber optics. The light pipe 52 is tubular in shape and surrounds the object lens 72 and the image guide 74 . Specifically, the light emitting end of the light pipe 52 is preferably a ring approximately 2 mm in diameter with a wall thickness of 0.1 mm to 0.3 mm (best seen in FIG. 5 ). The light receiving entrance to the light pipe 52 is a cone 54 , expanding from the thin wall tube of the probe portion of the light pipe 52 to a circle which abuts the fiber optic annulus 33 at the pulse transfer interface 46 .
FIG. 2 is a schematic representation of the light path 60 from the light source 28 to the area to be viewed. Short duration pulses of broad spectrum light are generated by the xenon flash tube 28 a . The light focus optics 28 b filter and focus the light onto a light receiving, or input end of the fiber optic bundle 32 . The fiber optic bundle traverses the length of the service cable, enters the MED and divides to form the fiber optic annulus 33 , or light delivery portion of the pulse transfer interface 46 . The cone 54 of the light pipe 52 forms the receiving side of the pulse transfer interface 46 . When the integrated optical probe 50 and MED housing 48 are installed over the sensor head 49 , the cone 54 and the fiber optic annulus 33 are directly coupled. Light received by the light pipe 52 travels the length of the probe and exits the light pipe 52 to illuminate the viewing area.
The ME system also comprises an image path 70 for collecting, guiding, focusing, and displaying the reflected light from which an image of the area being viewed will be constructed. A schematic representation of the ME system image path 70 is found in FIG. 3 . Reflected image light is gathered by an objective lens 72 which focuses the light into the first segment 74 a of the image guide 74 . Relay optics 75 allow the image light to pass from one guide segment 74 a to the next 74 b without excessive loss or distortion. The image guide segments 74 a , 74 b , etc. guide the image light to image focus optics 42 where the image light is focused on the CCD sensor array 44 . Conductors 34 in the service cable transmit the signals produced by the CCD sensor array 44 to the service module where processing electronics display the image on a monitor 22 for viewing by the physician.
The image guide 74 is approximately 1 mm in diameter and must therefore address the issue of birefringence. In one embodiment, the image guide 74 may comprise a segmented glass rod approximately 1 mm in diameter. Breaking the image guide 74 into segments avoids the stresses that induce birefringence in a longer glass rod of this diameter (see FIG. 4 ). The segments 74 a - 74 d are joined by relay optics 75 which facilitate the transfer of image light from one guide segment to another.
The image guide 74 utilizes reverse fiber optic technology. The outside surface of the guide 74 is coated with light absorbent material 76 to absorb stray light in the image guide. It is desirable to provide the coating to absorb any light which strays from the focused path within the guide to avoid the deleterious effects stray light can have on image quality. Each image path segment may also comprise an aperture stop 80 at the light entry end and at the light transmission end. In combination, the aperture stops 80 and light absorbent coatings 76 ensure that only properly focused image light will be delivered to the image focus optics 42 and in turn the CCD sensor array 44 .
The image guide 74 may also be comprised of high quality plastic, such as the optical grade resins used in opthalmic lenses, having an index of refraction in excess of 1.6. The segmenting of a glass rod and the relay optics necessary to transmit an image from one segment to another may be avoided. The somewhat reduced light transmission capability of a plastic material can be compensated for by the increased intensity of light from the pulsed xenon light source.
The light pipe 52 may be constructed by molding optical quality glass or plastic materials into a unitary piece. FIG. 10 illustrates an alternative configuration for the light pipe 52 incorporating optical fibers formed into a tube surrounding the image guide. In this configuration, the fibers making up the fiber optic bundle 32 are separated and arranged around the image guide 74 in a tubular configuration. The complexity and inefficiencies associated with a pulse transfer interface are thus avoided entirely.
FIGS. 11-13 illustrate alternative configurations of the optical probe. FIG. 11 illustrates a probe having an objective lens 72 oriented perpendicular to the length of the probe 50 . A probe having this configuration will provide an image of the viewing area directly in front of the objective lens 72 . FIGS. 12 and 13 illustrate probes 50 equipped with prisms in their objective lens assemblies 72 a , 72 b . The angled end face of each probe houses a prism that captures and bends light into the image guide 74 . Probes so equipped will give a view of the viewing area angularly offset from the MED. Rotating the MED will allow the physician a panoramic field of view surrounding the location of the MED.
FIG. 7 illustrates a zoom/focus optics arrangement which may be incorporated into the MED. Zoom capability allows the physician to get a closer view of the viewing area without having to adjust the physical position of the optical probe 50 . This feature is desirable in close quarters or where movement of the probe could possibly damage sensitive tissues. The spacing of lenses 45 in the zoom/focus optics are adjustable by a zoom focus control 47 that permits user selection among multiple zoom positions. The zoom/focus control 47 is provided on the MED housing 48 (see FIG. 6 ).
While preferred embodiments of the foregoing invention have been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and the scope of the present invention.
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A micro-endoscopic system employs a pulsed xenon light source and image collection optics with a fine diameter optical probe for an endoscope. Very bright pulses of light emitted by a xenon flash tube increase the intensity of light incident on the light transmitting optics, allowing a reduction in size of the optical components, resulting in a corresponding reduction in the size of the optical probe. A segmented glass image guide directs the reflected light to a sensor array. Segmentation of the image guide avoids the stress related problems associated with fine diameter glass optical structures.
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BACKGROUND
[0001] The present invention relates to a method of laminating an adherend which rarely causes air bubbles to occur between the adherend and an adhesive layer.
[0002] In recent years, a flexible printed circuit (FPC) which is thin and flexible and has excellent flexural characteristics has been widely used as a circuit board for electrodynamic machines or electronic instruments, as a connection wiring board used in a movable section, as a wiring board used in a chip-level package, or the like. The FPC is generally formed by providing a circuit pattern on one side of a film-shaped base material. Since the film-shaped base material is formed of a polymer resin or the like having flexibility, the FPC exhibits flexural characteristics. The FPC is reinforced by thermocompression bonding a stiffener film to the FPC with an adhesive film provided therebetween at a high temperature of about 160° C. to bond the FPC and the stiffener film through the adhesive film.
[0003] However, if thermocompression bonding is insufficient, air bubbles occur between the adhesive film used for bonding the stiffener film and the FPC base material. This problem is not limited to the case of bonding the stiffener film to the FPC. Specifically, when laminating adherends through an adhesive film, if compression bonding is insufficient, or recesses and protrusions are formed at the bonding surface between the adherends, air bubbles can remain at the bonding surface.
[0004] As a means for removing air bubbles at the bonding surface, a method of absorbing the air bubbles using a vacuum device, or by applying pressure to the bonding surface using a roll device has been known (see patent document 1 relating to a technology for laminating a decorative film). However, this method requires large-scale manufacturing equipment.
SUMMARY
[0005] The invention has been achieved in view of the above-described problems. An objective of the invention is to provide a means for bonding adherends with an adhesive film interposed therebetween without causing air bubbles to occur at the bonding surface. More particularly, an objective of the invention is to provide a means which is suitable for laminating and bonding adherends when the adherends consist of an FPC and a stiffener film, and can be carried out by using a general laminator or a thermocompression bonding device without causing air bubbles to occur at the lamination or bonding surface and without using large-scale manufacturing equipment. As a result of extensive studies, the present inventors have found that the above objectives can be achieved by the following means.
[0006] According to an aspect of the invention, there is provided a method of laminating an adherend, the method comprising: providing a laminate in which a flat base material is laminated on one surface of an adhesive layer of a half-cured (B stage) reactive adhesive and a minute embossing pattern is formed on the other surface of the adhesive layer; and thermocompression bonding an adherend to the other surface of the laminate on which the minute embossing pattern is formed (hereinafter may be called “first aspect”).
[0007] According to another aspect of the invention, there is provided a method of laminating an adherend, the method comprising: a first step of providing a laminate in which flat liners are provided on upper and lower surfaces of an adhesive layer of a half-cured reactive adhesive, removing one of the flat liners from the laminate, and bonding a flat surface of a first adherend to the surface (surface B) of the adhesive layer from which the flat liner has been removed; a second step of removing the other flat liner from the laminate, pressure bonding a minute embossing pattern surface of an embossed liner to the surface of the adhesive layer from which the other flat liner has been removed to form a minute embossing pattern on the surface of the adhesive layer; and a third step of removing the embossed liner from the surface of the adhesive layer, and thermocompression bonding a second adherend to the surface (surface A) of the adhesive layer on which the minute embossing pattern has been formed and from which the embossed liner has been removed (hereinafter may be called “second aspect”).
[0008] In the second aspect, it is preferable that the embossed liner having the minute embossing pattern surface be a liner in which continuous groove sections having a lattice pattern with a pitch of about 300 μm or less and a height of about 5 to about 30 μm are formed to reach side faces of the liner.
[0009] According to another aspect of the invention, there is provided a method of laminating an adherend, the method comprising: a first step of providing an embossed liner having a minute embossing pattern surface, and applying a half-cured (B stage) reactive adhesive to the minute embossing pattern surface of the embossed liner to form an adhesive layer in which a minute embossing pattern is formed on one surface; a second step of bonding a flat surface of a first adherend to the other surface (surface B) of the adhesive layer; and a third step of removing the embossed liner from the one surface of the adhesive layer, and thermocompression bonding a second adherend to the one surface (surface A) of the adhesive layer on which the minute embossing pattern has been formed and from which the embossed liner has been removed (hereinafter may be called “third aspect”).
[0010] In the third aspect, it is preferable that the embossed liner having the minute embossing pattern surface be a liner in which continuous groove sections having a lattice pattern with a pitch of about 300 μm or less and a height of about 5 to about 30 μm are formed to reach side faces of the liner.
[0011] The “method of laminating an adherend according to the invention” used herein refers to all of the first, the second, and the third aspects. In the specification, one of the two surfaces of the adhesive layer on which the minute embossing pattern is formed is called a surface A, and the surface on which the minute embossing pattern is not formed is called a surface B.
[0012] The method of laminating an adherend of the invention includes the step of forming the minute embossing pattern on the adhesive layer by using the embossed liner having the minute embossing pattern surface, and laminating one of the adherends on the surface (surface A) of the adhesive layer on which the minute embossing pattern has been formed. In the method of laminating an adherend according to the invention, a thermosetting adhesive may be used as the B stage adhesive which forms the adhesive layer, a base material made of a polymer resin having a thickness of 50 to 200 μm and a melting point of 200° C. or higher may be bonded to the surface B of the adhesive layer as the first adherend, and an FPC may be bonded to the surface A as the second adherend. According to this feature, the method of laminating an adherend of the invention can be used as a means suitable for reinforcing the FPC from the viewpoint of flexibility and heat resistance. The strength of the FPC can be adjusted without causing air bubbles to occur at the lamination surface between at least the surface (surface A) of the adhesive layer on which the minute embossing pattern is formed and the FPC merely by laminating the FPC and the base material on the adhesive layer using a general laminator or a thermocompression bonding device in thermocompression bonding in the third step.
[0013] In the method of laminating an adherend according to the invention, the minute embossing pattern is formed on the surface A of the adhesive layer by using the embossed liner having the minute embossing pattern surface in the second step in the second aspect and the first step in the third aspect. It is preferable that the minute embossing pattern be formed on a substantially flat surface, continuous groove sections having a lattice pattern be formed in the flat surface so as to reach side faces of the adhesive layer, and the groove sections have a lattice pattern pitch of 300 μm or less and a depth of 5 to 30 μm. It is preferable that the groove section be formed so that the width of the groove section is continuously reduced from the open surface toward the bottom section, the width at the open surface be 10 to 30 μm, and the width at the bottom section be 0 to 5 μm. If the minute embossing pattern has such a feature, a fluid such as air is easily removed (is not confined) through the groove section. The statement “substantially flat surface” used herein means that the surface is mainly formed as a flat surface, and that the flat surface exists between the groove sections and the surface is flat excluding the groove sections or the like. The open surface is an insubstantial surface and is a surface equivalent to the surface (flat surface) of the adhesive layer when the groove section does not exist.
[0014] The embossed liner having the minute embossing pattern surface for forming the minute embossing pattern at the surface A of the adhesive layer is an embossed liner on which projection sections which engage the groove sections of the minute embossing pattern are formed. In the method of laminating an adherend according to the invention, since the embossed liner is laminated on the surface A of the adhesive layer until the embossed liner is thermocompression bonded to the second adherend in the third step, the groove section is not deformed even if the adhesive layer is formed of a half-cured (B stage) thermo-setting adhesive. Therefore, the effect of causing air to be removed and the groove section to be undetected after lamination can be securely obtained by removing the embossed liner immediately before lamination (third step).
[0015] In the method of laminating an adherend according to the invention, it is preferable to form projection sections disposed at almost equal intervals on the surface A of the adhesive layer in addition to the groove sections. The position can be adjusted by contacting and sliding the protrusion sections on the surface of the second adherend before applying sufficient pressure to laminate (completely bond) the second adherend in the third step. Therefore, positioning can be performed more accurately and more easily when laminating the second adherend (e.g. FPC) on the adhesive layer (surface A).
[0016] In the method of laminating an adherend according to the invention, the thermocompression bonding in the third step is preferably performed using a laminator under conditions of a roll temperatures of 80 to 95° C., a roll speed of 0.5 to 1.5 m/min, and a pressure of 200 to 400 kPa.
[0017] In the method of laminating an adherend according to the invention, a cover lay film, a dry film, an FPC, or the like may be used as the first adherend, and a base material, an FPC, or the like may be used as the second adherend. The method of laminating an adherend of the invention is suitably utilized when the first adherend is an integrated circuit (IC) chip and the second adherend is a base material (including a lead frame) or when the first adherend is a heat sink on a semiconductor and the second adherend is one surface (e.g. top surface) of the semiconductor, so that the first adherend and the second adherend can be bonded (thermocompression bonded) without causing air bubbles to occur between the first adherend and the second adherend.
[0018] The method of laminating an adherend of the invention enables the adherend to be laminated on the adhesive layer without causing air bubbles to occur at the lamination surface between the adherend and the adhesive layer. In more detail, since the method of laminating an adherend of the invention forms a minute embossing pattern on the adhesive layer by using the embossed liner having the minute embossing pattern surface, the minute embossing pattern causes a fluid such as air to be removed through the space between the adherend and the adhesive layer when the adherend (e.g. FPC) is laminated on the surface (surface A), and the adhesive layer in a B stage sufficiently adheres to the adherend.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a side view showing one embodiment of an embossed adhesive film according to the invention.
[0020] FIG. 2 is a plan view of the embossed adhesive film shown in FIG. 1 .
[0021] FIG. 3 is an enlarged view of a groove section of the embossed adhesive film shown in FIG. 1 .
[0022] FIG. 4 is an enlarged view of a groove section of the embossed adhesive film shown in FIG. 1 .
[0023] FIG. 5 is a plan view showing another embodiment of an embossed adhesive film according to the invention.
[0024] FIG. 6 is an enlarged view of a groove section and a projection section of the embossed adhesive film shown in FIG. 5 .
[0025] FIG. 7 is an enlarged view of a groove section of the embossed adhesive film shown in FIG. 5 .
[0026] FIG. 8 is an enlarged view of a groove section and a projection section of the embossed adhesive film shown in FIG. 5 .
[0027] FIG. 9 is an enlarged view of a projection section of the embossed adhesive film shown in FIG. 5 .
[0028] FIG. 10 is a plan view showing yet another embodiment of an embossed adhesive film according to the invention.
[0029] FIG. 11 is an enlarged view of the surface of an adhesive layer of the embossed adhesive film shown in FIG. 10 .
[0030] FIGS. 12( a ) to 12 ( e ) are explanatory diagrams of steps of an FPC stiffener film lamination method according to the invention.
DETAILED DESCRIPTION
[0031] Embodiments of the present invention are described below with reference to the drawings. However, the present invention should not be construed as being limited to the following embodiments. Various alterations, modifications, and improvements may be made within the scope of the present invention based on knowledge of a person skilled in the art. For example, although the drawings show preferred embodiments of the invention, the invention is not limited to modes shown in the drawings or to information given in the drawings. Although means similar to or equivalent to means described in the specification may be applied when carrying out or verifying the invention, preferable means are means as described herein.
[0032] A method of laminating an adherend according to the invention includes a step of bonding an adherend (first adherend) having a flat surface to the surface (surface B) of the adhesive layer on which a minute embossing pattern is not formed, and a step of forming a minute embossing pattern on the adhesive layer by using an embossed liner having a minute embossing pattern surface, and thermocompression bonding an adherend (second adherend) to the surface (surface A) of the adhesive layer on which the minute embossing pattern has been formed. In the method of laminating an adherend according to the invention, a film-shaped base material such as a cover lay film or a dry film may be suitably used as the first adherend having a flat surface, and the first adherend is bonded to the surface B of the adhesive layer and the minute embossing pattern is formed on the surface A of the adhesive layer by using the embossed liner before thermocompression bonding the second adherend to the surface A of the adhesive layer. In the specification, a film in which the film-shaped base material (first adherend) is bonded to the surface B of the adhesive layer and the minute embossing pattern is formed on the surface A of the adhesive layer is called an embossed adhesive film according to the invention. The embossed adhesive film according to the invention is described below.
[0033] FIGS. 1 to 4 are diagrams showing one embodiment of an embossed adhesive film according to the invention. FIG. 1 is a side view showing a side face, FIG. 2 is a plan view showing an adhesive layer, FIGS. 3 and 4 , showing the surface of the adhesive layer, are enlarged views of a groove section in the cross section perpendicular to the longitudinal direction of the groove section.
[0034] An embossed adhesive film 1 shown in the drawings includes a base material layer 2 (layer formed by film-shaped base material) and an adhesive layer 3 laminated on the base material layer 2 . The surface of the adhesive layer 3 on the side opposite to the base material layer 2 is a substantially flat surface, and continuous groove sections 4 disposed in a lattice pattern are formed to reach side faces 5 of the adhesive layer 3 . It is preferable that an embossed liner (not shown), having projection sections that form the groove sections 4 , be further laminated on the surface of the adhesive layer 3 opposite to the base material layer 2 . The embossed liner is then removed from the embossed adhesive film 1 .
[0035] The lattice pattern is an example of a minute embossing pattern formed by providing the groove sections 4 to intersect, as shown in FIG. 2 . However, the lattice pattern is not limited to a pattern in which each grid forms a square as in the embossed adhesive film 1 insofar as the pattern is in the shape of a lattice. The embossment represents a state in which grooves and projections exist due to formation of the groove sections 4 . The continuous groove section 4 refers to a groove continuously formed in the shape of a stripe. The statement “formed to reach side faces 5 of the adhesive layer 3 ” means a state in which the continuous groove section 4 is formed to reach the side faces 5 of the adhesive layer 3 and is open at the side faces 5 so that the groove section 4 can be seen at the side faces 5 (see FIG. 1 ).
[0036] In the embossed adhesive film 1 , a thickness t 2 of the base material layer 2 is typically 50-200 μm and in at least one embodiment is 125 μm, and a thickness t 3 of the adhesive layer 3 is typically 15-100 μm and in at least one embodiment is 40 μm (see FIG. 1 ).
[0037] The material for the base material layer 2 of the embossed adhesive film 1 is not limited insofar as the material exhibits heat resistance. The statement “the material exhibits heat resistance” means that the material exhibits heat resistance even at a temperature higher than 200° C. encountered in a solder reflow step or the like. A preferable material for the base material layer is a resin material such as polyimide or glass epoxy or a metal material such as copper, stainless steel, or aluminum.
[0038] The adhesive layer 3 of the embossed adhesive film 1 is formed by a reactive adhesive in a B stage, such as an epoxy adhesive which is a thermo-setting adhesive. The thermo-setting adhesive undergoes a reaction due to heat to exhibit an adhesive performance, differing from a pressure sensitive adhesive (tackiness agent). A polyester, phenol, or polyurethane thermo-setting adhesive may be used instead of the epoxy thermosetting adhesive. A thermoplastic adhesive may also be used as the reactive adhesive in a B stage. However, the epoxy thermo-setting adhesive is still more preferable.
[0039] In the embossed adhesive film 1 , it suffices that the pitch of the lattice pattern be 300 μm or less between arbitrary groove sections. The pitch of the lattice pattern is preferably 250 μm or less, and still more preferably 200 μm or less. The depth of the groove section is preferably 5 to 30 μm, and more preferably 8 to 12 μm. In at least one embodiment the groove sections 4 have a lattice pattern pitch P of 197 μm, and have a depth D of 10 μm. The pitch P refers to the distance between the adjacent groove sections 4 , and the depth D of the groove section 4 refers to the distance from an open surface S to a bottom section E (deepest section).
[0040] In the embossed adhesive film 1 , the groove section 4 is formed so that the width of the groove section 4 is continuously reduced from the open surface S toward the bottom section E. It suffices that the width at the open surface 5 be 10 to 30 μm, the width at the bottom section E be 0 to 5 μm, and the angle theta (θ) be 7 to 90°. In at least one embodiment, the groove section 4 has an angle theta (see FIG. 4 ) of 60°, a width WS at the open surface S of 14 μm, and a width WE at the bottom section E of 3 μm. The angle theta is determined by (ratio of) these widths. The width used herein refers to the distance in the lateral direction of the groove section which is a groove continuously formed in the shape of a stripe, as indicated by the width WS and the width WE. The open surface is an insubstantial surface and is a surface equivalent to the flat surface of the adhesive layer opposite to the base material layer where the groove section does not exist. The width at the open surface 5 is preferably 15 to 25 μm. The bottom section refers to a section including the deepest section (viewed from the open surface) of the groove section, as indicated by the bottom section E. A case where the width at the bottom section is “0” means that, when the cross-sectional shape of the groove section in the lateral direction (see FIGS. 3 and 4 ) has vertices, the groove section has an inverted triangular cross-sectional shape, for example. When the width at the bottom section is greater than “0” as in the embossed adhesive film 1 , the bottom section forms a predetermined surface so that the cross-sectional shape of the groove section in the lateral direction is a trapezoid (upper side is longer). The width at the bottom section is preferably 2 to 4 μm.
[0041] FIGS. 5 to 9 are diagrams showing another embodiment of an embossed adhesive film according to the invention. FIG. 5 is a plan view showing the side of an adhesive layer, FIGS. 6 , 7 , and 9 , showing the surface of the adhesive layer, are enlarged views of a groove section and a projection section in the cross section perpendicular to the longitudinal direction of the groove section, and FIG. 8 is an enlarged plan view of the groove section and the projection section. A side view of the side face is omitted.
[0042] An embossed adhesive film 51 shown in the drawings includes the base material layer (not shown) and the adhesive layer 3 laminated on the base material layer in the same manner as the above-described embossed adhesive film 1 . The surface (surface A) of the adhesive layer 3 on the side opposite to the surface (surface B) on the side of the base material layer is a substantially flat surface, and the continuous groove sections 4 disposed in a lattice pattern are formed to reach the side faces 5 of the adhesive layer 3 . It is preferable that an embossed liner (not shown), having projection sections that form the groove sections 4 , be further laminated on the surface of the adhesive layer 3 on the side opposite to the base material layer. The embossed liner is then removed from the embossed adhesive film 51 .
[0043] The embossed adhesive film 51 differs from the embossed adhesive film 1 in that projection sections 6 disposed at almost equal intervals are formed on the surface (surface A) of the adhesive layer 3 on the side opposite to the base material layer. The remaining features are the same as those of the embossed adhesive film 1 . Therefore, further description is omitted.
[0044] In the embossed adhesive film 51 , the projection section 6 is in the shape of a pyramid (see FIGS. 8 and 9 ). The projection section 6 is provided at the center of an area enclosed by the groove sections 4 of the lattice pattern formed by causing the groove sections 4 to intersect (area corresponding to the grid) (see FIGS. 5 and 8 ). In the embossed adhesive film 51 , it is preferable that the projection section be in the shape of a pyramid. The projection section may be in the shape of a cone. The number of projection sections is not limited insofar as the projection sections are disposed at approximately equal intervals.
[0045] In the embossed adhesive film 51 , it suffices that the projection section have a width WN of 5 to 50 μm, a height H of 5 to 15 μm, and an angle phi (φ) of 20 to 180°. In at least one embodiment the projection section 6 has a width WN of 38 μm, a heights H of 10 μm, and an angle phi of 125°. The angle phi is determined by the width and the height of the projection.
[0046] In the embossed adhesive films 1 and 51 , the surface (surface A) of the adhesive layer opposite to the base material layer is substantially flat. This means that a flat surface exists between the groove sections and the like, and the surface A is flat excluding the groove sections (and the projection sections). FIGS. 10 and 11 show another embodiment.
[0047] FIGS. 10 and 11 are diagrams showing still another embodiment of an embossed adhesive film according to the invention. FIG. 10 is a plan view showing the side of an adhesive layer (similar to FIGS. 2 and 5 ), and FIG. 11 is an enlarged diagram of the surface of the adhesive layer (similar to FIGS. 3 and 6 ). An embossed adhesive film 101 shown in the drawings includes the base material layer and the adhesive layer 3 laminated on the base material layer. Grooves and projections are formed at the surface of the adhesive layer 3 opposite to the base material layer 2 so that a flat surface does not exist between the groove sections 4 . In other words, the surface of the adhesive layer 3 which is the substantial section is formed by a series of projection sections in the shape of a cone or pyramid. In the embossed adhesive film 101 , the pitch P of groove section 4 is preferably 10 μm to 300 μm and the depth D of groove section 4 is preferably 5 μm to 30 μm.
[0048] A method of laminating an adherend according to the invention is described below based on specific embodiments. The following embodiment illustrates the case where an adhesive film is used as an adhesive layer, a first adherend is a base material film, and a second adherend is a flexible printed circuit. This embodiment is called a FPC stiffener film lamination method according to the invention.
[0049] FIG. 12 is a diagram showing one embodiment of the FPC stiffener film lamination method according to the invention. FIG. 12 shows steps of the method in the order of (a) to (e) as indicated by the arrows. A flat adhesive film 123 formed of a thermo-setting adhesive and provided with flat liners 7 a and 7 b on either side is provided (see (a) in FIG. 12 ). The adhesive film 123 is a film which forms an adhesive layer. The adhesive film 123 may be prepared, or a commercially available product may be used as the adhesive film 123 . An adhesive film made of a thermo-setting polymer resin such as an epoxy resin, a polyester resin, a phenolic resin, or a polyurethane resin is commercially available. The adhesive film 123 may be a thermoplastic adhesive film. The thickness of the adhesive film 123 differs depending on the composition of the adhesive film 123 , the type of an embossed liner described later, the type of the FPC as the adherend, and the like. A person skilled in the art may arbitrarily adjust the thickness of the adhesive film 123 . A preferable thickness is 30 to 200 μm.
[0050] The flat liner 7 b on one side of the adhesive film 123 is removed, and a base material film 122 is laminated on the side of the adhesive film 123 from which the flat liner 7 b is removed (see (b) in FIG. 12 ). The base material film 122 is a film which forms a base material layer. Since the base material film 122 is subjected to a high temperature of 200° C. or more in a solder reflow step, the base material film 122 exhibiting heat resistance is used. The base material film 122 may be prepared, or a commercially available product may be used as the base material film 122 . A film exhibiting excellent heat resistance made of a resin material such as polyimide or glass epoxy, a metal material such as copper, stainless steel, or aluminum, or the like is commercially available. The thickness of the base material film 122 is preferably 50 to 200 μm.
[0051] A primer may be used to increase the adhesion between the adhesive film 123 and the base material film 122 . The type of the primer differs depending on the type of the materials for the adhesive film 123 and the base material film 122 . A person skilled in the art may select an appropriate primer (see patent document 4).
[0052] After removing the flat liner 7 a from the other side of the adhesive film 123 , an embossed liner 8 having a minute embossing pattern surface, on which projection sections 124 are formed, is pre-laminated on the side of the adhesive film 123 from which the flat liner 7 a is removed, and the embossed liner 8 is thermocompression-bonded to the adhesive film 123 , preferably by using a laminator (see (c) in FIG. 12 ). When thermocompression bonding the embossed liner 8 , the laminator used is preferably set at a roll temperature of 80 to 95° C., a roll speed of 0.5 to 1.5 m/min, and a pressure of 200 to 400 kPa. An embossed adhesive film 125 with the embossed liner 8 , in which groove sections are formed in the adhesive film 123 , can be obtained by these steps. The embossed adhesive film 125 is an FPC stiffener film of which the base material film 122 has a reinforcement function.
[0053] An embossed liner having groove sections disposed at approximately equal intervals may be used as the embossed liner 8 . To form projection section 124 , slurry prepared by mixing a thermo-setting adhesive of the same material as the adhesive film and beads may be provided to the groove sections to form projection sections on the adhesive film (see patent document 3).
[0054] The projection section 124 forms a groove section 4 in the adhesive film 123 (see (d) in FIG. 12 ). The projection sections 124 are provided in a lattice pattern and continuously formed to reach the side faces of the embossed liner 8 . The projection sections 124 are formed so that the pitch of the lattice pattern is 300 μm or less and the height of the projection section is 5 to 30 μm. The projection section 124 is preferably formed so that the width of the projection section 124 is continuously reduced from the bottom surface toward the vertex, the width at the bottom surface is 10 to 30 μm, and the width at the vertex is 0 to 5 μm.
[0055] The embossed liner 8 may be formed by subjecting a flat release liner, made of a polymer resin material such as polyethylene, polypropylene, or polyvinyl chloride, or another material coated with such a polymer resin material, to embossing processing using a heated embossing roll or the like to form the projection sections 124 (see patent document 2). The embossed liner 8 may be formed by using a technology disclosed in the patent document 5. The embossed liner 8 is preferably provided with improved release properties by subjecting the embossed liner 8 to release processing.
[0056] A separately provided flexible printed circuit 11 having a circuit pattern layer 10 and a base material layer 9 is bonded to the embossed adhesive film 125 . This step is carried out by removing the embossed liner 8 from the embossed adhesive film 125 , pre-laminating the surface of the embossed adhesive film 125 , on which the groove sections 4 are formed, on the base material layer 9 of the flexible printed circuit 11 , and thermocompression bonding the embossed adhesive film 125 by using a laminator (see (d) in FIG. 12 ). In this step, the laminator is preferably set at a roll temperatures of 80 to 95° C., a roll speed of 0.5 to 1.5 m/min, and a pressure of 200 to 400 kPa. A fluid (air) confined in the groove section 4 is caused to flow toward the outside of the system by pressing the flexible printed circuit 11 against the embossed adhesive film 125 at this setting, whereby air bubbles can be removed. In this case, all the groove sections 4 in the adhesive film 123 flatten to increase the contact area between the flexible printed circuit 11 and the adhesive film 123 , whereby a desired bond strength is obtained and the entire appearance is improved.
[0057] A flexible printed circuit 121 reinforced by the base material layer 2 can be obtained by these steps (see (e) in FIG. 12 ). In the reinforced flexible printed circuit 121 , the base material layer 2 is formed by the base material film 122 , and the adhesive layer 3 is formed by the adhesive film 123 . In the above-described embodiment, an adhesive film in which a minute embossing pattern is formed can also be obtained by directly applying an adhesive to the embossed liner 8 in the shape of a film without using the adhesive film 123 and the flat liner 7 a.
EXAMPLES
[0058] The invention is described below in detail based on examples.
Example 1
[0059] A polyimide film with a thickness of 125 μm (manufactured under the trade name APICAL NPI by Kaneka Corporation), an epoxy adhesive film with a thickness of 40 μm (manufactured under the trade name NIKAFLEX SAFW by Nikkan Industries Co., Ltd.), an FPC (prepared by plating copper to a thickness of 12 μm on a polyimide film with a thickness of 25 μm (manufactured under the trade name KAPTON E by DuPont-Toray Co., Ltd.) by an additive method) were provided. A flat release liner made of polyethylene (manufactured by Tomoegawa Paper Co., Ltd.) was provided, and subjected to embossing processing by using an embossing machine to prepare an embossed liner on which projection sections were formed. Incidentally, the embossed liner was produced in such a manner that an adhesive film later subjected to embossing processing with the embossed liner might have a minute embossing pattern having P of 197 μm and D of 10 μm in FIG. 3 and theta of 60°, WE of 3 μm, and WS of 14.5 μm in FIG. 4 .
[0060] After removing the flat liner from one side of the epoxy adhesive film, the polyimide film was bonded to the side of the epoxy adhesive film from which the flat liner was removed. After removing the flat liner from the other side of the epoxy adhesive film, the embossed liner was pre-laminated on the side of the epoxy adhesive film from which the flat liner was removed, and subjected to thermocompression bonding using a laminator at a roll temperature of 90° C., a roll speed of 1 m/min, and a pressure of 300 kPa to obtain an embossed adhesive film. The resulting embossed adhesive film was similar to the embossed adhesive film 1 shown in FIGS. 1 to 4 .
[0061] The resulting embossed adhesive film was cut to a size of 38×8.1 mm. After removing the embossed liner, the embossed adhesive film was pre-laminated on the FPC, and subjected to thermocompression bonding using a laminator at a roll temperature of 90° C., a roll speed of 1 m/min, and a pressure of 300 kPa to obtain a reinforced flexible printed circuit.
[0062] The presence or absence of air bubbles in the resulting reinforced flexible printed circuit was examined (examination 1). After subjecting the resulting reinforced flexible printed circuit to pre-curing at 80° C. for 30 min and curing at 160° C. for 60 min, the presence or absence of air bubbles in the reinforced flexible printed circuit was examined (examination 2). The results are shown in Table 1. The examination was carried out by naked eye observation conducted by five persons. The presence or absence of air bubbles was evaluated as a ratio “number of persons who recognized air bubbles/total number of persons (five persons)”, and the size of the air bubbles is also indicated in Table 1.
Example 2
[0063] A reinforced flexible printed circuit was obtained in the same manner as in Example 1 except for thermocompression bonding the embossed adhesive film by using a thermocompression bonding device instead of the laminator at a heating plate temperature of 150° C., a pressure of 500 kPa, and a thermocompression bonding time of 30 sec. After subjecting the flexible printed circuit to pre-curing and curing, the presence or absence of air bubbles was examined. The results are shown in Table 1.
Example 3
[0064] Using the same method of processing the embossed liner, embossing machine, liner, and other materials as in Example 1, projection sections were formed on an epoxy adhesive film. The resulting embossed adhesive film was similar to the embossed adhesive film 51 shown in FIGS. 5 to 9 . Incidentally, the embossed liner was produced in such a manner that an adhesive film later subjected to embossing processing with the embossed liner might have a minute embossing pattern having P of 197 μm, WS of 20 μm, WE of 3 μm, theta of 60°, D of 15 μm, WN of 38 μm, and H of 10 μm in FIGS. 5 to 9 . A reinforced flexible printed circuit was obtained in the same manner as in Example 1. After subjecting the flexible printed circuit to pre-curing and curing, the presence or absence of air bubbles was examined. The results are shown in Table 1.
Comparative Example 1
[0065] A reinforced flexible printed circuit was obtained in the same manner as in Example 1. However, after removing the flat liner from one side of the epoxy adhesive film, the polyimide film was bonded to the side of the epoxy adhesive film without using the embossed liner to obtain an adhesive film formed only of a flat surface. After removing the flat liner from the other side of the epoxy adhesive film, the epoxy adhesive film was pre-laminated on the FPC, and subjected to thermocompression bonding using the laminator. After subjecting the flexible printed circuit to pre-curing and curing according to Example 1, the presence or absence of air bubbles was examined. The results are shown in Table 1.
[0000]
TABLE 1
Examination 1
Examination 2
Example 1
0/5
0/5
Example 2
0/5
0/5
Example 3
0/5
0/5
Comparative
5/5
Large air
5/5
Large air
Example 1
bubble
bubble
[0066] (Consideration) As shown in Table 1, the results of Examples 1 to 3 suggest that excellent air bleeding properties were obtained so that an excellent appearance was provided due to the absence of air bubbles. In Comparative Example 1, occurrence of air bubbles was confirmed by all persons.
[0067] The method of laminating an adherend according to the invention can be suitably used as a means for laminating a stiffener film on a flexible printed circuit. The method of laminating an adherend according to the invention can also be suitably used as a means for laminating a cover lay film or a dry film used during circuit pattern formation. The method of laminating an adherend according to the invention can also be suitably used as a means for laminating and securing a heat sink on the top surface of a semiconductor or a means for securing an integrated circuit (IC) chip on a flexible printed circuit.
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There is provided a means for laminating and bonding a flexible printed circuit and a stiffener film with an adhesive layer therebetween by using a laminator without creating air bubbles at the lamination surface and without using large-scale manufacturing equipment. A method comprising: providing a laminate in which liners are on upper and lower surfaces of a half-cured reactive adhesive layer ( 3 ), removing one of the liners from the laminate, and bonding a surface of a first adherend ( 2 ) to the first exposed surface of the adhesive layer; removing the other liner from the laminate, pressure bonding a minute embossing pattern ( 4 ) surface of an embossed liner to the second exposed surface of the adhesive layer to form a minute embossing pattern on the surface of the adhesive layer; and removing the embossed liner from the surface of the adhesive layer, and thermocompression bonding a second adherend to the surface of the adhesive layer having the minute embossing pattern.
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This invention relates to a process for preparing certain biscyclopentadienyl Group 4 transition metal complexes possessing diene ligands. The complexes are valuable commercial polymerization catalysts for use in preparing polyolefins, especially crystalline polypropylene.
The preparation and characterization of certain biscyclopentadienyl (Cp 2 ) zirconium and hafnium diene complexes is described in the following references: Yasuda, et al., Organometallics, 1982, 1, 388 (Yasuda I); Yasuda, et al. Acc. Chem. Res., 1985, 18 120 (Yasuda II); Erker, et al., Adv. Organomet. Chem., 1985, 24, 1 (Erker I); Erker et al. Chem. Ber., 1994, 127, 805 (Erker II); and U.S. Pat. No. 5,198,401. The present metal complexes were first disclosed in U.S. application Ser. No. 08/284,925, filed Aug. 2, 1994, of which U.S. Ser. No. 08/481,791, filed Jun. 7, 1995 is a continuation-in-part application, the teachings of which are hereby incorporated by reference.
U.S. Pat. No. 5,470,993 disclosed monocyclopentadienyl diene complexes with titanium or zirconium in which the metal is in the +2 formal oxidation state. Such metal complexes were formed by contacting a metal dihalide with a source of the cyclopentadienyl dianion ligand, a reducing agent and the neutral diene compound in any order.
SUMMARY OF THE INVENTION
The present invention relates to a process for preparing metal complexes containing two cyclopentadienyl groups or substituted cyclopentadienyl groups, said complex corresponding to the formula:
(Cp).sub.2 MD
wherein:
M is titanium, zirconium or hafnium in the +2 or +4 formal oxidation state;
Cp independently each occurrence is a substituted or unsubstituted cyclopentadienyl group bound in an η 5 bonding mode to the metal, said substituted cyclopentadienyl group being substituted with from one to five substituents independently selected from the group consisting of hydrocarbyl, silyl, germyl, halo, cyano, hydrocarbyloxy, siloxy, and mixtures thereof, said substituent having up to 20 nonhydrogen atoms, or optionally, two such substituents (except cyano or halo) together cause Cp to have a fused ring structure, or together form one or two linking moieties joining the two Cp groups;
D is a stable, conjugated diene ligand, optionally substituted with one or more hydrocarbyl groups, silyl groups, hydrocarbylsilyl groups, silylhydrocarbyl groups, or mixtures thereof, said D having from 4 up to 40 nonhydrogen atoms and forming a π-complex with M when M is in the +2 formal oxidation state, and forming two σ-bonds with M when M is in the +4 formal oxidation state,
said process comprising contacting in any order:
a) a Group 4 metal salt corresponding to the formula M'X 3 or M"X 4 , or a Lewis base adduct thereof,
b) a conjugated diene, D',
c) a reducing agent, and
d) a compound of the formula: CpM* or (Cp-Cp)M* n , wherein,
M' is titanium, zirconium or hafnium in the +3 formal oxidation state;
M" is titanium, zirconium or hafnium in the +4 formal oxidation state;
X is a halide, C 1-6 hydrocarbyloxy or di(C 1-6 hydrocarbyl)amido group;
D' is an uncoordinated diene having the same number of carbons as D and the same substitution pattern as D;
M* is a Group 1 or 2 metal cation, a Grignard reagent cation or a tri(C 1-4 hydrocarbyl)silyl group; and
n is 1 when M* is a Group 2 metal cation and n is 2 when M* is a Group 1 metal cation, a Grignard reagent cation, or a trihydrocarbylsilyl group with the proviso that reagents a), and d) are not contacted with one another in the absence of reagent c).
Thus, suitable processes entail:contacting components a), b) and c), and thereafter contacting the resulting product with component d),
contacting components b) and c), contacting the resulting product with component a) and thereafter contacting the resulting product with component d), or
contacting all four components simultaneously.
In the diene complexes in which M is in the +2 formal oxidation state, the diene is associated with M as a π-complex in which the diene normally assumes an s-trans configuration or an s-cis configuration in which the bond lengths between M and the four carbon atoms of the conjugated diene are nearly equal (Δd as defined hereafter ≧-0.15 Å) whereas in the complexes in which M is in the +4 formal oxidation state, the diene is associated with the transition metal as a σ-complex in which the diene normally assumes a s-cis configuration in which the bond lengths between M and the four carbon atoms of the conjugated diene are significantly different (Δd<-0.15 Å). The formation of the complex with M in either the +2 or +4 formal oxidation state depends on the choice of the diene, the specific metal complex and the reaction conditions employed in the preparation of the complex.
Uniquely, where racemic or meso isomers may be produced (that is when the two Cp groups are optionally bonded together) the process results in formation of increased quantities of the racemic form of the diene metal complex. Typically, mixtures containing greater than 60 mole percent of the racemic isomer are produced.
It is to be understood that the present complexes may be formed and utilized as a mixture of the π-complexed and σ-complexed diene compounds where the metal centers are in the +2 or +4 formal oxidation state. Preferably the complex in the +2 formal oxidation state is present in a molar amount from 0.1 to 100.0 percent, more preferably in a molar amount from 10 to 100.0 percent, most preferably in a molar amount from 60 to 100.0 percent. Techniques for separation and purification of the complex in the +2 formal oxidation state from the foregoing mixtures are known in the art and disclosed for example in the previously mentioned Yasuda, I, supra, and Erker, I to III, supra, references and may be employed if desired to prepare and isolate the complexes in greater purity.
DETAILED DESCRIPTION
All reference to the Periodic Table of the Elements herein shall refer to the Periodic Table of the Elements, published and copyrighted by CRC Press, Inc., 1989. Also, any reference to a Group or Groups shall be to the Group or Groups as reflected in this Periodic Table of the Elements using the IUPAC system for numbering groups.
Useful dienes, D', are dienes that do not decompose under reaction conditions used to prepare the complexes according to the invention. Under subsequent polymerization conditions, or in the formation of catalytic derivatives of the present complexes, the diene ligand, D, may undergo chemical reaction or be replaced by another ligand.
Examples of suitable D ligands include: η 4 -1,4-diphenyl-1,3-butadiene; η 4 -1,3-pentadiene; η 4 -1-phenyl-1,3-pentadiene; η 4 -1,4-dibenzyl-1,3-butadiene; η 4 -2,4-hexadiene; η 4 -3-methyl-1,3-pentadiene; η 4 -1,4-ditolyl-1,3-butadiene; η 4 -1,4-bis(trimethylsilyl)-1,3-butadiene, 2,3 dimethyl butadiene, isoprene. Of the foregoing complexes, terminally substituted derivatives (that is, the 1,4-disubstituted 1,3-dienes and 1- or 4-monosubstituted 1,3-dienes) generally form π-complexes whereas solely internally substituted derivatives (that is, the 2,3-disubstituted 1,3-dienes and 2- or 3-monosubstituted 1,3-dienes) generally form σ-complexes. Examples of terminally substituted dienes include 1,4-diphenyl-1,3-butadiene, 1-phenyl-1,3-pentadiene, and 2,4 hexadiene. Examples of internally substituted dienes include isoprene or 2,3-dimethyl butadiene.
Preferred diene ligands are 1,3-pentadiene, 1,4-diphenyl-1,3-butadiene, 1-phenyl-1,3-pentadiene, 1,4-dibenzyl-1,3-butadiene, 2,4-hexadiene, 3-methyl-1,3-pentadiene, 1,4-ditolyl-1,3-butadiene, and 1,4-bis(trimethylsilyl)-1,3-butadiene. All geometric isomers the foregoing diene compounds may be utilized.
By the term "reducing agent" as used herein is meant a metal or compound which, under reducing conditions can cause the transition metal to be reduced from the +4 or +3 formal oxidation state to the +2 formal oxidation state. The same procedure is employed for the preparation of the diene complexes where M is in the +2 formal oxidation state or in the +4 formal oxidation state, the nature of formal oxidation state of M in the complex being formed being primarily determined by the diene employed. Examples of suitable metal reducing agents are alkali metals, alkaline earth metals, aluminum, zinc and alloys of alkali metals or alkaline earth metals such as sodium/mercury amalgam and sodium/potassium alloy. Specific examples of suitable reducing agent compounds are sodium naphthalenide, potassium graphite, lithium alkyls, aluminum trialkyls and Grignard reagents. Most preferred reducing agents are the alkali metals or alkaline earth metals, C 1-6 alkyl lithium, tri C 1-6 alkyl aluminum and C 1-6 alkyl Grignard reagents, especially lithium, n-butyl lithium, n-butyl MgCl, and triethyl aluminum.
The metal salts used as reactants in the present invention are preferably Group 4 metal halides, or dimethoxyethane (DME) or tetrahydrofuran (THF) adducts thereof, most preferably titanium tetrachloride, zirconium tetrachloride, hafnium tetrachloride, ZrCl 4 ·2THF, or HfCl 4 ·2THF.
By the term "mixtures" used with respect to Cp substituent groups are included Cp moieties bearing differing groups as well as Cp moieties bearing groups that are mixtures of the previously named entities, such as trihydrocarbylsilyl groups, especially trialkylsilyl groups, as well as trihydrocarbylgermyl groups, halohydrocarbyl groups and hydrocarbyloxy-substituted hydrocarbyl groups. Preferred substituents are C 1-6 hydrocarbyl or tri(C 1-6 hydrocarbyl)silyl groups. Additionally preferably, component d) is a Grignard salt, lithium salt or trimethylsilyl derivative of Cp or Cp-Cp.
Preferred complexes formed by the present invention correspond to the formula: ##STR1## wherein: M is titanium, zirconium or hafnium, preferably zirconium or hafnium, in the +2 or +4 formal oxidation state;
R' and R" in each occurrence are independently selected from the group consisting of hydrogen, hydrocarbyl, silyl, germyl, cyano, halo and combinations thereof, said R' and R" having up to 20 non-hydrogen atoms each, or adjacent R' groups and/or adjacent R" groups (when R' and R" are not hydrogen, halo or cyano) together form a divalent derivative (i.e., a hydrocarbadiyl, siladiyl or germadiyl group) or one R' and one R" together (when R' and R" groups are not hydrogen halo or cyano) combine to form a divalent radical (i.e., a hydrocarbadiyl, germadiyl or siladiyl group) linking the two substituted cyclopentadienyl groups; and
D is as previously defined.
Preferably, R' and R" independently in each occurrence are selected from the group consisting of hydrogen, methyl, ethyl, and all isomers of propyl, butyl, pentyl and hexyl, as well as cyclopentyl, cyclohexyl, norbornyl, benzyl, and trimethyl silyl, or adjacent R' groups and/or adjacent R" groups on each cyclopentadienyl ring (except hydrogen) are linked together thereby forming a fused ring system such as an indenyl, 2-methyl-4-phenylindenyl, 2-methyl-4-naphthylindenyl, tetrahydroindenyl, fluorenyl, tetrahydrofluorenyl, or octahydrofluorenyl group, or one R' and one R" are linked together forming a 1,2-ethanediyl, 2,2-propanediyl or dimethylsilanediyl linking group.
Examples of the above metal complexes where the metal is titanium, zirconium or hafnium and preferably zirconium or hafnium include: bis(η 5 -cyclopentadienyl)zirconium (η 4 -1,4-diphenyl-1,3-butadiene), bis(cyclopentadienyl)zirconium (2,3-dimethyl-1,3-butadiene), (bis-η 5 -cyclopentadienyl)-zirconium η 4 -1,4-ditolyl-1,3-butadiene, bis(η 5 -cyclopentadienyl)zirconium η 4 -2,4-hexadiene, bis(η 5 -cyclopentadienyl)zirconium η 4 -3-methyl-1,3-pentadiene, bis(η 5 -cyclopentadienyl)zirconium η 4 -1-phenyl-1,3-pentadiene, bis(pentamethyl-η 5 -cyclopentadienyl)zirconium η 4 -1,4-diphenyl-1,3-butadiene, bis(pentamethyl-η 5 -cyclo-Pentadienyl)zirconium η 4 -1,4-dibenzyl-1,3-butadiene, bis(pentamethyl-η 5 -cyclopentadienyl)zirconium η 4 -2,4-hexadiene, bis(pentamethyl-η 5 -cyclopentadienyl)zirconium η 4 -3-methyl-1,3-pentadiene, bis(ethyltetramethyl-η 5 -cyclopentadienyl)zirconium η 4 -1,4-diphenyl-1,3-butadiene, bis(ethyltetramethyl-η 5 -cyclopentadienyl)zirconium η 4 -1,4-dibenzyl-1,3-butadiene, bis(ethyltetramethyl-η 5 -cyclopentadienyl)zirconium η 4 -2,4-hexadiene, bis(ethyltetramethyl-η 5 -cyclopentadienyl)zirconium η 4 -3-methyl-1,3-pentadiene, (pentamethyl-η 5 -cyclopentadienyl), (η 5 -cyclopentadienyl)zirconium η 4 -1,4-dibenzyl-1,3-butadiene, (η 5 -cyclopentadienyl)zirconium η 4 -2,4-hexadiene, bis(t-butyl-η 5 -cyclopentadienyl)-1,2-zirconium η 4 -1,4-diphenyl-1,3-butadiene, bis(t-butyl-η 5 -cyclopentadienyl)zirconium η 4 -1,4-dibenzyl-1,3-butadiene, bis(t-butyltetramethyl-η 5 -cyclopentadienyl)-zirconium η 4 -2,4-hexadiene, η 5 -cyclopentadienyl, (tetramethyl-η 5 -cyclopentadienyl)zirconium η 4 -3-methyl-1,3-pentadiene, bis(pentamethyl-η 5 -cyclopentadienyl)zirconium η 4 -1,4-diphenyl-1,3-butadiene, bis(pentamethyl-η 5 -cyclopentadienyl)zirconium η 4 -1-phenyl-1,3-pentadiene, bis-(tetramethyl-η 5 -cyclopentadienyl)zirconium η 4 -3-methyl-1,3-pentadiene, bis(methyl-η 5 -cyclopentadienyl)zirconium η 4 -1,4-diphenyl-1,3-butadiene, bis(η 5 -cyclopentadienyl)zirconium η 4 -1,4-dibenzyl-1,3-butadiene, bis(trimethyl-silyl-η 5 -cyclopentadienyl)zirconium η 4 -2,4-hexadiene, bis(trimethylsilyl-η 5 -cyclopentadienyl)-zirconium η 4 -3-methyl-1,3-pentadiene, (η 5 -cyclopentadienyl)(trimethylsilyl-η 5 -cyclopentadienyl)zirconium η 4 -1,4-diphenyl-1,3-butadiene, (η 5 -cyclopentadienyl)(trimethylsilyl-η 5 -cyclopentadienyl)zirconium η 4 -1,4-dibenzyl-1,3-butadiene, (trimethylsilyl-η 5 -cyclopentadienyl)(pentamethyl-η 5 -cyclopentadienyl)zirconium η 4 -2,4-hexadiene, bis(benzyl-η 5 -cyclopentadienyl)zirconium η 4 -3-methyl-1,3-pentadiene, bis(η 5 -indenyl)-zirconium η 4 -1,4-diphenyl-1,3-butadiene, bis(η 5 -indenyl)zirconium η 4 -1,4-dibenzyl-1,3-butadiene, bis(η 5 -indenyl)zirconium η 4 -2,4-hexadiene, bis(η 5 -indenyl)zirconium η 4 -3-methyl-1,3-pentadiene, bis(η 5 -fluorenyl)zirconium η 4 -1,4-diphenyl-1,3-butadiene, (pentamethylcyclopentadienyl)(η 5 -fluorenyl)zirconium η 4 -1-phenyl-1,3-pentadiene, bis(η 5 -fluorenyl)zirconium η 4 -1,4-dibenzyl-1,3-butadiene, bis(η 5 -fluorenyl)-zirconium η 4 -2,4-hexadiene, and bis(η 5 -fluorenyl)zirconium η 4 -3-methyl-1,3-pentadiene.
Highly preferred bis-cyclopentadienyl compounds of formula A include those containing one or two bridging groups linking the cyclopentadienyl groups. Preferred bridging groups are those corresponding to the formula (ER"' 2 ) x wherein E is carbon, silicon or germanium, R"' independently each occurrence is hydrogen or a group selected from silyl, hydrocarbyl, hydrocarbyloxy and combinations thereof, or two R"' groups together form a ring system, said R"' having up to 30 carbon or silicon atoms, and x is an integer from 1 to 8. Preferably R"' independently each occurrence is methyl, benzyl, tert-butyl or phenyl.
Examples of the foregoing bridged cyclopentadienyl containing complexes are compounds corresponding to the formula: ##STR2## wherein: M, D, E, R"' and x are as previously defined, and R' and R" in each occurrence are independently selected from the group consisting of hydrogen, hydrocarbyl, silyl, germyl, cyano, halo and combinations thereof, said R' and R" having up to 20 non-hydrogen atoms each, or adjacent R' groups and/or adjacent R" groups (when R' and R" are not hydrogen, halo or cyano) together form a divalent derivative (i.e., a hydrocarbadiyl, siladiyl or germadiyl group) or one R' and one R" together (when R' and R" groups are not hydrogen halo or cyano) combine to form a divalent radical (i.e., a hydrocarbadiyl, germadiyl or siladiyl group) linking the two cyclopentadienyl groups.
Such bridged structures are especially suited for the preparation of polymers having stereoregular molecular structure. In such capacity it is preferred that the complex be nonsymmetrical or possess a chiral, stereorigid structure. Examples of the first type are compounds possessing different delocalized π-bonded systems, such as one cyclopentadienyl group and one fluorenyl group. Similar systems based on Ti(IV) or Zr(IV) were disclosed for preparation of syndictactic olefin polymers in Ewen, et al., J. Am. Chem. Soc. 110, 6255-6256 (1980). Examples of chiral structures include bis-indenyl complexes. Similar systems based on Ti(IV) or Zr(IV) were disclosed for preparation of isotactic olefin polymers in Wild et al., J. Organomet. Chem, 232, 233-47, (1982).
Exemplary bridged cyclopentadienyl moieties in the complexes of formula (B) are: dimethylsilanediylbis((2-methyl-4-phenyl)-1-indenyl)zirconium (η 4 -1,4-diphenyl-1,3-butadiene), dimethylsilanediyl-bis((2-methyl-4-(1-napthyl))-1-indenyl)zirconium (η 4 -1,4-diphenyl-1,3-butadiene), 1,2-ethanediylbis(2-methyl-4-(1-phenyl)-1-indenyl)zirconium (η 4 -1,4-diphenyl-1,3-butadiene), 1,2-ethanediyl-bis(2-methyl-4-(1-napthyl)-1-indenyl)zirconium (η 4 -1,4-diphenyl-1,3-butadiene), (1,2-ethanediylbis(1-indenyl)!zirconium (η 4 -1,4-diphenyl-1,3-butadiene), 1,2-ethanediylbis(1-tetrahydroindenyl)!zirconium (η 4 -1,4-diphenyl-1,3-butadiene), 1,2-ethanediylbis(1-indenyl)!hafnium (η 4 -1,4-diphenyl-1,3-butadiene), and 2,2-propanediyl(9-fluorenyl)(cyclopentadienyl)!zirconium (1,4-diphenyl-1,3-butadiene).
In general, the process involves combining the respective reactants, preferably in a solution, optionally while agitating and heating above ambient temperature (25° C.). Recovery and purification of the intermediate products when a multiple step reaction is employed may be desirable. The process preferably is conducted in an inert, noninterfering solvent at a temperature from -100° C. to 300° C., preferably from -78° to 130° C., most preferably from -10° to 120° C.
Suitable inert, noninterfering solvents for the formation of the complexes are aliphatic and aromatic hydrocarbons and halohydrocarbons, ethers, and cyclic ethers. Examples include straight and branched-chain hydrocarbons such as isobutane, butane, pentane, hexane, heptane, octane, and mixtures thereof; cyclic and alicyclic hydrocarbons such as cyclohexane, cycloheptane, methylcyclohexane, methylcycloheptane, and mixtures thereof; aromatic and hydrocarbyl-substituted aromatic compounds such as benzene, toluene, xylene, and the like, C 1-4 dialkyl ethers, C 1-4 dialkyl ether derivatives of (poly)alkylene glycols, and tetrahydrofuran. Mixtures of the foregoing list of suitable solvents are also suitable.
The recovery procedure involves separation of the resulting byproducts and devolatilization of the reaction medium. Extraction into a secondary solvent may be employed if desired. Alternatively, if the desired product is an insoluble precipitate, filtration or other separation technique may be employed.
The complexes are rendered catalytically active by combination with one or more activating cocatalysts, by use of an activating technique, or a combination thereof. Suitable activating cocatalysts include polymeric or oligomeric alumoxanes, especially methylalumoxane, triisobutyl aluminum modified methylalumoxane, or diisobutylalumoxane; strong Lewis acids (the term "strong Lewis acid" as used herein is defined as trihydrocarbyl substituted Group 13 compounds, especially tri(hydrocarbyl)aluminum- or tri(hydrocarbyl)boron compounds and halogenated derivatives thereof, having from 1 to 10 carbons in each hydrocarbyl or halogenated hydrocarbyl group, more especially perfluorinated tri(aryl)boron compounds, and most especially tris(pentafluorophenyl)borane); amine, phosphine, aliphatic alcohol and mercaptan adducts of halogenated tri(C 1-10 hydrocarbyl)boron compounds, especially such adducts of perfluorinated tri(aryl)boron compounds; nonpolymeric, ionic, compatible, noncoordinating, activating compounds (including the use of such compounds under oxidizing conditions); bulk electrolysis (explained in more detail hereinafter); and combinations of the foregoing activating cocatalysts and techniques. The foregoing activating cocatalysts and activating techniques have been previously taught with respect to different metal complexes in the following references: EP-A-277,003, U.S. Pat. No. 5,153,157, U.S. Pat. No. 5,064,802, EP-A-468,651 (equivalent to U.S. Ser. No. 07/547,718), EP-A-520,732 (equivalent to U.S. Ser. No. 07/876,268), and WO93/23412 (equivalent to U.S. Ser. No. 07/884,966 filed May 1, 1992) the teachings of which are hereby incorporated by reference.
The catalysts may be used to polymerize ethylenically and/or acetylenically unsaturated monomers having from 2 to 20 carbon atoms either alone or in combination. Preferred monomers include the C 2-10 α-olefins especially ethylene, propylene, isobutylene, 1-butene, 1-hexene, 4-methyl-1-pentene, and 1-octene and mixtures thereof. Other preferred monomers include vinylcyclohexene, vinylcyclohexane, styrene, C 1-4 alkyl substituted styrene, tetrafluoroethylene, vinylbenzocyclobutane, ethylidenenorbornene, piperylene, 1,4-hexadiene, methyl-1,4-hexadiene and 7-methyl-1,6-octadiene.
When the present bridged cyclopentadienyl polymerization catalysts are used to polymerize prochiral olefins, syndiotactic or isotactic polymers are attainable. As used herein, the term "syndiotactic" refers to polymers having a stereoregular structure of greater than 50 percent, preferably greater than 75 percent syndiotactic of a racemic triad as determined by 13 C nuclear magnetic resonance spectroscopy. Conversely, the term "isotactic" refers to polymers having a stereoregular structure of greater than 50 percent, preferably greater than 75 percent isotactic of a meso triad as determined by 13 C nuclear magnetic resonance spectroscopy. Such polymers may be usefully employed in the preparation of articles and objects having an extremely high resistance to deformation due to the effects of temperature via compression molding, injection molding or other suitable technique.
EXAMPLE
Having described the invention the following examples are provided as further illustration thereof and are not to be construed as limiting. Unless stated to the contrary all parts and percentages are expressed on a weight basis.
EXAMPLE 1
Preparation of 1,2-ethanediylbis(η 5 -indenyl)zirconium (1,4-diphenyl-η 4 -butadiene)
In an inert atmosphere glove box, 377 mg (1.00 mmol) of ZrCl 4 , 106 mg (1.00 mmol) of 1,4-diphenyl-1,3-butadiene were combined in 60 ml of tetrahydrofuran (THF). To the stirred solution was added 0.80 ml (2.00 mmol) of 2.5M n-butyl lithium in mixed hexanes. The solution turned from colorless to bright orange. After two minutes 520 mg (1.00 mmol) of 1,2-ethylene bis(indenide)!(MgCl) 2 (THF) 2 was added as a solid. The solution turned dark red immediately. After stirring at 25° C. for 3 hours, the volatiles were removed under reduced pressure. The red paste residue was triturated with mixed hexanes and extracted 3 times with a total of 60 ml of toluene. The extracts were filtered and combined with the hexanes filtrate and volatiles removed under reduced pressure. The solid residue was slurried in 2 mL of tetramethylsilane which was then decanted from the solid. Further drying under reduced pressure gave 286 mg of a red solid.
1 H NMR analysis showed that racemic 1,2-ethylenebis(indenyl)!zirconium (1,4-diphenyl-1,3-butadiene) was the major product. Conversion to the dichloride by addition of concentrated HCl gave 63 percent of racemic 1,2-ethylenebis(indenyl)!zirconium dichloride and 37 percent of the meso isomer as the only identifiable indenyl containing products.
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Biscyclopentadienyl, Group 4 transition metal complexes containing a conjugated diene ligand group wherein the diene is bound to the transition metal either in the form of σ-complex or a π-complex are readily prepared by reacting in any order:
a) a Group 4 metal salt corresponding to the formula M'X 3 or M"X 4 , or a Lewis base adduct thereof,
b) a conjugated diene, D',
c) a reducing agent, and
d) a compound of the formula: CpM* or (Cp-Cp)M*n n , wherein,
M' is titanium, zirconium or hafnium in the +3 formal oxidation state;
M" is titanium, zirconium or hafnium in the +4 formal oxidation state;
X is a halide, C 1-6 hydrocarbyloxy or di(C 1-6 hydrocarbyl)amido group;
D' is an uncoordinated diene having the same number of carbons as D and the same substitution pattern as D;
M* is a Group 1 or 2 metal cation, a Grignard reagent cation or a tri(C 1-4 hydrocarbyl)silyl group; and
n is 1 when M* is a Group 2 metal cation and n is 2 when M* is a Group 1 metal cation, a Grignard reagent cation, or a trihydrocarbylsilyl group with the proviso that reagents a), and d) are not contacted with one another in the absence of reagent c).
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to piperazine derivatives, vasodilators containing the same and a vasodilating method for vascular disorders. The piperazine derivatives provided by the present invention are novel compounds which have potent vasodilating activities. Therefore, they are useful for the therapy of vascular disorders such as cerebral, coronary and peripheral vascular diseases, which are to be treated by increasing blood flow.
2. Description of the Prior Art
Vascular diseases occuring after cerebral embolism, myocardial infarction or the like have recently taken a large portion of adult diseases, and development of drugs effectively preventing such disorders is highly desirable.
There have been developed a large number of vasodilators including derivatives of 3,4,5-trimethoxycinnamic acid such as, for example, 1-[3-(3,4,5-trimethoxyphenyl)-2-propenoyl]-piperazine (cinepazide), which are not necessarily satisfactory in efficacy of the drug.
SUMMARY OF THE INVENTION
As a result of our extensive studies on the pharmacological activities of a variety of piperazine derivatives which were synthesized starting with 5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoic acid, we have found that the compounds of the invention have excellent vasodilating activities. The present invention is based upon the above finding.
Therefore, it is an object of the invention to provide novel piperazine derivatives and vasodilators containing the same as well as to provide a vasodilating method for vascular disorders.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, there are provided piperazine derivatives represented by the general formula ##STR1## wherein Y represents pyrrolidyl group or a lower alkylamino group.
Further, according to the invention, a vasodilator containing a medically effective amount of the piperazine derivative represented by the above-mentioned general formula (I) and a method for controlling or preventing vascular disorders are provided.
Further, a pharmaceutical composition for the treatment of vascular disorders comprising a vasodilating amount of a piperazine derivative having the formula (I) together with a pharmaceutically acceptable carrier or diluent.
As the preferable amino group in the above formula (I) are mentioned methylamino, ethylamino, isopropylamino, propylamino, butylamino, dimethylamino or diethylamino.
Vasodilators as used herein means pharmaceutical preparations that have vasodilating activities to increase blood flow.
The piperazine derivatives of the above formula (I) are obtained by reacting thiazolidinethionamide of 5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoic acid with piperazine to give 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl]-piperazine which is then condensed with a chloroacetic amide of the formula ClCH 2 COY wherein Y has the same meaning as defined above.
The piperazine derivatives of the invention represented by the above-mentioned formula (I) can also be converted to acid addition salts. The acid addition salts thus obtained are within the scope of the invention. As the acid salts are preferably mentioned the salts with a mineral acid such as hydrochloric acid or sulfuric acid and the salts with an organic acid such as acetic acid, maleic acid, fumaric acid or malic acid.
The piperazine derivatives of the invention can be used as vasodilators effectively acting on cerebral, coronary and peripheral vascular and other diseases, the dosage of which is generally from 50 to 1500 mg per day, divided, as needed, into 1 to 3 doses. The route of administration is desirably by oral administration, but possibly by intravenous injection.
The piperazine derivatives of the invention are incorporated with pharmaceutical carriers or excipients by conventional methods to formulate tablets, powders, capsules or granules. As examples of the carrier or excipient are mentioned calcium carbonate, calcium phosphate, starch, sucrose, lactose, talc, magnesium stearate and the like. The piperazine derivatives of the invention can also be formulated in liquid preparations such as oily suspension, syrup or injectable solution.
This invention will be described in more details by means of examples and results of general pharmacological tests for determining the vasodilating activity as well as of acute toxicity tests.
EXAMPLE 1
To a solution of 1090 mg (12.65 mmol) of piperazine in a mixed solvent of 8 ml of water and 8 ml of tetrahydrofuran was added a solution of 500 mg of 5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoic thiazolidinethionamide in 3 ml of tetrahydrofuran. The mixture was reacted at room temperature for 1 hour. To the reaction mixture was added 0.5 N aqueous solution of sodium hydroxide, followed by extraction with three portions of chloroform and washing with water. The organic layer from the extraction was dried over anhydrous sodium sulfate, and then the solvent was distilled off under reduced pressure to yield 475 mg of the residue of the extract. Said residue was chromatographed on silica gel column. There was obtained 368 mg of 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl,]-piperazine from the eluate fractions with chloroform-methanol (96:4).
To a solution of 266 mg of said piperazine derivative in 10 ml of dry toluene were added in an atmosphere of argon a solution of 146 mg of N-chloroacetylpyrrolidine in 2 ml of dry toluene and subsequently 1.24 ml of triethylamine. The mixture was reacted by heating under reflux for 3.5 hours. After cooled, water was added to the reaction mixture, followed by extraction with three portions of methylene chloride and washing with water. The organic layer from the extraction was dried over anhydrous sodium sulfate. Then the solvent was removed by distillation under reduced pressure to yield 391 mg of the residue of the extract. Said residue was chromatographed on silica gel column. There was obtained 197 mg of 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl]-4-(pyrrolidinocarbonylmethyl)-piperazine. Spectrophotometric data of the product support the structure of the formula (II) shown below.
IRγ max CHCl 3 (cm -1 ): 1645, 1600, 1585
1 H-NMR(deutero chloroform) δ(ppm): 1.80-2.14(4H), 2.47-2.77(4H), 3.17(2H,s), 3.30-3.82 (8H), 3,84(3H,s), 3.87(6H,s), 6.40 (1H,d,J=14 Hz) ##STR2##
EXAMPLE 2
To a solution of 320 mg of 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl]-piperazine in 10 ml of dry toluene were added in an atmosphere of argon 131 mg of N-isopropylchloroacetamide and subsequently 0.70 ml of triethylamine. The mixture was heated under reflux for 6.5 hours. After cooled, water was added to the reaction mixture, followed by extraction with three portions of methylene chloride and washing with water. The organic layer from the extraction was dried over anhydrous sodium sulfate, and the solvent was removed by distillation under reduced pressure to give 421 mg of the residue of the extract. Said residue was chromatographed on silica gel column. There was obtained 364 mg of 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl]-4-(N - isopropylaminocarbonylmethyl)-piperazine from eluate fractions with chloroform-methanol (97:3). Spectrophotometric data of the product support the structure of the formula (III) shown below.
IRγ max CHCl 3 (cm -1 ): 3375, 1665, 1640, 1615, 1600, 1580
1 H-NMR(deutero chloroform)δ(ppm): 1.18(6H,d,J=7 Hz), 2.40-2.67(4H), 3.00 (2H,s), 3.50-3.83(4H), 3.83(3H,s), 3.86(6H,s), 6.38(1H,d,J=14 Hz) ##STR3##
EXAMPLE 3
To a solution of 279 mg of 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl,]-piperazine in 10 ml of dry toluene were added a solution of 155 mg of N,N-dimethylchloroacetamide in a mixed solvent of 1 ml of dry toluene and 1 ml of dry chloroform and subsequently 0.82 ml of triethylamine in an atmosphere of argon. The mixture was heated under reflux for 4.5 hours. After cooled, water was added to the reaction mixture, followed by extraction with three portions of methylene chloride and washing with water. The organic layer from the extraction was dried over anhydrous sodium sulfate, and the solvent was removed by distillation under reduced pressure to give 429 mg of the residue of the extract. Said residue was chromatographed on silica gel column. There was obtained 313 mg of 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl]-4-(N,N-dimethylaminocarbonylmethyl)-piperazine from the eluate fractions of chloroform-methanol (97:3). Spectrophotometric data of the product support the structure of the formula (IV) shown below.
IRγ max CHCl 3 (cm -1 ) : 1640, 1615, 1600, 1585
1 H-NMR(deutero chloroform) δ(ppm): 2.42 2.70(4H), 2.93(3H,s), 3.05(3H,s), 3.37 (2H,s), 3.57-3.80(4H), 3.83(3H,s), 3.86(6H,s), 6.40(1H,d,J=14 Hz) ##STR4##
EXAMPLE 4
To a solution of 302 mg of 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl]-piperazine in dry toluene (12 ml) were added in an atmosphere of argon 1.3 ml of triethylamine and subsequently a solution of 254 mg of N-methylchloroacetamide in dry toluene-chloroform (1:1, 2 ml). The mixture was refluxed for 8 hours. To the reaction mixture was added water, and extraction was made with methylene chloride. The organic layer was concentrated under reduced pressure, and the residue thus obtained was chromatographed on silica gel column. There was obtained 263 mg of 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl]-4-(methylaminocarbonylmethyl)-piperazine. Spectrophotometric data of the product support the structure of the formula (V) shown below. ##STR5##
IRγ max CHCl 3 (cm -1 ): 3400, 1670, 1640, 1615, 1600, 1580 1 H-NMR(deutero chloroform)δ(ppm): 2.3-2.70(4H), 3.68-3.87(each s, total 3H), 3.00(2H,s), 3.37-3.80(4H), 3.82(s,3H), 3.84(s,6H), 6.40(1H,d,J=14 Hz)
TEST EXAMPLE
(Vasodilating Activity)
Blood flow in the femoral artery was measured in hybrid adult dogs (weighing about 10 Kg) anesthesized with pentobarbital (30 mg/kg, i.v.) which were subjected to autoperfusion at the left femoral artery under artificial respiration while being equipped with a blood observation probe. The test compound dissolved in 5% ethanol solution was administered through the femoral artery. Percent increase in femoral arterial blood flow after administration of the test compound is shown in Table 1 below in comparison with that prior to the administration.
TABLE 1______________________________________Vasodilating Activities Dose (mg/Kg, Intra- Number Increase in femoral arterial injec- of arterial blood flowTest compound tion) animals (Δ% ± S.E.)______________________________________Example 1 0.3 4 50.8 ± 21.3(Compound of 1.0 4 164.5 ± 47.3formula II)Example 2 0.3 4 42.3 ± 3.8(Compound of 1.0 4 107.3 ± 14.5formula III)Example 3 0.3 4 32.0 ± 9.0(Compound of 1.0 4 75.3 ± 6.2formula IV)Example 4 0.3 4 16.8 ± 4.0(Compound of 1.0 4 66.8 ± 13.7formula V)Cinepazide 0.3 4 16.9 ± 6.4(Control drug) 1.0 4 35.9 ± 7.3______________________________________
(Acute Toxicity)
An acute toxicity test was made using ICR male rats (5 weeks old) by oral administration. The LD 50 values for all of the compounds of the present invention tested were 400 mg/Kg or higher, thereby demonstrating high safety.
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There are disclosed novel piperazine derivatives and vasodilators containing the same. The compounds are useful for controlling or preventing vascular disorders such as cerebral embolism, myocardial infarction and limb arterial obstruction. As typical compounds are mentioned 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl]-4-(pyrrolidinocarbonylmethyl)-piperazine, 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl]-4-(N-isopropylaminocarbonylmethyl)-piperazine, 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl]-4-(N,N-dimethylaminocarbonylmethyl)piperazine and 1-[5-(3,4,5-trimethoxyphenyl)-2,4-pentadienoyl]-4-(methylaminocarbonylmethyl)-piperazine.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to an exhaust gas turbocharger for an internal combustion engine including an exhaust gas turbine and a compressor driven by the exhaust gas turbine, wherein the turbine comprises a turbine housing with a turbine wheel rotatably supported in the turbine housing.
[0002] DE 28 43 202 discloses an exhaust gas turbocharger which includes an exhaust gas turbine driven by the exhaust gases of an internal combustion engine and a compressor, which is coupled to the turbine by a shaft for rotation with the turbine and which compresses inducted combustion air to a charge pressure with which the combustion air is supplied to the cylinder inlets of the internal combustion engine. The housing of the exhaust gas turbocharger consists of three individual housings for the turbine, for the compressor and for the bearing between the turbine and the compressor. Each individual housing is formed as a casting wherein the housing for the turbine and the compressor, which are arranged at opposite sides of the bearing housing, include also the supply and the discharge passages for the turbine and, respectively, the compressor.
[0003] The housings, which are manufactured by casting, can be produced inexpensively and they also provide for the necessary safety if the turbine or the compressor wheel should burst. They are however heavy, particularly for utility vehicle applications because they are relatively large, and they require expensive and complicated connecting and support elements for their support in the vehicle. In addition, those high-mass housing have the disadvantage that, because of their high heat capacity, a large amount of heat is stored in the walls of the housings. As a result, a relatively large amount of heat is removed from the exhaust gas supplied to the turbine, whereby the energy supplied to the turbine wheel is reduced which results in power losses particularly after a cold start of the engine.
[0004] On the other hand, there is the problem that, after shut down of the engine, the heat stored in the housing, particularly in the area of the turbocharger, may lead to coking of the oil in the charger. The high temperatures may further result in thermal stresses in the housing. In order to avoid excessively high thermal stresses, the housings must be provided with complicated cooling systems whereby the already large weight is further increased.
[0005] Another disadvantage resides in the fact that, because of the removal of heat from the exhaust gas, the catalytic converter is insufficiently heated particularly at the beginning of the engine operation so that the catalytic converter becomes fully effective only with a certain time delay.
[0006] It is the object of the present invention to provide a 25 turbocharger, which is of a simple design but has a high efficiency. It should also have a relatively low weight.
SUMMARY OF THE INVENTION
[0007] In an exhaust gas turbocharger for an internal combustion engine including an exhaust gas turbine and a compressor connected to the turbine so as to be operated thereby, the turbine includes a housing consisting of an inner and an outer shell formed from steel sheets arranged in spaced relationship so as to form therebetween an intermediate.
[0008] A coolant may be conducted through the space between the sheet metal shells. The two metal shells, which delimit particularly a spiral passage for guiding the exhaust gas to the turbine wheel, are—compared with the cast components of the state of the art—relatively lightweight since the relatively thin sheet metal walls are substantially lighter than the cast walls. Inspite of the small wall thickness, they have a high burst resistance. Another advantage is the low heat storage capacity of the double wall of sheet metal whereby the thermal efficiency of the turbocharger and also the start-up behavior of the catalytic converter of the respective engine are improved. There is no need for providing the heat shield panels by means of which the radiation heat has been contained in the past.
[0009] In a particular embodiment, the inner and outer sheet metal shells consist of sheet steel wherein the outer sheet consists of temperature resistant material and the inner sheet consists of a high-temperature resistant material. The inner metal shell is in direct contact with the hot exhaust gas and is therefore heated to a greater degree than the outer metal shell, which is not contacted by the hot exhaust gas. The inner shell, which delimits the spiral inlet passage and which consists of a highly temperature resistant material is selected so that it is resistant to the high exhaust gas temperatures. The outer shell, which extends around the inner shell, however is not in contact with the exhaust gas so that it can be made of a material with lower temperature resistance than that of which the inner shell is made.
[0010] The inner shell as well as the outer shell can be shaped parts formed by suitable deformation techniques, such as internal high-pressure shaping procedures, from planar metal sheets. They may have complex shapes to form for example the spiral gas inlet channel of the turbine. It is also possible to form a spiral inlet with two inlet passages from a single inner shell, the two passages of the spiral channel being separated by a divider wall, which is formed by an appropriate shaping of the inner shell.
[0011] The inner and the outer shells are preferably constructed so as to be separated from the exhaust channel of the turbine wherein the turbine wheel is supported. The exhaust channel which, at the opposite side of the turbine wheel, may be connected with a bearing housing is preferably a casting which is capable of withstanding the static and dynamic forces of the turbine wheel and which is capable of maintaining its original shape and dimensions. The inner and the outer shells are separate from the outlet channel and are therefore not subjected to the high forces effective on the turbine wheel. The heat generated by the turbine wheel is generally taken up and conducted out by way by the exhaust channel so that the inner and outer shell remain to a large degree unaffected by the heat generated by the turbine wheel.
[0012] The intermediate space between the inner and the outer shells may accommodate a coolant, which, in a preferred embodiment, is admitted by way of inlet nozzles and discharged by way of outlet nozzles. In another embodiment, the turbine housing, which consists of inner and outer shells, may form a single component with an exhaust manifold, which is mounted to the cylinder outlet of the internal combustion engine.
[0013] The invention will become more readily apparent from the following description of particular embodiments thereof on the basis of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a cross-sectional view of a turbine housing with a two-channel spiral inlet structure,
[0015] [0015]FIG. 2 is a cross-sectional view of a turbine housing with a single-channel spiral inlet structure,
[0016] [0016]FIG. 3 is a side view of the exhaust gas turbine housing according to FIG. 2,
[0017] [0017]FIG. 4 is a front view of the exhaust gas turbine housing of FIG. 2, and
[0018] [0018]FIG. 5 is a top view of the exhaust gas turbine of FIG. 2 formed integrally with an exhaust manifold of an engine.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] In the figures, identical parts are designated by the same reference numerals.
[0020] As shown in FIG. 1, the exhaust gas turbine of an exhaust gas turbocharger of an internal combustion engine which may be a gasoline engine or a Diesel engine and which may be installed in a passenger car or a utility vehicle, comprises a turbine housing 2 and a turbine wheel 3 onto which the exhaust gas of the internal combustion engine is conducted so that the turbine wheel is rotated thereby. The turbine wheel 3 is rotatably supported in an exhaust channel 4 of the exhaust gas turbine and is connected to a shaft 5 for rotation therewith. The rotation of the turbine wheel 3 is transmitted, by way of the shaft 5 , to the impeller of the compressor of the exhaust gas turbocharger for compressing the intake air. The exhaust channel 4 is connected to a bearing housing 6 by means of connecting elements 7 . The exhaust channel 4 and the bearing housing 6 are disposed at opposite sides of the turbine wheel 3 . The turbine housing 2 is of a double-wall design and comprises an inner shell 8 and a spaced outer shell 9 , which together form a spiral turbine inlet channel 10 . In the embodiment as shown in FIG. 1, the inlet channel 10 includes two inlet passages, that is, a first inlet passage 10 a and a second inlet passage 10 b. Exhaust gas from the cylinder exhaust of the internal combustion engine is supplied to the turbine wheel 3 by way of an inlet area 11 from the spiral channel 10 and is then conducted, by way of the exhaust channel 4 , to a downstream catalytic converter. The two inlet passages 10 a and 10 b are separated from each other inside the spiral channel 10 by a divider wall 12 , which is formed integrally with the inner shell 8 . The plane of the divider wall 12 intersects the inlet area 11 . In the example as shown in FIG. 1, the divider wall 12 however does not extend into the inlet area 11 . Rather, near the inlet area 11 , the two flow passages 10 a and 10 b are joined to permit a gas exchange between the two flow passages.
[0021] The inner shell 8 and the outer shell 9 of the turbine housing 2 are spaced from each other and form an intermediate space 13 through which advantageously a coolant can be conducted. The coolant is introduced by way of an inlet nozzle 14 and is discharged by way of an outlet nozzle 15 , which are both arranged in the outer shell 9 . In the intermediate space 13 , between the inner shell 8 and the outer shell 9 , there are provided support ribs 16 by which the inner and outer shells 8 and 9 are supported with respect to each other. The support ribs 16 act also as reinforcement ribs to make the turbine housing 2 more rigid and to improve its overall strength.
[0022] The inner shell 8 and the outer shell 9 consist of sheet metal, especially of sheet steel and can be manufactured by a mechanical deforming process. The divider wall 12 separating the two inlet flow passages 10 a and 10 b is formed integrally with the wall of the inner shell 8 , whereby the inner shell 8 has a closely heart-shaped cross-section. The outer shell 9 surrounds the inner shell without projections or recesses in its contour. The inner shell 8 consists preferably of a highly temperature resistant sheet steel; the outer shell 9 is not exposed directly to the high exhaust gas temperatures and consists therefore only of a temperature resistant sheet steel.
[0023] The inner shell 8 and the outer shell 9 are manufactured as individual components separate from the exhaust channel 4 and the bearing housing 6 . When assembled, the inner shell 8 and the outer shell 9 radially surround the inlet area 11 between the exhaust gas outlet channel 4 and the bearing housing 6 by way of which the exhaust gas flows from the inlet flow passages 10 a and 10 b onto the blades 3 b of the turbine wheel 3 . The connecting element 7 disposed in the inlet area 11 between the exhaust channel 4 and the bearing housing 6 may be in the form of a flow guide structure by which a desired momentum is imparted to the exhaust gas which is directed onto the turbine wheel 3 . The connecting element 7 may be part of a variable turbine inlet geometry for the variable adjustment of the inlet flow cross-section to the turbine wheel 3 .
[0024] The exhaust channel 4 and the bearing housing 6 are preferably castings. The inner shell 8 , which is disposed on the outside of the exhaust channel 4 , and the bearing housing 6 are preferably gas- and pressure-tight in order to avoid flow and pressure losses.
[0025] In the embodiment of FIG. 2, the exhaust gas turbine 1 includes a spiral inlet channel 10 with a single inlet flow passage, which is in communication, by way of the inlet area 11 , with the exhaust channel 4 and the turbine wheel disposed therein. The connecting element 7 is preferably in the form of a stationary guide structure. In addition, a variable turbine geometry 17 may be disposed in the turbine inlet area 11 for example in the form of a guide vane structure with variable vanes, which can be moved by a control element 18 between a closed position in, which the flow cross-section of the inlet area is minimized, and an open position, in which the exhaust gas flow through the turbine in unrestricted.
[0026] From the representations of FIGS. 3 and 4, it is apparent that the turbine housing is connected to an exhaust gas manifold 19 wherein an expansion-accommodating element 20 (FIG. 3) may be provided for the interconnection. The turbine housing 2 is connected to the exhaust channel 4 and the bearing housing by struts 21 and 22 .
[0027] [0027]FIG. 5 shows an arrangement wherein the turbine housing is formed integrally with the exhaust manifold.
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In an exhaust gas turbocharger for an internal combustion engine including an exhaust gas turbine and a compressor connected to the turbine so as to be operated thereby, the turbine includes a housing consisting of an inner and an outer shell formed from steel sheets and being arranged in spaced relationship so as to form therebetween an intermediate space.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority based on Japanese Patent Application No. 2002-379970, filed Dec. 27, 2002, the entirety of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a cylindrical-shaped bearing for supporting a reciprocating shaft, for example, a piston rod of a shock absorber for damping of a shock load in automobiles, industrial machinery or the like.
[0003] Automobiles, two-wheelers or the like have spread worldwide, which correspondingly demands various performances such as safety, comfortableness, stillness or the like. Also, an improvement achieved in engines generally and widely leads to enhancement lengthening of travel distance and in durability in body structure now.
[0004] For example, in order to improve a ride feeling, shock absorbers are provided between a body and wheels in an automobile. Such shock absorbers are of a known hydraulic-type construction such that a piston having an orifice is arranged in a cylinder, the cylinder being mounted on, for example, a wheel side and a piston rod being mounted on a body side. Such shock absorbers are normally mounted with an axial direction thereof inclined relative to a direction, in which wheels and a body reciprocate, so that there is caused a state, in which the piston rod is supported on an extremely small area of a bearing. When such state of extremely small area support continues, the bearing will wear early. In order to cope with this, for example, a material for forming bearings has been improved. Since there are limits to such improvement of the material, however, an improvement has been also demanded in terms of a structure.
[0005] In complying with such demand, there has been proposed a bush provided in a bearing for bearing a piston rod in, for example, shock absorbers, in which bush end inner-peripheral surfaces extending from ends of the bush to a bearing surface for bearing the rod are defined by a plurality of inclined surfaces such that an angle relative to a central axis of the bearing gradually decreases toward the bearing surface from the ends (see, for example, JP-A-11-270556 (paragraph numerals “0007”-“0011”, FIG. 1).
[0006] With the constitution described in the above prior art document, however, since both axially end portions of the inner-peripheral surface of the bearing form so-called inclined portions including a plurality of joined cone-shaped side surfaces or arcuate surfaces, both side portions of an equal-diameter portion (parallel portion) between the inclined portions on both ends, which are contiguous to the inclined portions, become locally high in surface pressure, so that wear increases in some cases.
BRIEF SUMMARY OF THE INVENTION
[0007] The invention has been thought of in view of the above circumstances, and has its object to provide a cylindrical-shaped bearing for reciprocatory sliding, which eliminates a fear of occurrence of extremely small supporting area and locally high pressure surface area and is excellent in wear resistance.
[0008] According to the invention, a cylindrical-shaped bearing for supporting a reciprocating shaft, comprises, an inner peripheral surface for supporting thereon the reciprocating shaft, wherein the inner peripheral surface includes a first surface extending parallel to a central axis of the cylindrical-shaped bearing, and second and third tapered surfaces between which the first surface is arranged in a direction of the central axis and which are inclined with respect to the central axis in such a manner that diameters of the second and third tapered surfaces decrease gradually in respective axial directions away from respective axial ends of the inner peripheral surface toward the first surface.
[0009] As described above, an inner-peripheral surface of a bearing for bearing a piston rod in a shock absorber has a so-called crowning shape, and the inventors of the present application have earnestly studied about a cylindrical-shaped bearing for reciprocatory sliding, which possesses a more excellent wear resistance, in order to impart a further durability to shock absorbers, and found that an effect with excellent durability is obtained when inclined portions on both axial ends are lengthened and a central, parallel portion is shortened as compared with the prior art.
[0010] That is, when an axial length of the first surface is P and an axial length of the inner peripheral surface as a total amount of the axial length of the first surface and axial lengths of the second and third tapered surfaces is W, a relationship between P and W satisfies a formula of 0.5/W≦P/W≦⅓ (claim 2 ).
[0011] With this constitution, since the first surface centrally of the bearing is small in length, a shaft to be supported can be borne at a lengthy area (second and third tapered surfaces) when the shaft is inclined with respect to the bearing. That is, since the bearing supports the shaft in a large area, surface pressure is small to attack the bearing to a less degree, so that the bearing is made excellent in wear resistance.
[0012] Also, it is preferable that an angle between the central axis and each of the second and third tapered surfaces (or a tangential line of each of the second and third tapered surfaces) in a cross sectional view taken along an imaginary plane extending along the central axis is not less than 0.05 degree and not more than 5.0 degree.
[0013] Further, it is preferable for decreasing the surface pressure between the inner peripheral surface and shaft or increasing the support area therebetween that in the cross sectional view taken along the imaginary plane extending along the central axis, one of side surfaces (or a tangential line of the one of the side surfaces) of the second tapered surface and one of side surfaces (or a tangential line of the one of the side surfaces) of third tapered surface opposed to each other through the central axis is parallel to each other. It is preferable for preventing the surface pressure between the shaft and the inner peripheral surface from increasing locally (particularly, at a boundary between the first surface and at least one of the second and third tapered surfaces and/or at least one of axial ends of the inner peripheral surface) that a distance in a direction perpendicular to the ones of side surfaces opposed to each other through the central axis and parallel to each other (or the tangential lines of the ones of the side surfaces opposed to each other through the central axis and parallel to each other) between the ones of the side surfaces (or the tangential lines of the ones of the side surfaces opposed to each other through the central axis and parallel to each other) is not less than a diameter of the reciprocating shaft, over the whole axial lengths of the second and third tapered surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a partially cross sectional view taken along an imaginary plane extending along an central axis of a cylindrical bearing to show an embodiment of the invention with a bearing and a piston rod; and
[0015] [0015]FIG. 2 is a partially cross sectional view showing a shock absorber for automobiles in which the bearing of the invention is usable.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] An explanation will be given below to an embodiment of a bearing of the invention for bearing a piston rod of a shock absorber for automobiles, with reference to the drawings.
[0017] As shown in FIG. 2, a shock absorber 1 for automobiles is constructed such that an outer shell 3 receiving therein a cylinder 2 is connected at its lower end to a side of a wheel 4 through a connection 12 and a piston rod 6 of a piston 5 fitted slidably into the cylinder 2 is connected at its upper end to a side of a body 7 through a connection 13 . In addition, an outer cylinder 8 covering an upper end of the outer shell 3 is mounted on the upper end of the piston rod 6 .
[0018] A stepped guide member 9 is fittingly mounted in an upper portion of the outer shell 3 , and the guide member 9 is compressively secured between the cylinder 2 and a cap 10 fixed by welding or the like to the upper end of the outer shell 3 . A wrapped-bush type bearing 11 as a cylindrical-shaped bearing for reciprocatory sliding is mounted on an inner-periphery of the guide member 9 , and the bearing 11 slidably supports the piston rod 6 . In addition, in this mounting state, an axial direction of the shock absorber 1 is inclined relative to a direction, in which the wheel 4 and the body 7 reciprocate.
[0019] The bearing 11 is formed by winding a sheet material including a steel back plate and a bearing alloy material on the steel back plate into a cylindrical shape, and a slide surface (inner-peripheral surface) of the bearing alloy material is covered by a synthetic resin layer, in which PTFE (polytetrafluoroethylene) is added to and mixed with PFA (tetrafluoroethylene-perfluoro alkyl vinyl ether copolymer resin) of a main component of the synthetic resin layer. And the piston 5 is provided with an orifice 14 , so that when the wheel 4 moves up and down due to traveling, or starting/stoppage of an automobile to generate a vertical mutual movement between the cylinder 2 and the piston 5 , an oil filled in the cylinder 2 passes through the orifice 14 of the piston 5 to perform a damping action based on its viscous resistance and frictional resistances of various parts.
[0020] And as shown in FIG. 1 as an enlarged view of structural portions of the bearing 11 and the piston rod 6 , an inner-peripheral surface of the bearing 11 comprises a parallel portion 15 on a central area thereof and inclined portions 16 extending from both axial end portions of the bearing 11 to the parallel portion 15 . Here, the parallel portion 15 keeps its inner diameter constant in an axial direction, and the inclined portions 16 have respective inner diameters decreasing respectively from the axial end portions of the inner-peripheral surface to the parallel portion 15 . Incidentally, in a cross sectional view taken along an imaginary plane extending along a central axis 0 of the bearing 11 , the inclined portions 16 may be defined by straight lines inclined relative to the central axis O, or by internally projecting convex curves capable of supporting the piston rod 6 with a large support area between the piston rod 6 and each of the inclined portions 16 when the inner-peripheral surface of the bearing 11 is deformed to conform with an outer surface of the piston rod 6 . The inclined portions 16 may be defined by both the straight lines and internally projecting convex curves in the cross sectional view.
[0021] The parallel portion 15 is set to be small in axial length while the inclined portions 16 are set to be large in axial length. More specifically, when the bearing 11 has an axial length W (mm) and the parallel portion 15 has a length P (mm), the length P of the parallel portion 15 is set in a range to meet 0.5/W≦P/W≦⅓. Also, when the inclined portions 16 have an inclination of θ degrees relative to the central axis O of the bearing 11 , the inclination angle θ is set to meet 0.05 degree ≦θ≦5.0 degree. In addition, the inclination angle θ of the piston rod 6 is drawn largely with exaggeration in FIG. 1, although it is different from the reality.
[0022] Here, since the shock absorber 1 is mounted in an inclined attitude as shown in FIG. 2, the piston rod 6 is supported at edges of the bearing 11 . And when the wheel 4 moves up and down relative to the body 7 as the automobile travels, the piston 5 reciprocates vertically in the cylinder 2 and the piston rod 6 correspondingly moves vertically while supported at the edges of the bearing 11 .
[0023] In this case, the piston rod 6 is borne by a one-side half of an entire inner-peripheral surface of the inclined portion 16 above the central parallel portion 15 of the bearing 11 and by the other-side half of another entire inner-peripheral surface of the inclined portion 16 below the central parallel portion 15 . Further, since the parallel portion 15 is small in length and the inclined portions 16 are large in length, a length of the piston rod 6 borne by the inclined portions 16 becomes large. Therefore, the surface pressure on the inclined portions 16 of the bearing 11 is small to maintain smooth reciprocatory sliding, thus resulting in low wear and low friction. Incidentally, the piston rod 6 borne at the edges of the bearing 11 is shown by two-dot chain lines in FIG. 1.
[0024] Also, although being small in length, the parallel portion 15 is formed at the central area of the bearing. Therefore, as the piston rod 6 reciprocates, a lubricating oil is drawn onto the parallel portion 15 to form wedge oil films on the parallel portion 15 and the inclined portions 16 , so that the bearing 11 achieves low wear and low friction.
[0025] Tests were given to verify the above-mentioned effect of the invention. The verifying tests included a friction test for measuring friction (N) and an wear test for measuring wear loss (μm) of the bearing 11 , performed when the bearing 11 and the piston rod 6 slid relative to each other. A value of the friction (N) was measured in a state in which the bearing 11 was assembled into a concerned shock absorber, and the wear loss (μm) was measured by a circularity meter. Test pieces included items 1 to 9 of the invention and items 1 to 3 for comparison, whose axial length W (mm) of the bearing 11 , length P (mm) of the parallel portion 15 , and inclination angle θ (degrees) of the inclined portions 16 relative to the central axis were set respectively to be different among the items, and TABLE 1 indicates respective results and conditions of the tests.
TABLE 1 Friction Wear loss W(mm) P/W θ (deg) (N) (μm) Item of invention 1 15.0 0.033 1.19 93.1 25 Item of invention 2 15.0 0.1 1.32 100.0 31 Item of invention 3 15.0 0.15 2.45 98.0 29 Item of invention 4 15.0 0.25 0.25 107.8 36 Item of invention 5 15.0 0.333 0.86 109.8 33 Item of invention 6 15.0 0.333 0.17 103.9 28 Item of invention 7 15.0 0.333 1.72 96.0 30 Item of invention 8 6.0 0.333 4.29 87.2 42 Item of invention 9 30.0 0.017 0.06 105.8 19 Item for comparison 1 15.0 0.01 0.58 147.0 73 Item for comparison 2 15.0 0.5 1.15 139.2 62 Item for comparison 3 15.0 1 0 142.1 80
[0026] conditions of wear test:
[0027] load: 1960N stroke: +25 mm frequency: 2.5 Hz
[0028] number of times: two million
[0029] temperature: 80° C. lubrication: SA oil
[0030] shaft material: steel with Cr plating
[0031] Rz: 1 μm or less bush size: θ20×W mm×t 1.5 mm
[0032] conditions of friction test:
[0033] load: 980N stroke: +5 mm
[0034] temperature: room temperature
[0035] lubrication: SA oil
[0036] shaft material: steel with Cr plating
[0037] Rz: 1 μm or less bush size: φ41×W mm×t 2.0 mm
[0038] From the results of tests, remarkably favorable results in both friction (N) and wear loss (μm) have been obtained by items 1 to 9 of invention as compared with items 1 to 3 for comparison.
[0039] In addition, the invention is not limited to the embodiment described above and shown in the drawings but susceptible to the following extension or modification.
[0040] Shock absorbers, to which the invention is applicable, are not limited to the use for automobiles.
[0041] A mating shaft or member to be borne by the cylindrical-shaped bearing for reciprocatory sliding according to the invention, is not specifically limitative but may be any one on which an offset load acts and which reciprocates with sliding, as well as the piston rod of the shock absorber.
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In order to provide durable shock absorbers, a bearing to bear a piston rod is enhanced in wear resistance and made low in friction. A cylindrical-shaped bearing for reciprocatory sliding, to bear a piston rod comprises lengthy inclined portions and a short parallel portion on an inner-peripheral surface of the bearing.
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TECHNICAL FIELD
This invention is in the field of power operated tools used during surgery for cutting, drilling, and similar functions, as applied to muscle, bone, or other types of tissue.
BACKGROUND OF THE INVENTION
During the performance of endoscopic or arthroscopic surgery, it is often necessary or useful to be able to perform a power assisted cutting, drilling, chipping, or other similar action on a variety of tissues. Such actions may be applied to muscle tissue, other soft tissue, or bone. The type of knife or other implement used for each function is specifically designed for the given type of action to be performed on a given type of tissue. Similarly, the motion which is imparted to the implement is designed to operate the specific implement in the preferred way. The mode of motion used in known power tools is either pure rotation or pure reciprocation.
For instance, the implement could be a drill, a scalpel, a burr, a rasp, a chisel, a rotary cutter, or a reciprocating cutter. The particular implement selected might perform better with a rotary action, or a reciprocating action. The preferred action might depend upon the type of tissue being operated on, as well as upon the type of implement. For the sake of simplicity, the action performed by these implements often will be referred to herein generally as "cutting", it being understood that for some implements, the action might more accurately be described as chiseling, filing, or some other action.
Such a known power tool would be an integral tool which might typically incorporate a handle such as a pistol grip, a drive mechanism, and a sheath through which the cutting implement is driven. The sheath might be open ended, or it might have an enclosed end, with the integral cutting implement being exposed through a side window. It is currently known to select a power tool which incorporates the desired type of cutting implement, with the power tool being designed to impart the selected mode of motion to the implement. Each currently known tool is limited to imparting either a rotary mode or a reciprocating mode of motion, to the cutting implement.
Such currently known power tools are typically electrically powered through a cable attached to the handle, or pneumatically powered through a hose. The electric motor and other elements of the drive mechanism are specifically designed to impart a rotary mode of motion to the cutting implement, or to impart a reciprocating mode of motion to the implement. When the surgeon wishes to switch to a different cutting implement, he must switch to a different power tool which incorporates the desired implement, and which is designed to impart the desired mode of motion to the implement.
There are several disadvantages to the currently known power surgery tools. First, the surgeon must switch to a different power tool if he wishes to use a different cutting implement. This requires that a relatively large number of power tools be made available for an operation, adding to clutter in the operating room, and adding to the expense of the surgery. Second, sterilization of a large number of power tools adds to the cost of the surgery and further taxes the resources of the hospital. Third, the hospital must insure that it has on hand a large number of power tools in order to meet the needs experienced during a wide variety of surgical operations. Fourth, currently known power tools are capable of imparting only rotary or reciprocating motion to a cutting implement. Many implements perform optimally when given a combination of rotary and reciprocating motion.
Therefore, it is an object of the present invention to provide a portable power surgery tool in which a portion of the drive mechanism can be changed to switch from one mode of motion to another mode. It is a further object of the present invention to provide a portable power surgery tool in which the cutting implement and a portion of the drive mechanism can be replaced as a disposable unit, to switch from one implement which requires a given mode of motion to another implement which requires a second mode of motion. It is a still further object of the present invention to provide a portable power surgery tool which is capable of imparting a combination of rotary and reciprocating motion to a cutting implement. It is yet a further object of the present invention to provide a portable power surgery tool which is economical to make and easy to use.
SUMMARY OF THE INVENTION
A preferred embodiment of the present invention, by way of example only, is a portable power tool having a housing in the shape of a pistol grip. The housing contains a battery or small power cartridge, an electric motor with a rotating output shaft, a transmission mechanism, a drive shaft, a cutting implement on the drive shaft, and a sheath partially covering the drive shaft and the implement. The transmission mechanism, drive shaft, cutting implement and sheath can be removed and replaced easily with another similar assembly which incorporates a different cutting implement, and which imparts a different mode of motion to the implement. This assembly is designed to be disposable.
The transmission mechanism is driven by the rotating output shaft of the motor, and it converts this rotary motion to a given mode of output motion, which may be rotary, reciprocating or a combination of rotary and reciprocating. The type of output motion developed by a given transmission depends upon the design of a drive piston or bushing and a limiter piston or bushing within the transmission. The drive piston or bushing is driven in rotating motion by the output shaft of the motor. The drive piston or bushing is connected to the output shaft of the motor in such a way that the drive piston or bushing can move longitudinally with respect with the motor shaft, if necessary. If the desired output motion of the transmission is pure rotary motion, a drive bushing is used which has a smooth cylindrical outer surface, and it rotates within the housing of the tool, without any longitudinal motion.
On the other hand, if the desired output motion of the transmission has a reciprocating component, a drive piston is used or the outer surface of the drive piston is encircled with a continuous cam groove which bends toward one end of the piston and then toward the other end, such as a continuous sine wave. The tool has at least one cam follower element mounted within the housing so that the element will protrude into the cam groove in the drive piston. The element is captured so that it can not move with respect to the housing when the tool is assembled. Therefore, as the drive piston is rotated by the motor, the stationary element follows the continuous cam groove as the piston rotates, driving the piston back and forth longitudinally in a reciprocating motion. This element can be a ball or a pin, or some other element which will readily follow the cam groove.
A drive piston or bushing designed to produce motion having a rotary component is fixedly attached to the drive shaft, so that rotation of the drive piston or bushing results in rotation of the drive shaft. A drive piston designed to impart pure reciprocating motion to the cutting implement, with no rotary motion, is rotatably attached to the drive shaft, so that as the drive piston rotates, the drive shaft will not rotate.
Therefore, a drive piston designed to produce pure rotary motion will have no cam groove in its outer surface, and it will be fixedly attached to the drive shaft. A drive piston designed to produce a combination of rotary and reciprocating motion will have a cam groove in its outer surface, and it will be fixedly attached to the drive shaft. Finally, a drive piston designed to produce pure reciprocating motion will have a cam groove in its outer surface, and it will rotate freely with respect to the drive shaft.
At an intermediate point on the drive shaft, within a limiter piston cavity in the transmission body, a limiter piston or bushing is fixedly attached to the drive shaft. The limiter piston or bushing is specifically designed for the mode of motion desired for the attached cutting implement. The limiter piston cavity within the transmission body has a relatively square cross section in all cases. For a transmission designed to impart pure rotary motion to the cutting implement, the limiter bushing is cylindrical, with a diameter essentially equal to one side of the square cross section of the limiter piston cavity, so that the limiter bushing can rotate within the cavity as the drive piston rotates. The length of the limiter bushing is essentially equal to the length of the limiter piston cavity, preventing any longitudinal motion of the drive shaft which might result from causes such as vibration. This type of limiter bushing is referred to as a reciprocation limiter because it allows rotation but limits reciprocation.
For a transmission designed to impart pure reciprocating motion to the cutting implement, the limiter piston is relatively square in cross section, substantially matching the square cross section of the limiter piston cavity. This prevents any rotary motion of the drive shaft which might result from vibration. The length of the piston is somewhat less than the length of the limiter piston cavity, allowing longitudinal motion of the drive shaft which results from reciprocation of the drive piston. This type of limiter piston is referred to as a rotation limiter because it allows reciprocation but limits rotation.
For a transmission designed to impart a combination of rotary and reciprocating motion to the cutting implement, the limiter piston is cylindrical, with a diameter essentially equal to one side of the square cross section of the limiter piston cavity, so that the limiter piston can rotate within the cavity as the drive piston rotates. The length of the limiter piston is somewhat less than the length of the limiter piston cavity, allowing longitudinal motion of the drive shaft which results from reciprocation of the drive piston. This type of limiter piston is referred to as a free wheeling limiter because it allows reciprocation and rotation.
The drive shaft of each transmission mechanism has affixed to its distal end a cutting element, such as a scalpel, drill, burr, osteotome, or other implement. The drive shaft and cutting implement are encased within a rigid sheath, which is attached to the transmission body by means of a sheath housing. The sheath can have an open distal end, with the cutting implement protruding from the opening, or the sheath can have a window in its side, through which the cutting implement is exposed.
Irrigation fluid can be supplied to an irrigation port on the sheath housing and routed through the transmission body to the interior of the hollow drive shaft through holes in the drive shaft wall, within the transmission body. The irrigation fluid can be supplied to the treatment area via the transmission body and the drive shaft, to remove cut material from around the cutting implement. An aspiration tube can be connected to an aspiration port on the sheath housing, which is connected to a passageway through the housing to the interior of the sheath, outside the drive shaft. Irrigation fluid and other material can be aspirated from the area around the cutting implement via the sheath and the sheath housing.
If desired, the assembly consisting of the transmission body, drive shaft, cutting implement, sheath housing and sheath, referred to herein as the disposable surgical implement assembly, can be removed and replaced as a disposable unit, as described above, to switch from one cutting implement to another. Alternatively, the surgical implement assembly can be removed from the power tool, and the transmission body, drive shaft, drive piston or bushing, limiter piston or bushing, and cutting implement can be removed from the sheath and sheath housing. Then, the replacement transmission body, drive shaft, drive piston or bushing, limiter piston or bushing, and cutting implement can be installed in the sheath housing and sheath, and the whole surgical implement assembly can be reinstalled in the power tool. As an added feature, most or all of the components in the surgical implement assembly can be made of plastic or other disposable materials, eliminating the need to sterilize reusable components.
The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of the portable power tool of the present invention;
FIG. 2 is a sectional view of a reciprocating drive mechanism for the portable power tool shown in FIG. 1, showing a rotation limiter piston;
FIG. 3 is an elevational view of a reciprocating drive piston of the portable power tool shown in FIG. 1, with the drive piston in the forward position;
FIG. 4 is an elevational view of the reciprocating drive piston shown in FIG. 3, with the drive piston in the rear position;
FIG. 5 is a sectional view of a rotary drive mechanism for the portable power tool shown in FIG. 1, showing a reciprocation limiter mandrel;
FIG. 6 is a cut away view of the transmission body and sheath of the portable power tool shown in FIG. 1;
FIG. 7 is a cut away view of a reciprocating drive piston and rotation limiter piston for the portable power tool shown in FIG. 1;
FIG. 8 is a cut away view of a rotary drive bushing and reciprocation limiter bushing for the portable power tool shown in FIG. 1;
FIG. 9 is a cut away view of a rotary/reciprocating drive piston and free wheel limiter piston for the portable power tool shown in FIG. 1; and
FIG. 10 is a partial sectional view of a rotary/reciprocating cutter, drive shaft and sheath for use on the portable power tool shown in FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1, the portable power tool 10 of the present invention iscomprised of handle assembly A and disposable surgical implement assembly B. Handle assembly A includes a handle housing 12, a motor housing 13, a quick release collar 62, and a drive mechanism sleeve 64. Handle housing 12 is in the shape of a pistol grip, with a battery 14 mounted inside. Handle housing 12 would typically be constructed of a molded plastic material. Motor housing 13 is a generally hollow, rigid housing mounted near the top of handle housing 12, with electric motor 16 inside, and oriented so that motor output shaft 22 extends in a forward direction fromthe handle housing, much like the barrel of a gun.
Electric motor 16 is preferably a direct current motor, connected to battery 14 by wires 18, and controlled by switch 20, accessibly mounted onhandle housing 12. Electric motor 16 could also be wired for reversible operation. The forward end of motor output shaft 22 has fixedly mounted thereto a solid cylindrical drive mandrel 24. Drive mandrel 24 rotates about its longitudinal axis in drive mandrel cylinder 28, within sleeve 64. Formed on the forward end of drive mandrel 24 is a drive bushing tongue 26, which has two opposed flat surfaces.
The forward end of drive mandrel tongue 26 engages a drive slot 34 in the rear end of a solid cylindrical rod 32, which projects rearwardly from reciprocating drive piston 30. As motor 16 rotates drive mandrel 24, drivepiston 30 rotates and reciprocates within cylinder 36. As will be explainedlater, reciprocating drive piston 30 can be removed and replaced with a drive piston that only rotates, if desired. A continuous cam groove 38 is formed in the outer surface of reciprocating drive piston 30, to interact with cam follower balls 40 to cause reciprocating drive piston 30 to reciprocate as it rotates. Instead of balls 40, a different cam follower element could be used, such as one or more cam follower pins (not shown) projecting radially inwardly through sleeve 64 into continuous cam groove 38.
Connected to and projecting forwardly from drive piston 30 is pilot section48 of drive shaft 54. Rotation limiter piston 44 is fixedly mounted around drive shaft 54 near pilot section 48. As will be explained later, rotationlimiter piston 44 can be removed and replaced with a limiter bushing which limits reciprocation, or with a free wheeling limiter piston. Rotation limiter piston 44 oscillates longitudinally within limiter piston cavity 46 within transmission body 42. Limiter piston cavity 46 has a transverse cross section that is substantially square, and rotation limiter piston 44has a substantially square cross section which essentially matches the transverse cross section of limiter piston cavity 46, so that the limiter piston and drive shaft 54 can not rotate. Rotation limiter piston 44 has alength somewhat shorter than the longitudinal length of limiter piston cavity 46, so that the limiter piston 44 and drive shaft 54 can oscillate longitudinally.
Drive shaft 54 is a hollow rigid tube which projects forwardly from limiterpiston 44, through sheath housing 52 and sheath 50. The rear end of drive shaft 54 in the embodiment shown in FIG. 1 is rotatably attached to drive piston 30, so that the reciprocating motion of drive piston 30 is impartedto drive shaft 54, but the rotary motion of drive piston 30 is not imparted. As will be explained later, alternate embodiments of drive piston 30 can be provided, which will either impart only rotary motion or impart both rotary and reciprocating motion. The forward end of drive shaft 54 has fixedly attached thereto a cutter 58, shown in FIG. 1 as a reciprocating cutter. Cutter 58 could also be a variety of other surgical implements, such as a drill, a burr, a chisel, or others. Cutter 58 is exposed to the tissue to be cut through window 56 in the side of sheath 50.
Referring now to FIG. 2, the drive mechanism of the power tool shown in FIG. 1 can be seen. Whereas FIG. 1 showed drive piston 30 and rotation limiter piston 44 in their forward positions, with limiter piston 44 abutting its forward stop ring 82, FIG. 2 shows drive piston 30 and limiter piston 44 in their rear positions, with limiter piston 44 abuttingits rear stop ring 84. In both positions, pilot section 48 of drive shaft 54 extends through, and is guided by the central bore of rear limiter piston stop ring 84. Additional centralization of drive shaft 54 is achieved by the alignment of rod 32 within drive mandrel cylinder 28.
Drive mechanism sleeve 64 and quick release collar 62 are permanently mounted in handle assembly A, while drive piston 30, drive shaft 54, and transmission body 42 are removable therefrom along with the other components of disposable surgical implement assembly B. Drive mechanism sleeve 64 is fixedly attached to motor housing 13, while quick release collar 62 is slidably mounted on the outer surface of sleeve 64. Collar return spring 68 is positioned between opposed shoulders of sleeve 64 and collar 62 to continuously urge collar 62 rearwardly against motor housing 13.
Drive mechanism sleeve 64 is a generally cylindrical sleeve having three different inside diameters at drive mandrel cylinder 28, cylinder 36, and the forward bore of sleeve 64 which receives transmission body 42. There are at least two countersunk holes through the wall of sleeve 64 into its forward bore, alongside transmission body 42, to receive transmission retaining balls 66. Retaining balls 66 are of sufficient diameter to prevent their passage completely through the wall of sleeve 64, but to allow their partial projection into a retaining groove 78 on the outer surface of transmission body 42.
There are also two countersunk holes through the wall of sleeve 64 into cylinder 36, to receive cam follower balls 40. If cam follower pins were used instead of balls 40, as mentioned earlier, the pins could be receivedin straight, rather than countersunk, holes through sleeve 64. Cam followerpins, if used, could also have rounded inner ends, or be spring biased outwardly, to facilitate their entry into and exit from continuous cam groove 38. Cam follower balls 40 are of sufficient diameter to prevent their passage completely through the wall of sleeve 64, but to allow theirpartial projection into cam groove 38 on the outer surface of drive piston 30. Collar 62 is a generally hollow cylindrical collar which has an annular retaining ball release channel 74 around its inner surface near retaining balls 66, and an annular cam follower release channel 76 around its inner surface near cam follower balls 40.
When collar 62 is abutting motor housing 13, as shown, release channels 74,76 are not aligned with retaining balls 66 and cam follower balls 40, so the balls are forced into the bottoms of their respective countersunk holes by the inner surface of collar 62. This causes retaining balls 66 toretain transmission body 42 within sleeve 64, and it causes cam follower balls 40 to project into cam groove 38 to impart reciprocating motion to drive piston 30 as it rotates. If cam follower pins were used instead of balls 40, the pins could have rounded outer ends to facilitate their entryinto and exit from release channel 76. Abutment of collar 62 against motor housing 13 would then force the pins radially inwardly into cam groove 38 to impart reciprocating motion to drive piston 30.
A J-groove 72 is formed in the outer surface of sleeve 64, aligned with a lock pin 70 projecting inwardly from collar 62. Lock pin 70 interacts withJ-groove 72 to lock collar 62 in a forward position which aligns release channel 74 with retaining balls 66 and aligns release channel 76 with cam follower balls 40. When channels 74, 76 are so aligned, balls 66, 40 are released to rise in their respective countersunk holes. This allows disposable surgical implement assembly B to be removed from handle assembly A and replaced with a different surgical implement assembly B, having a different surgical implement and a different mode of motion.
Referring now to FIGS. 3 and 4, the reciprocation of drive piston 30 can bemore fully explained. Drive piston 30 is encircled by continuous cam groove38, which has two bends nearer to the forward end 35 of piston 30, separated by two bends nearer the rear end 33 of piston 30. Keeping in mind that cam follower balls 40 are held in place with respect to handle assembly A, FIG. 3 shows piston 30 in a forward position, with balls 40 located in the rear bends of cam groove 38. FIG. 4 shows piston 30 after it has been rotated 90 degrees from the position shown in FIG. 3, by drivemandrel 24. Balls 40 are now located in the forward bends of cam groove 38,and piston 30 has been forced to its rear position. It can be seen that each complete revolution of piston 30 will cause piston 30 to go through two complete reciprocation cycles. Varying the number of forward and rear bends of cam groove 38 can vary the number of complete reciprocation cycles per revolution. As piston 30 reciprocates, slot 34 of piston 30 slides back and forth along tongue 26 of drive mandrel 24.
Referring now to FIG. 5, a drive mechanism can be seen which is designed toimpart pure rotary motion to the surgical implement. Drive bushing 30' is shown without a cam groove, and cam follower balls 40 simply ride along the outer surface of bushing 30'. To allow balls 40 to bottom out in theircountersunk holes, drive bushing 30' must have a slightly reduced outside diameter as compared to drive piston 30. Reciprocation limiter bushing 44'is a cylindrical piston with a diameter substantially equal to the length of a side of square cavity 46 in transmission body 42. Limiter bushing 44'has a length substantially equal to the length of cavity 46. Therefore, reciprocation limiter piston 44' rotates freely within cavity 46, but it can not reciprocate.
Referring now to FIG. 6, the attachment of sheath housing 52 to transmission body 42 can be seen. Sheath housing 52 is a solid cylindricalbody having a central longitudinal bore therethrough. Sheath 50 is fixedly attached to the forward end of sheath housing 52. Limiter piston cavity 46within transmission body 42 is formed by four cavity walls 80, which meet in radiused corners, but which could meet in square corners. Cavity 46 hasan essentially square transverse cross section, and an essentially rectangular longitudinal cross section. Forward stop ring 82 limits the forward travel of the limiter piston, while rear stop ring 84 limits the rearward travel of the limiter piston. Both stop rings 82, 84 are fixedly mounted in transmission body 42.
A neck 43 extends forward from transmission body 42 into the central bore of sheath housing 52, where it is locked in place by the engagement of latch 90 within latch groove 88 of sheath housing 52. Irrigation fluid canbe supplied to irrigation port 100, to flow through irrigation passageway 86 in transmission body 42, and into the hollow drive shaft 54 as will be described later. A suction means can be attached to aspiration port 102, to aspirate material from the treatment area, up the sheath 50 on the outside of the drive shaft 54. Rear o-ring 94 seals between the transmission body 42 and the drive shaft 54, to prevent irrigation fluid from leaking back into the limiter piston cavity 46. Central o-ring 96 seals between the transmission body 42 and the sheath housing 52, to prevent irrigation fluid from leaking out to the atmosphere. Forward o-ring 98 seals between the transmission body 42, the sheath housing 52, and the drive shaft 54, to prevent a short circuit between the irrigation fluid and the aspirated material. The assembly shown in FIG. 6 is the samefor all surgical implement assemblies, regardless of the mode of motion used.
FIG. 7 shows a drive piston 30 and limiter piston 44 designed to impart a pure reciprocating motion to the surgical implement. Drive piston 30 has cam groove 38 on its outer surface, so drive piston 30 will be forced to reciprocate as it is rotated by drive mandrel 24. Rear stop ring 104 and forward stop ring 106 are fixedly attached to the drive shaft 54, but the drive shaft 54 and stop rings 104, 106 are rotatably mounted in drive piston 30. This causes drive shaft 54 to reciprocate as drive piston 30 reciprocates, but drive shaft 54 is not rotated by drive piston 30. Rotation limiter piston 44 is fixedly attached to the drive shaft 54, and it has a transverse cross section which substantially matches the transverse cross section of cavity 46.
Therefore, limiter piston 44 can allow drive shaft 54 to reciprocate, but any rotation of drive shaft 54 which might be caused by vibration or by friction between drive piston 30 and stop rings 104, 106 is prevented. Irrigation holes 110 are provided through drive shaft 54 to allow irrigation fluid to flow forward through drive shaft 54. Rearward flow of irrigation fluid through drive shaft 54 is prevented by plug 108.
FIG. 8 shows a drive bushing 30' and a limiter piston 44' designed to impart pure rotation to the surgical implement. It can be seen that drive bushing 30' has no cam groove, so drive bushing 30' will not be forced to reciprocate as it is rotated. Drive shaft 54 is fixedly attached to drive bushing 30', so rotation of drive piston 30' will result in rotation of drive shaft 54. Reciprocation limiter piston 44' has a round cross sectionwith a diameter equal to the length of a side of the transverse cross section of cavity 46, so limiter bushing 44' can rotate within cavity 46. Reciprocation limiter bushing 44' has a length substantially equal to the longitudinal length of cavity 46, so any reciprocation that might be caused by vibration is prevented.
FIG. 9 shows a drive piston 30" and a limiter piston 44" designed to imparta combination of rotary and reciprocating motion to the surgical implement.Drive piston 30" has a cam groove 38 in its outer surface, so drive piston 30" will be forced to reciprocate as it is rotated. Drive shaft 54 is fixedly attached to drive piston 30", so both rotary and reciprocating motion will be imparted to drive shaft 54. Free wheeling limiter piston 44" has a round cross section like limiter piston 44' and a short length like limiter piston 44, so both rotary and reciprocating motion will be allowed.
FIG. 10 shows the arrangement of a cutter 58 near the distal end 60 of sheath 50. The particular cutter shown is specifically designed to work optimally with a mode of motion having a combination of rotary and reciprocating motion. Skirt 114 of cutter 58 has fluted cutting edges 116,which reciprocate and rotate to increase the exposure of tissue to the cutting edge and to aid in cleaning cut material from the cutting edge. Irrigation fluid flows forward along the inside of drive shaft 54, throughcutter 58, and out orifice 112 in the distal end 60 of sheath 50. Aspiratedmaterial enters window 56 in the side of sheath 50 near cutter 58, and flows along the inside of sheath 50, on the outside of drive shaft 54, to the sheath housing 52 and the aspiration port 102.
OPERATION
As has been explained, rotation of drive piston 30 or drive bushing 30' or drive bushing 30", as the case may be, results in the desired mode of motion being imparted to the surgical implement installed. If it is desired to switch to a different surgical implement, with its preferred mode of motion, the disposable surgical implement assembly B being used isremoved from handle assembly A, and replaced with the desired surgical implement assembly B having the desired different surgical implement attached.
When it is desired to remove disposable surgical implement assembly B from handle assembly A, in order to change to another surgical implement and another mode of motion, collar 62 is pulled forward against the resistanceof return spring 68. This causes collar lock pin 70, projecting inwardly from collar 62, to pass along the longer leg of J-groove 72 in sleeve 64 to the curve of J-groove 72, at which time collar 62 is rotated slightly to cause lock pin 70 to enter the short leg of J-groove 72. Collar 62 can then be released, and it will remain in the forward, or release, position.
This allows disposable surgical implement assembly B to be removed and replaced with the desired assembly. Collar 62 is then pulled slightly forward, rotated, and released, allowing pin 70 to retrace through J-groove 72, and allowing return spring 68 to return collar 62 to its rearposition abutting motor housing 13, thereby locking the new disposable surgical implement assembly B in place.
While the particular Portable Power Cutting Tool as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood thatit is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.
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A portable power cutting tool is disclosed, having a plurality of replaceable tool assemblies for connection to the power cutting tool, with each tool assembly having a different cutting blade and a mode of motion selected for optimum operation of the cutting blade. Each tool assembly has a mode of motion selected from the group of rotation, reciprocation, and a combination of rotation and reciprocation. The tool assemblies can be disposable.
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FIELD OF THE INVENTION
The present invention relates to a method for the treatment/prophylaxis and control of a viral infection in a mammal. The invention also relates to compositions comprising galactofucan sulfate from the marine algae Undaria . This invention has particular application for use in the treatment and prophylaxis of Herpes infections and for illustrative purposes reference will be made to such application.
BACKGROUND OF THE INVENTION
Viruses having a lipid envelope or coat are important human and animal pathogens, Examples of conditions associated with such viruses include HIV, Hepatitis, Ross River and Herpes. The Herpes viruses cause both primary and secondary infections that range from trivial mucosal ulcers to life threatening disorders in immuno-compromised patients. The Herpes group includes HSV-1, HSV-2, Herpes Zoster (chicken pox/shingles), HCMV (human cytomegalovirus), Epstein Barr Virus (EBV), Herpes 6, 7 (Roseola, post transplant infections) and Herpes 8 (associated with Kaposi sarcoma).
Persons infected with a Herpes type virus are typically subjected to cycles of outbreaks where symptoms are experienced and asymptomatic latent periods. During the latent periods, the virus resides in the ganglia where it is inactive and the patient is asymptomatic. However, although asymptomatic, a patient may still be able to infect others. This is known as viral shedding. Reoccurrence of symptoms can occur when the virus is reactivated. Reactivation can be triggered by many different events and is particularly problematic in immunocompromised patients.
The conventional treatment of these infections is with drugs such as acyclovir (ACV) that target the viral DNA polymerase.
There are two generally recognized types of Herpes drug therapy. The first is often referred to as “Outbreak therapy” in which a patient begins drug therapy at the first indication of an outbreak. Following cessation of symptoms, drug therapy is discontinued. A disadvantage of such therapy is that recurrences of infection are not controlled. An alternative therapy is known as “Suppressive therapy” which involves long term doses of maintenance anti-Herpes drug levels. However, whilst the currently available drugs are undoubtedly efficient, they may possibly have side effects, and long-term use has led to the development of resistant viral strains. Such strains now comprise 5% of all HSV infections in immunocompromised patients. There is also patient concern with ongoing drug intake, together with the associated high cost of these drugs.
Subsequently, finding non-toxic alternatives and/or adjuncts to these drugs is extremely important for treatment of patients and also potentially as a prophylactic.
There are a plethora of classes of chemical compounds with putative antiviral effects. One such class is known broadly as the sulfated polysaccharides. The sulfated polysaccharides are an extremely large class of compounds and include sulfated homopolysaccharides, sulfated homooligosaccharides, sulfated heteropolysaccharides, sulfated heteroologosaccharides, sulfoglycolipds, carrageenans and fucoidans. Fucoidans are long branched chains of sugars found in marine algae and echinoderms which include a substantial amount of fucose.
Although encompassed by a single term, the chemical and physical properties of the respective fucoidans vary considerably between species. Such properties include degree of sulfation, molecular weight, degree of branching, linkage positions and fucose content, For example fucoidan from Fucus vesiculosis contains about 90% fucose, while fucoidan from Undaria contains about 50% fucose and about 50% galactose and is known as galactofucan or fucogalactan sulfate. The fucoldans from echinoderms are substantially linear whereas those from alga are highly branched.
Characterization of the fucoids has been severely inhibited by their complexity and the random nature and heterogeneity of the sugar backbone.
Sulfated polysaccharides are believed to be of potential therapeutic importance because they can mimic sugar rich molecules known as glycosaminoglyeans (GAGs). Examples of GAGs which are important in mammalian physiology are heparin sulfate, dermatan sulfate and chondroitin sulfate. Heparin, for example, is a critical regulatory factor of the blood clotting cascade.
Heparin sulfate receptors on cell surfaces are important in many physiological and pathological processes. They are key entry points for viral entry into some cells and are also necessary for leukocyte movement into tissues and for metastasis. It has been postulated that sulfated polysaccharides such as algal fucoidans may compete for binding sites normally occupied by GAGs and thus inhibit these processes.
Many studies have been conducted with a view to investigating the in vitro anti-viral activity of various sulfated polysaccharides. Studies have generally concentrated on synthetic dextran sulfates, pentosan sulfates, clinically used heparins, and seaweed derived carageenans. One review reports that sulfated homopolysaccharides are more potent than sulfated heteropolysaccharides. (Schaffer DJ et al., 2000 Ecotoxicology and Environmental Safety 45:208–227, Witvrouw M et al 1997 Gen Pharmacol 29:497–511). Another review expresses concern about the viability of sulfated polysaccharides as in vivo anti-viral agents in view of believed low bloavailability (Luscher-Mattli M, 2000 Antiviral Chemistry and Chemotherapy 11(4):249–259). One study which investigated the exploitation of cell-surface GAG's by HIV found that cell-surface heparin sulfate facilitates HIV entry into some cell lines but not primary lymphocytes. The authors expressed caution about extrapolating in vitro results obtained from immortalized cell lines. (Ibrahin J, Griffin P, Coombe D R, Rider C C and James W. Virus Res. 1999 Apr;60(2); 159–69).
Despite the recognized need for alternative anti-viral therapies and the interest in sulfated polysaccharides, to date the present inventors are unaware of any clinical studies on the potential anti-viral effects of sulfated polysaccharides.
Advantageously, it has been discovered that an Undaria extract containing galactofucan sulfate is useful in the treatment and/or prevention of conditions associated with viral infections.
SUMMARY OF THE INVENTION
According to a first broad form of the present invention, there is provided a method for the treatment, control or prophylaxis of a viral infection in a mammal, the method including administering to the mammal an effective amount of galactofucan sulfate from Undaria.
The viral infection may be caused by coated viruses including. Herpes Viruses and HIV. Preferably, the viral infection treated and/or controlled by the method of the invention may be HSV-1, HSV-2, Vadcella Zoster Virus (in the form of chicken pox or shingles), HCMV, EBV, Herpes 6, Herpes 7 and Herpes 8.
The method of the invention may be particularly suitable for the treatment of viral infections in an immunosuppressed individual. The method of the invention may also be used as an adjunct therapy with other anti-viral therapies.
When the viral infection is one in which the virus may be in an active or latent stage, it is understood that the method of the present invention may be used at any one or both stages of the infection.
According to a further broad form of the invention there is provided a composition for the treatment, control or prophylaxis of a viral infection, the composition comprising an effective amount of galactofucan sulfate from Undaria.
The galactofucan sulfate found in Undaria is a complex heterogenous carbohydrate whose component sugars are primarily galactose and fucose and small amounts of other sugars. The molecular weight may range from about 30 000 to about 1200 000, typically between about 500 000 to about 1 200 000. Characterization of galactofucan sulfate, and other complex naturally occurring sulfated polysaccharides, is difficult due to the highly complex nature of the molecules. To date, the structure of galactofucan sulfate has yet to be elucidated. However, it is believed that small sections of the molecule may be described as random, alternating or block copolymers of galactose and fucose. Linkage between the sugar units may vary but is believed to be predominantly by 1–3 linkages. The sulfur content is typically between about 4.5–6.5% which suggests a sulfate content of about 18% as SO 3 Na. This indicates that galactofucan sulfate has an average of about one sulfate group for every two sugar residues.
Undaria , the source of the galactofucan sulfate, is a member of the Phaeophyceae (brown) class of marine algae. Any member of the Undaria family may be used as the source of the galactofucan sulfate and a preferred source is Undaria Pinnatifida. Undaria Pinnatifida is an edible seaweed also known as Wakame.
The galactofucan sulfate for use in the method and composition of the invention may be sourced from the whole plant or any part of the plant, such as the leaves, stem, spores, or a combination thereof. If the plants are harvested prior to maturation suitably the whole plant is used.
The galactofucan sulfate may be in the form of dried plant material. Alternatively, or in addition to dried plant material the galactofucan sulfate may be provided in the form of a plant extract. The plant material may be dried prior to the extraction process.
The Undaria extract may be obtained by any suitable method to extract plant material that enables at least partial separation of galactofucan sulfate from other plant material. For example, an acid/water mixture may be used to extract the Undaria . Preferably, the acid is sulphuric acid. Suitably, the acid/water extract is then neutralised, typically with an alkali metal hydroxide, and filtered or dialysed to remove unwanted components. After filtration or dialysis, the extract may be used as a liquid or freeze dried. Typically such an extract includes at least about 60 wt % galactofucan sulfate.
An especially preferred extraction procedure utilizes an acid/water mixture at a pH of between about 0 to about 2, preferably between about 0 to about 1, at temperatures between about 0 and about 30° C., preferably between about 15 and about 25° C. Whilst not wishing to be bound by theory, it is believed that galactofucan sulfate extracted under these conditions has a similar physical and/or chemical profile to the galactofucan sulfate in its natural form i.e. prior to extraction. Conventional extraction procedures such as those used to extract fucoidans from Fucus vesiculosis use more aggressive conditions such as lower pH and/or higher temperatures. It is believed that these conditions may cause hydrolysis and degradation of the galactofucan sulfate which provides an extract having a lower average molecular weight than the “natural” galactofucan sulfate.
Typically a galactofucan sulfate extracted by the above method has a weight average molecular weight of greater than about 100 000, typically greater than about 200 000, preferably greater than about 500 000 Daltons. The upper weight average molecular weight limit is typically about 1 000 000 Daltons.
According to a further form of the invention, there is provided a process for obtaining a galactofucan sulfate extract from Undaria , the process comprising extracting plant material from Undaria in an aqueous solution having a pH of between about 0 and about 2 at a temperature of between about 0 and about 30° C., neutralizing the extracted solution and subjecting the solution to a separations step so as to separate out material having a molecular weight of less than about 10 000 Daltons.
An especially preferred composition comprises dried Undaria sporophyll material. Typically the sporophylls contain between about 8 to about 12 wt % galactofucan sulfate. Whilst not wishing to be bound by theory it is believed that dried sporophylls may include one or more phytochemicals which can act synergistically with the galactofucan sulfate or provide some other beneficial effect. It will be appreciated that any such other beneficial effect may not be limited to an anti-viral effect but may include any effect which may be perceived to be beneficial.
An especially preferred composition comprises dried sporophyll material having elevated levels of galactofucan sulfate. Typically an extract as described above is added to the dried sporophyll material. Typically the level of galactofucan sulfate in the sporophyll/extract mixture is between about 10 to about 20 wt %, typically between about 12 to about 15 wt %.
According to a further broad from of the invention there is provided a composition comprising sporophyll material from Undaria and an extract comprising galactofucan sulfate.
The effective amount of galactofucan sulfate for use in the method or composition of the invention may be dependent on the dosage protocol, the intended recipient, the virus and whether the virus is in a latent or active stage. Dosage levels of between about 0.05 g to about 5 g per day, suitably between about 0.9 g and 2.5 g, more suitably between about 0.1375 and about 0.55 g of galactofucan sulfate may be a sufficient amount to affect viral infections. It is to be understood that a person skilled in the art would be able to determine sufficient dosage levels of galactofucan sulfate to administer to a person to obtain effective antiviral activity.
Typical dosages for adult humans experiencing symptoms of an active herpes infection may be between about 0.275 to about 0.55 g per day. Dosage levels for an adult human wherein the virus in the latent stage may be between about 0.075 to about 0.1 375 g per day.
The galactofucan sulfate may be administered in any suitable form. Preferably the galactofucan sulfate is administered orally as a liquid or solid. This mixed extract may be used to form tablets, granules, powder, capsules or like. Solid preparations of the extract of the invention may include any adjuvant or adjuvants which are normally used in the preparation of pharmaceuticals, such as binder, inclusion, excipient, lubricant, disintegrator, wetting agent, etc. For example, the case where administration is as a liquid preparation, the preparation may take the form of liquid for internal use, shake mixture, suspension, emulsion, syrup or the like. These liquid preparations may contain other components ordinarily used in pharmaceutical formulations, such as diluents, excipients, additives and preservatives and the like. Such additives are well known to those of ordinary skill in the art. Pharmaceutical preparations may include any adjuvant or adjuvants which are normally used in the preparation of pharmaceuticals, such as one or more binder, inclusion, excipient, lubricant, disintegrator, wetting agent, etc. It is to be understood that the form of administration is not intended to be limited to oral administration.
DETAILED DESCRIPTION OF THE INVENTION
In order that this invention may be more readily understood and put into practical effect, reference will now be made to the accompanying examples which illustrate preferred embodiments of the invention.
EXAMPLE 1
In one embodiment, the extract of the invention may be made by grinding whole dried plants from Undaria pinnatifida to a particle size of less than 1 mm. The ground plant material is added to 1% w/v sulphuric acid in a ratio of 1:1 5 w/v in a 316 stainless steel tank. The mixture is stirred for 1 hour and then the solids removed by filtration on a plate and frame filter press. The solids are resuspended in. 1% w/v sulphuric acid in the ratio of 1:10 and the extraction procedure is repeated.
The combined filtrates are neutralised with sodium hydroxide to a pH of 6.0. The neutral solution is then subjected to ultra filtration and dialysis using 30,000 cut off membranes to remove low molecular weight components and to concentrate the product. This extraction process may provide an extract that has a galactofucan sulfate content of 60 to 70%. The extract is then freeze dried and milled to a particle size of less then 0.4 mm.
The Molecular Weight of the extract was determined by High Performance Liquid Chromatography-Multiangle Laser Light Scattering, Samples were run in 0.1 M NaNO 3 at 60° C. on TSK G4 and G5000PWXL columns in series, Detectors were Waters 2410 RI and UV, and Wyatt DAWN-EOS MALLS. Processing was with Wyatt ASTRA software.
Samples were prepared by dissolution in water and left for 24 hours at room temperature prior to analysis. This time prior was selected to allow for uniform dissolution of the extract between samples.
EXAMPLE 2
An extract from Undaria pinnatifida was prepared in accordance with the extract process described in Example 1. Dried spore bodies from Undaria pinnatifida were similarly milled and then mixed with ground extract in a ratio of about 23:2 to form 560 mg capsules containing about 13.25% galactofucan sulfate, The tests described below utilise these capsules and will hereinafter be referred to as Undaria extract capsules.
Treatment of Patients with Active Viral Infections
Patients were recruited for the study by health practitioners. Patients gave verbal informed consent to the study. Health practitioners monitored the patients' health. There are no known adverse effects related to the ingestion of Undaria . No other antiviral medications were taken at the same time as the Undaria extract capsules. The duration of the study was from one month to 24 months. Patient ages were from less than 10 years up to 72 years.
Fifteen patients with active herpetic viral infections were given four 560 mg Undaria extract capsules per day for ten days as a ‘therapeutic dose’. All patients except subject 14 (primary zoster infection) were suffering repeat outbreaks of known aetiology (See table 1).
All fifteen patients with active herpetic viral infections experienced relief from symptoms. No adverse side effects were noted during the study.
Two patients (subjects 4 and 5) with noncompliant dosage regimes resolved infections in normal time, but noted no spread of lesions (as occurred during previous outbreaks). Reduction in lesion severity and rapid clearance were noted in two patients (subjects 6 and 7), and pain reduction as compared to previous events was noted by two patients (subjects 2 and 14). Two females with genital HSV-2 had persistent lesions which resolved during the course of treatment (subjects 8 and 10).
In two cases of diagnosed EBV, one clear at four and the other by ten days, In the latter patient a chronic sinus condition also cleared (subjects 11 and 12)
Over ten days, faster drying of zoster lesions and increased speed of normal cycle as compared to previous outbreaks was noted by a male patient (subject 14) although no reduction in pain was reported. In an adult male suffering primary zoster (chicken pox) lesions of whole body (subject 15), pain reduction and rapid healing of lesions were noted.
TABLE 1 Patients with active Herpes infections If on maintenance, Resolution Inhibition of Patient Sex Age Virus Site infection of infection? breaks? Comment 1 M 50 HSVI Orolabial Yes, no Yes, Varied progression inhibition of dosage, to lesion further consistent outbreaks inhibition. on maintenance dose >2 years. 2 F 14 HSV1 Orolabial Yes, very N/a Patient noted severe rapid outbreak reduction in resolved pain. within course. 3 F 72 HSVI Orolabial Yes, no Yes, Notes prodrome (prodrome) and progression continued improvement ocular to lesion Inhibition of in skin conjunctiva low grade condition. conjunctival HSVI for three months 4 M 40 HSVI Orolabial Yes, in N/a Not taken prodrome normal consistently. time. No benefit noted but no spread of lesion. 5 F 50 HSVI Orolabial Yes, in N/a No spread of active n rmal time lesion and l sion pain reduced. Took half dose only. 6. F 47 HSVI Orolabial Yes, N/a No reduction in recurrence, lesion no spread of severity lesion. 7. F 47 HSVI Orolabial Yes, rapid N/a Post clearance chemotherapy compared outbreak to previous. (breast cancer) 8 F 20 HSVII Genital Yes, N/a lesions cleared. 9 F 42 HSVII Genital Yes. Yes, Prior two Existing inhibition of weekly lesion further outbreaks of healed. outbreaks ACV resistant on strain of maintenance HSVII. dose 3 mths. 10 F 23 HSVII Genital Yes, N/a chronic lesion healed 11 F 17 EBV systemic Yes N/a Normal blood exam after 4 days course. 12 F <10 EBV Systemic Yes, EBV N/a Three symptoms capsules per absent at day Chronic ten days sinus infection also cleared 13 F 85 Zoster Torso Yes Yes, Relief from (shingles) inhibition for lesions at 4 two months. capsules per day 14. M Adult Zoster Whole body Yes N/a Pain (chicken sores reduction, pox) rapid clearing of lesions. 15 M 40 Zoster T7, 8, dermatome Yes N/a Faster drying (shingles) Right side of lesions, increased speed of cycle, no change in pain
Treatment of Latent Infections
Six patients with latent HSV-1 or 2 were given two 560 mg capsules of Undaria extract per day as a ‘maintenance dose’. One patient (3) took four 560 mg capsules per day.
All six patients on maintenance doses noted inhibition of further outbreaks of infection (Table 2). No adverse side effects were noted during the study.
HSV-1 outbreaks were inhibited in two patients taking a maintenance dose over three months and two years respectively (subject 1 and 2). Low grade HSV-1 associated keratoconjunctivitis in the former patient was also inhibited.
Undaria extract ingestion correlated with inhibition of a previously persistent HSV-2 infection for three months in subject 4. In this patient, the infection was acyclovir (ACV) resistant and outbreaks had been apparent on a two weekly basis for over a year. ACV is a nucleic acid inhibitor that prevents viral replication after the virus has entered the cell and is commonly used to treat Herpes.
HSV-2 outbreaks at the genital site were inhibited in two other female patients whilst taking a maintenance dose of two capsules per day, for one month (subjects 5 and 6).
Low grade persistent Herpes zoster (shingles) lesions of the whole torso were inhibited for two months in an elderly patient whilst maintaining a dose of four capsules per day (3).
TABLE 2 Patients with latent Herpes infections. Inhibition of outbreak Also treated whilst on Site of for active maintenance Patient Sex Age Virus infection infection? dose? Comments 1 M 50 HSVI Orolabial Yes Existing Yes, Varied lesion healed. inhibition of dosage, further consistent outbreaks on inhibition. maintenance dose >2 years. 2 F 72 HSVI Orolabial Yes, no Yes, Notes prodrome (prodrome) progression continued improvement and ocular to lesion Inhibition of In skin conjunctiva low grade condition. conjunctival HSVI for three months 3 F 85 Zoster Torso Yes Yes, Relief from (shingles) inhibition for lesions two months. requires 4 capsules per day 4 F 42 HSVII Genital Yes, Existing Yes, Prior two lesion healed. inhibition of weekly further outbreaks of outbreaks on ACV maintenance resistant dos 3 strain f m nths. HSVII. 5 F 41 HSVII G nital No Yes, Did not take inhibition on during active two capsules lesion per day for 1 outbreak. month. 6 F 36 HSVII Genital No Yes, Did not take inhibition on during active two capsules lesion per day for 1 outbreak. month.
In vitro Effects of Undaria Extracts on HSV and Human Cytomegalovirus
An Undaria extract capsule was mixed 1:40 w/v with distilled water and boiled for 5 minutes. The liquid was filtered through a 0.45 μM filter for sterilization and stored at −20° C. An aliquot of the preparation was dried and the weight was obtained to determine the concentration. The concentration used was the dry weight of the dissolved solids present.
Immortalized human fibroblasts, HF cells, were grown in Minimal Essential Media supplemented with glutamine, antibiotics, and 10% foetal bovine serum (FBS). Maintenance medium was supplemented with 1% FBS. Laboratory strains of HSV and HCMV were tested in this study. A stock of each virus was grown in cultured HF cells and aliquots were frozen at −70° C. The titre of each virus was determined by a plaque assay using HF cells in 24-well plates with an agarose overlay.
Herpes viruses were assessed for infectivity of human fibroblasts cells in vitro. Inhibition by Undaria extract was noted as shown in Table 3.
TABLE 3 IC50 for Undaria extract as measured by infectivity of HSV1, HSV2 and HCMV (human cytomegalovirus) in human fibroblasts. Undaria extract Capsule mixed Herpes virus 1:40 w/v with water HSV - 1, strain F 3.1 ug/ml HSV - 2, strain G 1.6 ug/ml HCMV, AD169 2.5 ug/ml HCMV, D16 2.5 ug/ml
In vitro Effects of Extracts on HSV
Two Undaria extracts containing galactofucan sulfate were evaluated to determine their antiviral activity against clinical strains of HSV. Extract No. 1 was obtained by boiling Undaria sproprhyll in water for 10 minutes. Extract No. 2 was obtained as per the extraction procedure described in Example 1.
The extracts were significantly more active against clinical strains of HSV-2 than against HSV-1, p<0.001. The mode of action was unknown but preliminary testing indicated the mode of action may be the inhibition of viral entry into the host cell.
HSV-1 strain F and HSV-2 strain G were tested in binding assays and also in post-binding antiviral assay. The viruses were tested in 96-well microtiter plates format using human fibroblast cells. The viruses were inoculated at MOls of 0.1 and 0.25. For the binding assays, the effective concentration of extract ranged from 128 to 2 μg/ml. For the post-binding assays, the concentrations ranged from 4000 to 31 μg/ml.
The results of the assay tests are shown in Tables 4 and 5.
TABLE 4
Inhibition of binding, μg/ml.
(MOI = Multiplicity of Inf ction)
Undaria
Undaria
Extract
Extract
Virus
Strain
No. 1
No. 2
HSV-1, MOI = 0.1
F
32
16
HSV-1, MOI = 0.25
F
128
32
HSV-2, MOI = 0.1
G
2.0
0.125
HSV-2, MOI = 0.25
G
4.0
0.25
TABLE 5
Post-binding inhibition μg/ml.
(MOI = Multiplicity of Infection)
Undaria
Undaria
Extract
Extract
Virus
Strain
No. 1
No. 2
HSV-1, MOI = 0.1
F
>4000
>4000
HSV-1, MOI = 0.25
F
>4000
>4000
HSV-2, MOI = 0.1
G
>4000
>4000
HSV-2, MOI = 0.25
G
>4000
>4000
The extracts inhibited HSV from binding to cellular receptors in this in vitro assay. There was, however, no post-binding inhibition of HSV by the extracts at concentrations up to 4000 μg/ml. These results indicate that the extracts are effective in inhibiting HSV by blocking attachment and entry into the host cells.
T Cell Stimulation in vitro
T cell mitogenicity was evaluated by chromium uptake. Whole T cell preparations were obtained from buffy coats from human blood samples. They were incubated in RPMI supplemented with 10% heat inactivated foetal calf serum, 5 mM L-glutamine, 5×10 −5 M 2-mercaptoethanol and 30U/ml gentamycin. Incubation for 72 hours was at 5% CO 2 , 37° C. in 24 well plates. T cell mitogenicity was assessed by radioactive chromium uptake. Cells were incubated with either Undaria extract (at 25, 125 and 250 mcg/ml as 1%, 5% or 10% of total culture volume from a stock solution at 2.5 mg/ml) or with the known mitogens (PHA) (1 mcg/ml) or Concanavalin A (ConA) (1 mg/ml). Each concentration was assessed in triplicate (n=3)
The Undaria extract was assessed for effects on whole human T cell preparation in vitro. After incubation with the Undaria extract or mitogens PHA and ConA, for 72 hours the relative uptake of chromium was assessed as a measure of mitogenicity. The lowest concentration of Undaria extract tested (25 mcg/ml) exerted a four fold mitogenic effect on T cells, over 50% of the mitogenic potency of the known mitogens PHA (six fold) and ConA (seven fold). Paradoxically, increased concentrations of the whole extract showed decreasing effects on mitogenic activity. This may be accounted for by the increasing physical inhibition due to increased viscosity in the culture media, or the increasing concentration of unidentified inhibitory components present in the extract.
Additional studies illustrated little effect on NK cell activity and no effects on L929 fibroblast growth over 24 or 72 hours (results not shown). There was no bacterial contamination of the Undaria extract (results not shown), thus the presence of bacterial lipopolysaccharides (which may also act as mitogens) was ruled out.
The studies carried out in Example 2 assessed the effects of Undaria extracts containing galactofucan sulfate in patient studies and in vitro. The extracts of the invention was ingested by patients suffering active or latent herpes infections. Results indicated firstly, increased rate of healing, and secondly, inhibition of outbreaks in cases of HSV-1, HSV-2, ACV resistant HSV-2, and zoster. There were no adverse side effects noted, and Undaria extracts was well tolerated by all subjects. Reduced pain levels were noted in some cases, which may be a result of the increased rate of healing.
A particularly noteworthy result in this study was inhibition of an ACV resistant case of HSV-2. HSV-2 is a sexually transmitted disease of increasing incidence. In part, this is due to the fact that partner transmission may occur during asymptomatic shedding or unrecognised minor outbreaks. Suppressive therapies such as ACV have been tested for their ability to inhibit shedding. However, for long-term use, non toxic alternatives such as Undaria extracts may be preferred by patients, who perceive long term conventional drug use as detrimental. In addition, Undaria extracts may reduce the generation of resistant strains which arise through prolonged use of drugs such as ACV.
This study shows that ingestion of Undaria extracts of the invention is associated with resolution, reduced pain and outbreak inhibition of Herpes virus infections resulting in increased healing rates inpatients with active infections. In addition, patients with latent infection remained asymptomatic whilst ingesting the Undaria extracts containing galactofucan sulfate. The extracts of the invention inhibited Herpes viruses in vitro and was mitogenic to human T cells in vitro.
Although the experimental results are only in respect of Herpes Viruses, it is to be understood that any virus which adheres to the cell through a similar mechanism as Herpes Group Viruses would also be inhibited by Undaria extracts of the invention.
In the specification the terms “comprising” and “containing” shall be understood to have a broad meaning similar to the term “including” and will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. This definition also applies to variations on the terms “comprising” and “containing” such as “comprise”, “comprises”, “contain” and “contains”.
It will of course be realised that while the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth.
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Methods and compositions for the treatment, control or prophylaxis of a viral infection in a mammal, the method including administering to the mammal an effective amount of galactofucan sulfate from Undaria.
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ORIGIN OF THE INVENTION
The invention described herein was made by employees of the United States Government and may be manufactured and used by or for the government for government purposes without payment of any royalties thereon or therefore.
FIELD OF THE INVENTION
This invention relates to microwave devices, especially Magic-Tee or Magic-T couplers, and more particularly, to a device suitable for use in radar and communications systems.
BACKGROUND
Planar Magic-Ts are used in microwave integrated circuits to split or combine in-phase and out-of-phase signals. Applications include balanced-mixers, discriminators, interferometers, and beam-forming networks. Desirable properties of a magic-T include wide bandwidth phase and amplitude balance, low insertion loss, high isolation, compact size, and fabrication simplicity.
Several techniques have been developed to provide broadband response to a Magic-T. Co-planar waveguide (CPW) or microstrip (MS) to slotline (SL) mode conversion techniques are widely incorporated in a Magic-T to produce a broadband out-of-phase power combiner or divider such that the slotline transmission becomes the main part of these Magic-Ts. Since a slotline has less field confinement than a microstrip or a CPW, slotline radiation can cause high insertion loss in these Magic-Ts. In addition, the Magic-T constructed from CPW transmission lines requires the bonding process for air bridges which increases fabrication complexity. Although aperture coupled Magic-Ts have a small slot area, however, aperture coupled Magic-Ts require three metal layers causing high insertion loss and radiation.
For at least the reasons stated above, and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for Magic-T is compact and has less slotline radiation loss. There is also a need for improved Magic-T with reduced slotline radiation.
SUMMARY
The above-mentioned shortcomings, disadvantages and problems are addressed herein, which will be understood by reading and studying the following specification.
The invention uses the complementary properties of microstrip and slotline to produce a compact broadband out-of-phase combining structure with minimum loss due to slot line radiation. The structure has low loss and is highly symmetric which causes the structure to be less dependent on the transmission line phase variation. As a result, the structure has high port E-H isolation, extremely high phase balance, and has broadband response. The overall bandwidth is mainly limited by the slotline termination and the impedance transformation at the port. The ability to combine signal using only transmission line and slotline without incorporating complex fabrication processes such as bondwires, viaholes or airbridges.
In one aspect, the invention provides a microwave circuit arrangement having a Magic-T waveguide circuit element with a first and second input port and an output port, a microstrip slotline transition circuit with an input/output port, and a slotline coupling the Magic-T waveguide circuit element and the microstrip slotline transition circuit.
In another aspect, the invention provides a microwave circuit arrangement having a Magic-T waveguide circuit element with a first and second input port and an output port, a microstrip slotline transition circuit with an input/output port, a slotline coupling the Magic-T waveguide circuit element and the microstrip slotline transition circuit, a first slotline stepped circular ring positioned within the Magic-T waveguide circuit and coupled to one end of the slotline, and a second slotline stepped circular ring positioned within the microstrip slotline transition circuit and coupled to one end of the slotline.
In still another aspect, the invention provides a microwave circuit arrangement having a Magic-T waveguide circuit element, a microstrip slotline transition circuit, a slotline for forming a microstrip slotline tee junction, and a microstrip stepped impedance opened (SIO) stub coupled to one end of the microstrip slotline transition circuit.
In another embodiment, the invention is a four-port circuit for processing two incoming signals of arbitrary phase and amplitude. The four-port circuit provides a first input port and a second input port for receiving respective first and second incoming signals of arbitrary phase and amplitude, and a first output port and second output port. Further, a slotline having a first and second end terminated with slotline stepped circular ring (SCR) to combine the first and second incoming signals at a junction node when the signals are out-of-phase, and combined the first and second incoming signals at the first output port when the signals are in-phase.
Apparatus, systems, and methods of varying scope are described herein. In addition to the aspects and advantages described in this summary, further aspects and advantages will become apparent by reference to the drawings and by reading the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of a Magic-T in accordance to an embodiment;
FIG. 2 is an illustration of a slotline with a first and second slotline stepped circular ring (SCR) according to an embodiment;
FIG. 3 is an illustration of a microstrip stepped impedance open-end stub according to an embodiment;
FIG. 4 is an illustration of the electric fields across a microstrip in the odd mode according to an embodiment;
FIG. 5 is an illustration of electric fields across a microstrip in an even mode according to an embodiment;
FIG. 6 is an illustration of an equivalent circuit in an odd mode according to an embodiment;
FIG. 7 is an illustration of an equivalent circuit in an even mode according to an embodiment;
FIG. 8 is an illustration of the frequency response for the Magic-T according to an embodiment.
DETAILED DESCRIPTION
In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments which may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments, and it is to be understood that other embodiments may be utilized and that logical, mechanical, electrical and other changes may be made without departing from the scope of the embodiments. The following detailed description is, therefore, not to be taken in a limiting sense.
FIG. 1 is a representation of a Magic-T 100 according to an embodiment. The magic-T 100 comprises five λ/4 microstrip lines with characteristic impedances of Z 1 , Z 2 and Z t . The illustrated magic-T 100 requires only one short section of the MS-to-SL transition to achieve a broadband 180 degree phase shift and an out-of-phase power combiner. Additionally, the magic-T 100 structure has a small total slotline area, thus minimizing radiation loss and parasitic coupling to microstrip lines. The magic-T layout is also symmetric along the Y-axis 124 up to sum port 108 . As a result, the parasitic coupling from slotline sections to microstrip line sections at port 110 and port 122 are substantially equal. Thus, the sum port 108 and difference port 118 isolation of the magic-T 100 exhibits broad-band characteristics. Moreover, the magic-T 100 does not require via holes, bondwires or airbridges which increase fabrication complexity and allow broadband operation in millimeter wave frequency. It also comprises a slotline ( 120 ) of length Ls with the slotline characteristic impedance of Zs. All ports are terminated with the microstrip lines with the characteristic impedance of Z 0 . The slotline 120 section is terminated with the slotline SCR termination ( 106 , 116 ) at both ends to provide broadband and low-loss MS-to-SL transition and to allow out-of-phase combining to occur. Impedance Z t is used to transform slotline Zs to the microstrip line Z 0 at the difference port 118 . The Magic-T (Magic-TEE) 100 comprises a Magic-T waveguide circuit element 102 having input ports 110 and 112 and a first slotline stepped circular ring (SCR) 106 ; and, microstrip-slotline (MS-SL) junction having an input/output port 118 that ends with a microstrip stepped impedance open end (SIO) stub, and a second SCR 116 . Additionally, the first and second SCR are connected by slotline 120 . The Magic-T (Magic-TEE) 100 includes quarter-wavelength (λ/4) microstrip lines with the characteristic impedances of Z 1 , Z 2 and Z t . The Z 1 line with the length of L 1 is used to transform the characteristic impedance Z o at port 1 ( 110 ) or port 2 ( 112 ) to a slotline impedance (Zs) at the center of the structure (Axis Y, 124 ), Z 1 and Z t , lines (with the length of L 1 and L 2 , respectively) are used for transforming impedance from slotline impedance to Z o at the sum port or port H (port 108 ) and at the difference port or port E (port 118 ), respectively. The magic-T 100 also includes slotline 120 (Zs), with the length of L s . One end of the Z t line (port 118 ) is terminated with a microstrip stepped impedance open-end (SIO) stub 114 to produce a broadband virtual ground for the MS-SL transition. The SIO stub 114 includes microstrip lines with the characteristic impedances of Z T1 and Z T2 and the associated parameters describing widths and lengths (θ T1 and θ T2 ).
The ends of the slotline, having impedance Z S , are coupled to slotline stepped circular ring (SCR) 106 and 116 to provide broadband and low-loss MS-SL transition and to allow out-of-phase combining at MS-SL tee junction 204 along the X-plane 122 of the Magic-T waveguide circuit element 102 . The signals from the first port 110 and the second port 112 are combined out-of-phase at the MS-SL tee junction along X-plane and combined in-phase at output port 108 .
A slotline termination ( 120 , 106 ) is used at the MS-SL tee junction to provide a slotline virtual open and allow mode conversion in the out-of-phase combiner. It is also used in the MS-SL transition at input/output port 118 (port E). A slotline SCR termination is used in the Magic-T waveguide circuit element 102 due to its compact size and because the slotline SCR termination ( 106 ) minimizes the effect of parasitic and slotline radiation in slotline 120 . While Magic-T 100 has been described with planar waveguide circuits, it should be understood by those in the art that planar alternatives can be used such as retrace hybrid and planar magic-Ts using microstrip-coplanar waveguide transitions.
FIG. 2 is an illustration of slotline SCR 200 having a slotline 120 with a first SCR 106 and second SCR 116 coupled at each end. The slotline SCR 106 and 116 comprises three slotline sections 204 , 206 , 208 with the characteristic admittances, physical lengths, and electrical lengths. Due to symmetry, the circular structure forces the electric field (E-field) at input 202 to cancel at center, creating low-loss virtual ground over the operating band. The slotline SCRs ( 106 , 116 ) are used in Magic-T 100 as terminations for the microstrip-to-slotline transition so as to cause a virtual ground when the signals from the first input port 110 and second input port 112 are out-of-phase. The slotline SCR cause a virtual ground when the input signals ( 110 , 112 ) are in-phase.
FIG. 3 is an illustration of a microstrip stepped impedance opened (SIO) stub 300 in accordance to an embodiment. The SIO stub 114 is comprise of microstrip lines with characteristic impedances and associated electrical lengths. The impedance of the SIO Z t1 and Z t2 have the physical widths and lengths of W t1 ( 308 ) and W t2 ( 302 ), and L t1 ( 306 ) and L t2 ( 304 ), respectively. These electrical lengths are tuned such that the SIO stub 114 provides a virtual ground at the fundamental frequency (f o ). When the SIO stub 114 is connected to parallel line with the characteristic impedance of 2Z 1 , the SIO stub forms a grounded-end anti-parallel coupler having 2Z 1 ,e and 2Z 1,o as even- and odd-mode characteristic impedance.
The slotline SCR termination 106 can be modeled as stepped impedance transmission lines, for example, as shown in FIG. 6 . Its equivalent circuit parameters and its physical parameters designed on 0.25 mm-thick Duriod 6010 substrate are provided in Table I and Table II, respectively.
TABLE I
The Magic-T Circuit Design Parameters at 10 GHZ
MICROSTRIP LINE SECTION
SLOTLINE SECTION
Z 1 = 42.7 Ω, Z 2 = 60.33 Ω,
Z s = 72.8 Ω, Z sl0 = 72.8 Ω,
Z t1 = 40 Ω, Z t2 = 20 Ω,
Z sl1 = 163.4 Ω, Z sl2 = 72.8 Ω,
θ t1 = 23,3°, θ t2 = 46.6°
θ sl0 = 13.57°, θ sl2 = 6.2°,
θ sl1 = 34.95°, θ s = 113.3°
TABLE II
The Physical Parameters of the Compact Magic-T in Millimeters
Microstrip line section
Slotline section
L 1 = 2.62, W 1 = .26, L 2 = 1.83,
L s = 1.92, W s = 0.10, L so = 0.58,
W 2 = 0.14, L t = 2.8, W t = 0.16,
W so = 0.10, L s1 = 0.23, W s1 = 0.10,
L t1 = 0.68, W t1 = 0.37,
L s2 = 0.91, W s2 = 0.71
W t1 = 0.37, L t2 = 1.30,
W t2 = 1.05
In the odd mode, the signals from the first port 110 and second port 112 are out-of-phase. This creates a microstrip virtual ground plane along the Y-axis 124 of the Magic-T 100 . The slotline SCR ( 120 , 116 ) connected to the slotline 120 (Z SL ), also allows the MS-SL mode conversion to occurs as demonstrated by the electric-field (E-field) and current directions around the X-axis cross section as shown by 402 in FIG. 4 .
In the even mode, the signals from the first port 110 and second port 112 are in-phase, thus creating a microstrip virtual open along the Y-axis 124 of the Magic-T 100 as shown in FIG. 4 . The electric fields ( 502 at FIG. 5 ) in the slotline at the MS-SL tee junction 404 along X-plane are canceled creating a slotline virtual ground that prevents the signal flow to or from port 118 .
FIG. 6 is an illustration of the circuit model for Magic-T 100 in the odd mode. As noted earlier, the odd mode occurs when the signals from the first port 110 and the second port 112 are out-of-phase. The impedance of the first port 110 is labeled 602 , the connecting impedance to port 108 is labeled as 604 , and the half impedance of the line from the SIO to input/output port 118 is labeled as 608 . In order to match the impedance of the four ports of the Magic-T ( 110 , 112 , 108 , 118 ), the Magic-T 100 is analyzed at the center frequency in odd-mode and even-mode circuits up to the MS-SL tee junction 404 . The odd mode circuit model the λ/4 line (Z 1 or the impedance at the first port 110 ) is used to transform the input characteristic impedance at the first port 110 to the desired impedance value of Z S /2 ( 608 ) of the slotline 120 . The slotline SCR 106 has no effect on the circuit at the center frequency since it is a virtual open at that frequency. Therefore, Z 1 can be derived as follows:
Z
1
=
N
l
2
·
Z
S
2
·
Z
0
EQ
.
1
where N 1 , is the MS-SL transformer ratio. The λ/4 line Z 2 (the impedance at output port 108 ) is used to transform the grounded-end at port 108 to a virtual open at Z S . The practical value of Z 2 is set by the impedance matching in the even-mode analysis.
FIG. 7 is an illustration of the circuit model for Magic-T 100 in the even mode. As noted earlier, the even mode occurs when the signals from the first port 110 and the second port 112 are in-phase. The impedance of the first port 110 is labeled 702 , the connecting impedance to port 108 is labeled as 704 . Since a slotline virtual ground is created input/output port 118 is isolated from the rest of the other ports. In the even mode, the input impedance Z 0 at port 1 is transformed to the in-phase port impedance of 2Z 0 at 706 . Since the line Z 1 is used to transform impedance Z 0 to Z S /2 in odd-mode, the line Z 2 transforms the odd-mode impedance of Z S /2 to 2Z 0 at 706 . Therefore, Z 2 can be computed as follows:
Z
2
=
2
Z
0
·
N
t
2
·
Z
S
2
=
2
Z
1
EQ
.
2
The isolation between the first port 110 and the second port 112 and the return loss of the first port and the second port are derived in term of the reflective coefficients (Γ +− and Γ ++ ) and defined as follows:
Isolation
=
-
20
log
(
Γ
++
-
Γ
+
-
2
)
EQ
.
3
Return
loss
=
-
20
log
(
Γ
++
+
Γ
+
-
2
)
.
EQ
.
4
In an exemplary design, for example, a Magic-T 100 is designed on a 0.25 mm-thick Duroid 6010 substrate with the dielectric constant of 10.2. The slotline is 0.1 mm wide. This corresponds to the Z S , value of 72.8 Ohm. Given Z 0 =50 Ohm and N 1 =1, from EQ. 1 and EQ. 2, we obtain Z 1 and Z 2 of 42.7 Ohm and 60.4 Ohm, respectively.
Using the circuit model in FIGS. 6 and 7 , and the parameters at 10 GHz in Table I (infra), the Magic-T 100 frequency response to the tee junction is shown in FIG. 8 . In particular, FIG. 8 shows the frequency response of Magic-T 100 using odd and even-mode circuit model. Label 802 shows the return loss of the difference port ( 118 ), label 804 shows the return loss of the first port 110 , label 806 shows the isolation between the first and second ports, and label 808 shows the return loss of the sum port 108 . Magic-T 100 provides better broadband out-of-phase combining response than the in-phase combining response. The in-phase combining bandwidth is limited by the two impedance transformation sections in Z 1 and Z 2 used to transform Z 0 at first port 110 to 2 Z 0 at port 108 (sum port) in even mode. Moreover, the Z 2 value needs to satisfy the odd-mode matching condition.
CONCLUSION
In particular, one of skill in the art will readily appreciate that the names of the methods and apparatus are not intended to limit embodiments. Furthermore, additional methods and apparatus can be added to the components, functions can be rearranged among the components, and new components to correspond to future enhancements and physical devices used in embodiments can be introduced without departing from the scope of embodiments.
While the invention has been described in conjunction with specific embodiments therefor, it is evident that various changes and modifications may be made, and the equivalents substituted for elements thereof without departing from the true scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. Therefore, it is intended that this invention not be limited to the particular embodiment disclosed herein, but will include all embodiments within the spirit and scope of the disclosure. The terminology used in this application meant to include all waveguide, slotlines and microstrip slotline transitions environments and alternate technologies which provide the same functionality as described herein. For example, while the Magic-T has been described with planar waveguide circuits, retrace hybrids with microstrip coplanar waveguide transitions would be suitable alternatives.
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The design of a compact low-loss Magic-T is described. The planar Magic-T incorporates a compact microstrip-slotline tee junction and small microstrip-slotline transition area to reduce slotline radiation. The Magic-T produces broadband in-phase and out-of-phase power combiner/divider responses, has low in-band insertion loss, and small in-band phase and amplitude imbalance.
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BACKGROUND OF THE INVENTION
This invention relates to data acquisition and, in particular, to analog to digital conversion of an electrical signal.
As known in the art, transducers are used in a host of applications to convert the effect of some phenomenon into an electrical signal. The pervasiveness of the digital computer requires that the signal be in digital form for storage, analysis, or other manipulation. Since many transducers produce analog signals, these must be converted to digital form. In this conversion, some information is inevitably lost.
For example, if a transducer produces an output signal which varies smoothly from zero to five volts, converting the signal to digital form introduces discontinuities or steps in the signal in which information is lost. It is therefore desirable to obtain as small a step as possible. A problem with this goal is the fact that size of the step is directly related to the number of bits used to quantify the information. If a converter had a resolution of eight bits, then the five volt range could be divided into two hundred fifty-six discrete steps, each step spanning approximately twenty millivolts. If the converter had a resolution of twelve bits, the five volt range could be divided into four thousand ninety-six steps of about one millivolt each.
The greater resolution appears highly desirable until one starts to consider the time it takes to manipulate the data or the storage requirements for the data. One is then faced with the problem of trying to resolve apparently contradictory requirements of high speed and high resolution.
It should be noted that, as used herein, "resolution" and "accuracy" are distinct concepts. One may divide an interval into any number of steps but this says nothing of how well the conversation relates to the input signal. The former relates to resolution, the latter to accuracy. In implementing the present invention, currently available hardware is sufficiently accurate.
In view of the foregoing, it is therefore an object of the present invention to increase the apparent resolution of an analog to digital (A/D) converter.
Another object of the present invention is to provide a means for monitoring selected portions of a process.
A further object of the present invention is to provide high speed, high resolution A/D conversion.
Another object of the present invention is to provide a means capable of adapting itself to the observed data.
A further object of the present invention is to provide adaptive window means for acquiring or monitoring data.
Another object of the present invention is to provide an A/D converter having vernier resolution.
SUMMARY OF THE INVENTION
The foregoing objects are achieved in the present invention wherein an A/D converter has first and second digital to analog (D/A) converters connected to the high and low reference voltage inputs thereof, respectively. The output of the A/D converter is connected to a central processing unit (CPU) over a suitable bus. The CPU is connected to and controls the D/A converters, e.g. directly, via suitable bus drivers, or via input/output (I/O) port devices. The CPU establishes the size of the conversion range by setting the reference low voltage and reference high voltage to less than the maximum size possible with the given A/D converter. Thus a smaller interval is divided the same number of times, increasing the apparent resolution but not the number of bits of data. Thus, the speed of the system is not sacrificed.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention can be obtained by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a preferred embodiment of the present invention.
FIG. 2 illustrates the operation of the present invention.
FIG. 3 is an example of data to be monitored.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an A/D converter in accordance with the present invention wherein A/D converter 10 has its output connected to CPU 11 and input 12 connected to a suitable source of analog signal. The A/D converter in accordance with the present invention can be used in any environment in which a transducer is available for converting some effect into a variable voltage. Converter 10 has two reference inputs, one for receiving a reference low voltage the other for receiving a reference high voltage. These voltages are provided by D/A converter 14 and D/A converter 15 respectively. Converter 10 and CPU 11 are interconnected by a suitable bus 13, typically a parallel bus. Similarly, CPU 11 and converters 14 and 15 are interconnected by buses 16 and 17 respectively. CPU 11 also comprises a suitable output bus 18 for interfacing with other devices, e.g. for the control of a process being monitored. It is understood by those of skill in the art that buses 13, 16, 17, and 18 may comprise but a single bus, depending upon the particular implementation of the present invention.
In operation, CPU 11 sends to converters 14 and 15 data representative of the reference high and reference low voltages to be applied to converter 10. The voltages define a vernier range the size of which is divided into a number of steps or intervals, depending upon the resolution of converter 10. By virtue of programmable converters 14 and 15, one can establish that vernier range anywhere within the range of converter 10.
FIG. 2 is useful in understanding the operation of the present invention. In FIG. 2, reference low voltage 20 and reference high voltage 21 establish range 22 within the range illustrated in FIG. 2 as extending between ground potential and some positive voltage V. If one considers V as representing the maximum voltage which can be applied as an input to converter 10, one can visualize this range as being divisible into a particular number of steps or intervals. However, by moving reference low voltage up to the voltage represented at position 20 and moving reference high voltage down to the voltage represented at position 21, one narrows the voltage range to be divided into that same number of steps or intervals as illustrated by vernier range 24. Thus one has increased the apparent resolution of converter 10 and yet obtained that increase in resolution without increasing the number of bits.
A numerical example will further illustrate the present invention. If converter 10 has a useful range of 0-5 volts DC, and comprises an eight-bit A/D converter, that voltage range can be divided into two hundred fifty-six steps each comprising approximately 20 millivolts. On the other hand, if the voltage range is reduced from 0-5 volts to, for example, 1.5-2.5 volts, then each step comprises approximately 4 millivolts. Thus the apparent resolution is increased approximately five fold.
The benefits obtainable from the present invention depend, in part, upon the minimum voltage resolution of the particular hardware used to implement the present invention. For example, a preferred embodiment of the present invention has been implemented utilizing a 68HC11 microcomputer, as sold by Motorola, Inc. This chip comprises an eight-bit A/D converter and CPU within a single package. Thus blocks 10 and 11 as illustrated in FIG. 1 are contained within a single integrated circuit. The A/D converter portion of this circuit has a minimum voltage resolution of approximately 1 millivolt. Thus the minimum vernier range for implementating the present invention utilizing this particular integrated circuit is 256 millivolts. This vernier range is considerably smaller than the voltage rating of the A/D converter, which is five volts. Thus one can obtain approximately a 19× improvement in apparent resolution in accordance with the present invention. Stated another way, with this particular implementation of the present invention, one obtains what appears to be twelve bit resolution from an eight-bit device. Thus, one increases the apparent resolution without decreasing the speed with which the data can be handled.
The accuracy of the present invention depends both on the accuracy of the reference voltages and the linearity of the converter. The resolution of the D/A converters should at least equal the resolution of A/D converter 10. In a preferred embodiment of the present invention, the resolution of D/A converters 14 and 15 is typically twelve bits, while the resolution of A/D converter 10 is typically eight bits. Thus one maintains accuracy while improving resolution.
FIG. 3 illustrates an example of a use of the present invention wherein, regardless of accuracy, one wishes to monitor a particular portion of a signal, e.g. representative of a particular point in a process. In this example, it is assumed that one must detect minimum 36 on curve 33. Thus is it clear that window 22 need not comprise the entire range from 0-V volts. In this case, the range is reduced to interval 32 as illustrated in FIG. 3. CPU 11 is easily programmed, as well known to those of ordinary skill in the art, to monitor the output from converter 10 to detect any or all of magnitude, slope, maximum, and minimum. In this particular case, CPU 11 need only detect minimum 36, which is interpreted as an endpoint for the process. By improving the apparent resolution, one obtains a more accurate indication of when the minimum takes place and can therefore more accurately control the endpoint of the process.
Alternately, since CPU 11 is programmable for any desired function, one can easily make the system in accordance with the present invention adaptive to the incoming data by initially having a vernier range which covers the entire range of converter 10, monitoring the data to determine in what range the data primarily falls, and then establishing reference high and low voltages so that the vernier range encompasses only that portion and ignores other data. Thus one obtains, in effect, the self-calibrating system or a system which adapts itself to incoming data so that only relevant data is monitored. If need be, CPU 11 can also be programmed to move the vernier range in response to shifts in the data. Thus, one obtains from the system an indication of average or moving average of the incoming data. Vernier range 32 can be moved by changing the size thereof, i.e. reference voltage points 20 and 21 are moved relative to each other e.g. by moving point 21, or by changing its location, i.e points 20 and 21 are moved together. Alternatively, vernier range 32 can be placed where the least data, but the data of most interest, is expected. One can thereby significantly reduce the amount of data to be stored or further processed.
There is thus provided by the present invention a relatively simple system in which apparent resolution is increased without any penalty in the speed with which data can be handled. Further, one obtains a dynamic data acquisition system since the conversion system in accordance with the present invention is easily adapted to the incoming data.
Having thus described the present invention it should be apparent to those of ordinary skill in the art that modifications can be made within the spirit and scope of the present invention. For example, while noted as implemented on a 68HC11 microcomputer, this is not the only implementation which can be made of the present invention. Any CPU can be used for CPU 11 and any suitable D/A and A/D converter can be used. Further, the indication of a particular number of bits is by way of example only and should not be construed as limiting. The benefits of the present invention are obtainable whether CPU 11 is a four, eight, sixteen, or thirty-two bit CPU, and whether converters 10, 14 and 15 are eight, ten, twelve, fourteen, etc. bit devices.
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Analog data is collected by conversion to a digital representation thereof via an analog to digital converter. Reference voltages for the converter are provided by digital to analog converters. The reference voltages are varied under the control of a central processing unit to establish a range of interest in the analog data. The range of interest is narrower than the conversion range of the analog to digital converter.
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FIELD OF THE INVENTION
[0001] The present invention relates to a simply-constructed paint-spraying platform, and more particularly to a foldable and expandable paint-spraying platform to provide the advantages including easy carriage, good ventilation, low cost, and enhanced steadiness.
BACKGROUND OF THE INVENTION
[0002] The students and non-professional persons generally use a simply-constructed and paper-made paint-spraying platform for performing the paint spraying process. This simply-constructed paint-spraying platform is commonly a foldable paper box. In the opening mode, the foldable paper box has an opening on the front surface to prevent the paint from random scattering, and thus no cleaning is required. Therefore, it is very convenient to use.
[0003] However, the conventional paint-spraying platform has drawbacks as listed below:
[0004] 1. The paper plates on both sides of the opening are foldable/unfoldable and very unsteady, and thus the paper plates may be refolded up easily, causing the paint-spraying platform to be toppled down easily when the article to be sprayed is hung thereon.
[0005] 2. In the absence of ventilation hole, the odor of paint, which generates peculiar smell, is left on the paint-spraying platform easily.
[0006] 3. A high-cost honeycomb-shaped pad is mounted on the paint-spraying platform under the opening for holding the article to be sprayed, and the total cost is thus increased.
[0007] As a result, there exists a need to disclose an improved paint-spraying platform for overcoming the conventional drawbacks.
SUMMARY OF THE INVENTION
[0008] In view of the aforesaid drawbacks of the conventional structure, a major object of the present invention is to disclose a steady, good-ventilation, and low-cost paint-spraying platform.
[0009] In order to achieve the above-mentioned object, a paint-spraying platform comprises: a platform body comprising a top wall, a ventilation part, a bottom wall, two support plates, and a backing plate.
[0010] The top wall comprises a top reception plate and a bottom reception plate. The top reception plate has at lest one first insertion plate on the top, at least one insertion notch and a first folding edge on the bottom, and two first positioning fins on both sides, respectively. The bottom reception plate has a second folding edge on the bottom, a third folding edge between the second folding edge and the first folding edge, and two first insertion holes penetrating through both sides, respectively.
[0011] The ventilation part is for connection with the top wall via the second folding edge on the top. The ventilation part has a fourth folding edge on the bottom, a first ventilation hole penetrating through the region between the fourth folding edge and the second folding edge, a first ventilation device connected with the first ventilation hole, two second positioning fins located on both sides of the first ventilation hole, respectively, two fifth folding edges formed on the bottoms of the second positioning fins, respectively, and two second insertion holes formed on the center regions of the fifth folding edges, respectively.
[0012] The bottom wall has a bottom plate on the center. The bottom plate has a ventilation folding plate on the top, two lateral folding plates on both sides, and a bottom folding plate on the bottom. The top of the ventilation folding plate can be bent by means of the fourth folding edge to connect with the ventilation part. The ventilation folding plate has two first positioning plates protruding respectively from both sides and a sixth folding edge on the bottom. At least one second ventilation hole penetrates through the region between the sixth folding edge and the fourth folding edge for ventilation. Each of the lateral folding plates has a second insertion plate at the outer border, a seventh folding edge on the bottom, a second insertion hole penetrating through the seventh folding edge, and a second double-folding section formed on the center region between the seventh folding edge and the second insertion plate. The second double-folding section has a first folding line and a second folding line on both sides, respectively. The lateral folding plate has a second positioning plate and a third positioning plate protruding from one side. The bottom folding plate has a plurality of third insertion plates protruding from the bottom, an eighth folding edge on the top, a third insertion hole penetrating through the eighth folding edge, and a third double-folding section formed on the center region between the third insertion hole and the third insertion plates. The third double-folding section has a first folding line and a second folding line on both sides, respectively.
[0013] The support plates are for connection with both sides of the top wall and the ventilation part, and the support plates are located on the bottom wall. Each of the support plates has a first protruding plate protruding from the top. The first protruding plate has a folding line on the bottom and a positioning hole penetrating through the folding line, wherein the positioning hole is located in position corresponding to the first positioning fin. Each of the support plates has a second protruding plate and a third protruding plate protruding from one side, wherein the second and third protruding plates are located in positions corresponding to the first and second insertion holes, respectively.
[0014] The backing plate has two vertical plates respectively on both sides, at least one through hole penetrating through one surface, and a second ventilation device connected to the through hole.
[0015] When in use, the paint-spraying platform is expanded, and the article to be painted is hung on first and second hooking holes or placed on the backing palate for spraying paint by using a spray gun.
[0016] By means of the above-mentioned structure, the paint-spraying platform of the present invention overcomes the conventional drawbacks and provides the advantages as follows:
[0017] 1. Two support plates that have no folding line formed thereon can bilaterally support the platform body to provide high steadiness.
[0018] 2. The paint-spraying platform has several ventilation holes and ventilation devices to provide good ventilation, and the ventilation devices further allow the paint to be left in the platform.
[0019] 3. The backing plate that achieves purposes effectively is simply-constructed, and the total cost is thus reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is an elevational diagram showing the closing status of the present invention.
[0021] FIG. 2 is an elevational diagram showing the opening status of the present invention.
[0022] FIG. 3 is an elevational diagram showing the opening status of the present invention viewed from a different angle.
[0023] FIG. 4 is an elevational, exploded diagram of the present invention.
[0024] FIG. 5 is a plan diagram showing the support plate of the present invention.
[0025] FIG. 6 is a plan diagram showing the top wall, the ventilation part, and the bottom wall of the present invention.
[0026] FIG. 7 is a schematic diagram showing the action for folding the top wall, the ventilation part, and the bottom wall of the present invention.
[0027] FIG. 8 is a schematic diagram showing the utilization status of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] The objects, features, advantages, and benefits of the invention will become apparent in the following description taken in conjunction with the foregoing drawings.
[0029] Referring to FIGS. 2 through 6 , a paint-spraying platform of the present invention comprises a platform body 10 comprising a top wall 1 , a ventilation part 2 , a bottom wall 3 , two support plates 4 , and a backing plate 5 .
[0030] The top wall 1 has a top reception plate 11 and a bottom reception plate 12 , wherein the top reception plate 11 further has at lest one first insertion plate 111 on the top, at least one insertion notch 112 on the bottom, and a first folding edge 113 on the bottom. The top wall 1 further has a first double-folding section 114 on the center region between the insertion notch 112 and the first insertion plate 111 . A first folding line 115 and a second folding line 116 are formed on both sides of the first double-folding section 114 , respectively. Several first hooking holes 117 are formed between the first folding line 115 and the first insertion plate 111 . Several second hooking holes 118 are formed between the second folding line 116 and the insertion notch 112 . Two first positioning hems 119 are formed on both sides of the top reception plate 11 , respectively. The aforesaid first double-folding section 114 , the first folding line 115 , and the second folding line 116 jointly allow the top reception plate 11 to be foldable. After folding, the first insertion plate 111 can be correspondingly inserted into the insertion notch 112 , and the first hooking holes 117 and the second hooking holes 118 are located in positions corresponding to one another. The top of the bottom reception plate 12 can be bent by means of the first folding edge. 113 to connect with the top reception plate 11 . In addition, the bottom reception plate 12 has a second folding edge 121 on the bottom. A third folding edge 122 is formed between the second folding edge 121 and the first folding edge 113 . The bottom reception plate 12 further has two first insertion holes 123 penetrating through both sides, respectively.
[0031] The top of the ventilation part 2 can be bent by means of the second folding edge 121 to connect with the top wall 1 . The ventilation part 2 has a fourth folding edge 21 on the bottom. The ventilation part 2 has a first ventilation hole 22 penetrating through the region between the fourth folding edge 21 and the second folding edge 121 , wherein a first ventilation device 23 is connected with the first ventilation hole 22 . Two second positioning hems 24 are formed on both sides of the first ventilation hole 22 , respectively. Two fifth folding edges 241 are formed on the bottoms of the second positioning hems 24 , respectively. Two second insertion holes 242 are formed on the center regions of the fifth folding edges 241 , respectively.
[0032] The bottom wall 3 has a bottom plate 31 on the center. The bottom plate 31 has a ventilation folding plate 32 on the top and two lateral folding plates 33 on both sides, respectively. The bottom plate 31 has a bottom folding plate 34 on the bottom. The top of the ventilation folding plate 32 can be bent by means of the aforesaid fourth folding edge 21 to connect with the ventilation part 2 . The ventilation folding plate 32 has two first positioning plates 321 protruding from both sides, respectively. The ventilation folding plate 32 has a sixth folding edge 322 on the bottom. The bottom wall 3 has at least one second ventilation hole 323 penetrating therethrough the region between the sixth folding edge 322 and the fourth folding edge 21 . Each lateral folding plate 33 has a second insertion plate 331 at the outer border and a seventh folding edge 332 on the bottom. The bottom wall 3 has a second insertion hole 333 penetrating through the seventh folding edge 332 . In addition, a second double-folding section 334 is formed on the center region between the seventh folding edge 332 and the second insertion plate 331 . Each second double-folding section 334 has a first folding line 335 and a second folding line 336 on both sides, respectively. Each lateral folding plate 33 has a second positioning plate 337 and a third positioning plate 338 protruding from one side. The aforesaid bottom folding plate 34 has several third insertion plates 341 protruding from the bottom and an eighth folding edge 342 on the top. In addition, the bottom folding plate 34 has a third insertion hole 343 penetrating through the eighth folding edge 342 . A third double-folding section 344 is formed on the center region between the third insertion hole 343 and the third insertion plates 341 . The third double-folding section 344 has a first folding line 345 and a second folding line 346 on both sides, respectively.
[0033] The support plates 4 , which are for connection with respective both sides of the top wall 1 and the ventilation part 2 , are located on the bottom wall 3 . Each support plate 4 has a first protruding plate 41 protruding from on the top. The first protruding plate 41 has a folding line 42 on the bottom and a positioning hole 43 penetrating through the folding line 42 . The positioning hole 43 is located correspondingly to the aforesaid first positioning fin 119 . Each support plate 4 has a second protruding plate 44 and a third protruding plate 45 protruding from one side and corresponding to the first and second insertion holes 123 and 242 , respectively.
[0034] The backing plate 5 has two vertical plates 51 on both sides, respectively, and at least one through hole 52 penetrating through one surface. In addition, a second ventilation device 53 is connected to the through hole 52 .
[0035] The assembled structures of the aforesaid components are shown in FIGS. 1 , 4 , 6 , and 7 . The simply-constructed paint-spraying platform of the present invention is a rectangular box (shown in FIG. 1 ) in the closing mode. The ventilation folding plate 32 , the lateral folding plates 33 , and the bottom folding plate 34 are bent upward by using the sixth folding edge 322 , the seventh folding edge 332 , and the eighth folding edge 342 . In addition, the third positioning plate 338 is bent, and the first folding lines 335 and the second folding lines 336 on respective both sides of the second double-folding sections 334 are bent oppositely so as to allow the second insertion plates 331 and the third insertion plates 341 to be inserted and positioned into the second and third insertion holes 333 and 343 . Each aforesaid third positioning plate 338 is located between the first folding line 335 and the second folding line 336 on one side. Each aforesaid first positioning plate 321 is inserted between the first folding line 335 and the second folding line 336 from the other side. Each aforesaid second positioning plate 337 is inserted between the first folding line 345 and the second folding line 346 .
[0036] By bending the fourth folding edge 21 , the ventilation part 2 is located on the bottom wall 3 , and the support plates 4 and the backing plate 5 are located between the ventilation part 2 and the bottom wall 3 . By bending the fifth folding edge 241 , the second positioning hems 24 can be inserted into the respective one side of the respective lateral folding plates 33 , and the ventilation part 2 is positioned on the bottom wall 3 . By bending the second folding edge 121 and the third folding edge 122 , the top reception plate 11 and the bottom reception plate 12 can be attached to the outer surface of the bottom wall 3 . In addition, the first positioning hems 119 are bent to be inserted into the second insertion holes 333 , respectively, from the other side.
[0037] In the opening mode, as shown in FIG. 2 , the folding status of the bottom wall 3 is identical to that in the closing mode. The backing plate 5 is placed on the bottom plate 31 . The first folding line 115 and the second folding line 116 on both sides of the first double-folding section 114 are bent oppositely to allow the first insertion plate 111 to be inserted into the insertion notch 112 and allow the first hooking holes 117 and the second hooking holes 118 to attach to one another correspondingly. By bending the first folding edge 113 , the top and bottom reception plates 11 and 12 are bended by an angle. By bending the folding lines 42 of the support plates 4 , the first protruding plates 41 are bended by an angle, and the first positioning hems 119 are inserted into the positioning holes 43 . In addition, the second protruding plates 44 and the third protruding plates 45 are bended by an angle and inserted into the first insertion holes 123 and the second insertion holes 242 , respectively.
[0038] The utilization status of the aforesaid components is shown in FIG. 8 . When in use, the simply-constructed paint-spraying platform is expanded, and the article to be painted is hung on the first and second hooking holes 117 and 118 or placed on the backing palate 5 for being painted by using a spray gun.
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A simply-constructed paint-spraying platform comprises: a platform body comprising a top wall, a ventilation part, a bottom wall, two support plates, and a backing plate. When in use, the paint-spraying platform is expanded, and the article to be painted is hung on the first and second hooking holes or placed on the backing palate for spraying paint by using a spray gun. Therefore, the advantages including easy carriage, good ventilation, low cost, and enhanced steadiness can be provided.
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This application is a division of copending U.S. patent application Ser. No. 884,678 filed July 17, 1986 now U.S. Pat. No. 4,737,392, which in turn is a continuation of therewith copending U.S. patent application Ser. No. 678,477 filed Dec. 5, 1984, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to carbon steel wire for high tensile strength applications. The usual composition for this comprises alloying elements (herein defined as those elements that are present in an amount of at least 0.05%) among which the carbon is present in an amount ranging from 0.4% to 1.4%, manganese from 0.1 to 1% and silicon from 0.05% to 1%, the remainder being iron and impurities (herein defined as those elements that are in an amount of less than 0.05%), all percentages of this disclosure being percentages by weight.
By "wire" is meant here any elongated form, irrespective of the cross-sectional shape, the latter being circular in general, but the latter can also have another form, such as rectangular, with a widthto-thickness ratio ranging e.g. from 1 to 20, or any other form. In such cases, the diameter of the circle having the same cross-sectional area will be considered here as the "diameter"of the wire.
The high tensile strength will in general have been obtained by cold working a pearlitic steel microstructure, preferably by drawing, but this can also have been obtained, e.g. by cold rolling or a combination thereof with a preceding cold drawing operation.
It is known that steel of the composition above must not be cold drawn or worked into wire to such high tensile strength that this would result in insufficient ductility for supporting bending and torsional loads. In dependence on the diameter, there is a tensil strength limit above which special care must be taken. This limit is higher for thin final diameters than for thick ones. This limit in function of the diameter is given by the formula (R m being the tensile strength limit in N/mm 2 and d being the wire diameter in mm) :
R.sub.m =2250-1130 log d (1)
which, in a tensile strength-versus-diameter diagram, shows a line, the "line of special care", above which there is the field of high tensile strength.
It is to the wire in this field of high tensile strength that the invention applies. In this field the wires can rather easily pass the current tests on ductility for axial loads, but the problems become more difficult when bending and torsional ductility tests are involved. For the wires having a tensile strength R m above a given line, called here the "problem-line", given by the formula
R.sub.m =2325-1130 log d (2)
the percentage of rejections in these bending and torsional tests become excessive. The difficulty is, that among wires that usually successfully passed the ductility test under axial load, there is a part that passes the bending and torsional ductility tests and another part that does not, and that the reasons of this different behavior are unknown.
This puts a severe limit to the tensile strength to which the wires can be processed, at least for steel wire called for use under non-axial loads, when the wire will have to be deformed into the final product, such as the assembling into a steel cord, or when the wire in the final product is loaded as such, as in springs, bead wire, hose reinforcement wire, steel tire cord, conveyor belt cord and the like.
In order to minimize the rejection figures, and to be able to exceed the above problem line, we have tried in the sense of adding alloying elements, but the random and unpredictable character of rejections in the bending and torsional ductility tests remained. As a consequence, our attempts to minimize the rejection figures have been limited to conducting the patenting heat treatment operation in a careful way for obtaining the finest and most adequate pearlitic microstructure, and by drawing the wire very carefully, by adapting the speed and reduction per drawing-die in order to minimize microstresses and microcracks which might be the reason of this random behavior in the bending and torsional ductility tests.
SUMMARY OF THE INVENTION
It is an object of the present invention to procure a carbon steel wire of the usual composition given above for high tensile strength applications, processed to a tensile strength above the mentioned line of special care, given by formula (1), showing a better ductility under non-axial loading for a given tensile strength. It is a further object of the present invention to procure such a carbon steel wire, processed to a tensile strength above the problem line, given by formula (2), having sufficient residual bending and torsional ductility in the bending and torsional ductility tests, for use under non-axial loads.
According to the invention, the steel wire is characterized by a sulfur content of less than 0.015%, preferably less than 0.010%.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
We have found indeed, after analysis of the various raw materials and wire processing factors which may influence the tensile strength-ductility relationship, that the reason of the different non-axial ductility behavior of wires that answer the same composition specifications and pass the same high tensile/ductility tests, lies in the fluctuations of the low residual sulfur content.
Up to now, the composition specifications only required a sulfur content not exceeding 0.025% and for drawing wire to a high tensile strength, the mentioned usual compositions herefore in the delivered wire rods for industry had sulfur contents fluctuating somewhere between 0.015% and 0.025% without specifically taking care of the exact composition. The reason is that this residual amount, once it is kept below 0.025%, is of little importance. (But the invention and the explanation hereunder will show that this is only true for axial ductility tests). As a consequence however, the further purification and reduction of the sulfur content was not considered worthwhile, having regard to the sophisticated melting and refining equipment and costly pure raw materials that would be necessary. Instead, the "steel purity" that was optimized related more to the way in which the impurities appeared in the steel: more equal distribution over the volume, finer and more equal distribution of the segregations, etc.
We have found, however, that this residual sulfur content fluctuating between 0.015% and 0.025% strongly influences in a bad sense the non-axial ductility behavior, as explained hereunder, and that consequently, steel compositions must be taken with unusually low sulfor content for this application, i.e. below 0.015%, preferably below 0.010% and most preferably below 0.008%.
The reason why the residual sulfur content is less important with respect to axial tensileductility tests than for non-axial bending/torsion tests is believed to be as follows. During wire drawing, the deformable sulfide inclusions appear to be further elongated too, together with the steel and parallel to the wire axis. In normal axio-symmetric plastic deformation and tensile testing, the fracture occurs at the location of the weakest cross section. But as these cross sections are perpendicular to the direction in which these inclusions have been elongated, these cross sections are about equally strong and the weakening effect of the inclusion is only proportional to the average proportion of inclusion surface to the steel surface in these cross sections, which is negligible. Under non-axial load, however, the fracture planes of which the weakest one must be considered, are not the cross sections, but rather the fracture planes are of more complicated form, and no longer lie perpendicular to the axially elongated inclusions, but more in parallel with them. As a consequence, these fracture planes are not equally strong and the weakest one comprises a much higher proportion of inclusion surface to steel surface than the average proportion, and it is this weakest fracture plane that determines the strength. This deleterious effect is even more pronounced with higher local sulfide contents (such as e.g. in wire drawn from rod material with sulfur segregation), so that consequently, besides an extra-low sulfur content, it is preferable to have this sulfur content well distributed over the steel matrix and that any possible inclusions be finely distributed. We found out that even in low-sulfur rods (0.015% S max.) incidental segregation can be a nuisance factor for high-tensile wire production of elevated torsional ductility. Our investigations revealed that this problem depending on rod source and varying with rod manufacturer, is virtually eliminated when specifying an extra-low sulfur content of max. 0.010%, and most preferably max. 0.008% S.
Besides the advantages in the characteristics in the wire as drawn, the extra-low sulfur content also allows an extra-low freuqency of rupture during the drawing operation into such wire, owing to the better non-axial ductility of the material that is also exploited during the drawing operation. In cases in which the wire is cold rolled into a strip or wire with a rectangular cross section, surface delamination is also less frequent.
The invention is in particular applicable to steel wire of the composition for rubber reinforcement. By the latter is meant a steel wire of the usual composition above for high tensile strength applications, but in which the carbon, manganese and silicon are more specifically present in the ranges going respectively from 0.6 to 1% (preferably 0.7% to 0.9%), from 0.2% to 0.8% and from 0.1% to 0.4%, the amount of phosphorous not exceeding 0.020%. This wire for rubber reinforcement has a diameter ranging from 0.05 mm to 3 mm and, in most cases, is covered by a rubber adherable layer, such as brass or any of the organic compounds known for that purpose. Such wire, when processed to very high tensile strength above the problem-line given by formula (2), has sufficient residual bending and torsional ductility for use in rubber products, i.e. after they have been vulcanized in the rubber, especially in vehicle tires.
The difficulty with usual reinforcement wires in rubber is that vulcanization provokes a heat ageing effect by which the wires undergo an embrittlement with respect to torsional loads. As a consequence, an extra residual ductility must be reserved for this loss which makes the problems more acute in this application. However, with the wires according to the invention, this loss effect appears to be minimized as will be shown hereinafter.
The invention is even more in particular applicable to steel cord for rubber reinforcement. In this cord, the wires have a diameter ranging from 0.05 mm to 0.50 mm and have the above-mentioned composition for rubber reinforcement and are made rubber-adherable by use of a brass coating or another well-known organic or inorganic coating for that use. Such wires, even when drawn to the very high tensile strength above the problem-line, are shown to have sufficient resilient ductility to be stranded into cord without excessive ruptures, especially to have sufficient resilient torsional ductility to be stranded in machines where some or all individual wires receive a permanent twist, and then further to leave sufficient residual ductility, after vulcanization, for further use in the rubber tires. In the case of using the latter stranding machines, the microstructure of the twisted wires shows the elongated grains lying in a helicoidal form along the length of the wire. In the steel composition for such application, some elements such as Pb and Sn are well-known elements to be avoided and are in general limited to a value below 0.001%, 0.001% and 0.004%, respectively, and the total content of scrap elements (i.e. alloying elements such as Cu, Cr and Ni, coming from any possible scrap melt and serving as an indicator of the origin of the steel) are preferably limited to 0.10%.
Such extra-low sulfur pearlitic carbon steel, when used in the diameter range of 0.05 mm to 3 mm and with the composition for rubber reinforcement can be drawn to very high tensile strength, i.e. above the problem-line given by formula (2), but will preferably not be processed to an excessively high tensile strength, so that it will still show the well-known ductile fracture mode in the simple torsion and reverse bend test, and not the well-known brittle and delaminating fracture mode. By the simple torsion test is meant the simple torsion testing of steel wire according to international standard ISO 136, in which a length of wire is twisted round its own axis until it breaks. For diameters going from 1 mm (included) to 3 mm, a length of 100 times the diameter is taken and below 1 mm a length of 200 times the diameter. By the reverse bend test is meant the reverse bend testing of steel wire according to international standard ISO 144, in which a length of wire is repeatedly bent through 90° in opposite directions in one plane, over a cylindrical surface of a specified radius R. This radius R is equal to 1.25 mm, 1.75 mm, 2.5 mm, 3.75 mm, 5 mm or 7.5 mm depending on whether the diameter of the wire is respectively 0.5 mm or lower, ranging from 0.5 mm to 0.7 mm included, from 0.7 to 1 mm included, from 1 mm to 1.5 mm included, from 1.5 mm to 2 mm included and from 2 mm to 3 mm included.
The results of the invention are further illustrated hereinafter by a number of examples. In the results R m means the tensile strength (stress at rupture) in N/mm, δ t means the percentage total elongation, Z means the percentage reduction of area after rupture, N b means the number of reverse bends in the reverse test with repeated reverse bends through 90° in opposite directions in one plane over a cylindrical surface of radius R, and N t means the number of turns in the simple torsion test where a length of 100 times the diameter is twisted around its axis until it breaks.
EXAMPLE 1
Steel wire rods of a diameter of 5.5 mm were used of two different compositions A and B. A: 0.43% C; 0.62% Mn; 0.23% Si; 0.018% P; 0.006% S B: 0.45% C; 0.61% Mn; 0.23% Si; 0.014% P; 0.024% S
The wire rod properties are summarized in table I, for composition A in the as rolled condition (A r ) and in the condition after patenting in the conventional way (A p ), and for composition B in the as rolled condition.
TABLE I______________________________________Wire rod R.sub.m ε.sub.t Z N.sub.b______________________________________A.sub.r 785 12.8 65.7 9.5A.sub.p 905 12.0 70.4 10.2B.sub.r 774 11.9 58.5 7.0______________________________________ R = 10 mm
Direct drawing on a multiple pass machine from wire rod diameter 5.5 mm to final diameter 1.75 mm was carried out for checking the drawability. Rod A performed very well without any wire fractures, whereas in drawing B a few machine stops were noticed due to sudden wire fractures.
The mechanical properties of the drawn wires are given in Table II:
TABLE II______________________________________Wire rodMaterial R.sub.m ε.sub.t Z N N.sub.b______________________________________A.sub.r 1595 2.40 55.1 15.4 40A.sub.p 1720 2.25 58.0 16.0 39B.sub.r 1564 2.35 50.6 9.6 35______________________________________ R = 5 mm
Further drawing to lower diameters was no problem for material A, which was drawable to a wire diameter of 1 mm and smaller. For material B, however, drawability became difficult below 1.5 mm due to the increasing number of wire ruptures, and it was impossible to achieve the limit of 1 mm on a conventional production machine. Below 1.4 mm delamination fractures were observed during the simple torsion test.
The mechanical properties of the wire of material A, as obtained on further drawing below 1.75 mm were as follows:
TABLE III______________________________________Mechanical properties of wires afterfurther drawing below 1.75 mmWire rodmaterial Diameter* R.sub.m ε.sub.t Z N.sub.b ** N.sub.t______________________________________A.sub.r 1.35 1743 2.1 53.9 12 37.5 1.12 1980 1.2 49.7 12.4 36 1.00 2135 1.2 50.4 10.1 34A.sub.p 1.35 1980 1.8 55.7 15 42 1.12 2251 1.0 51.2 14 41 1.00 2450 0.95 51.0 11.8 33______________________________________ *in mm **R = 5 mm
From the results, it can be concluded that the steel wire of composition A according to the invention reveals a better drawing performance, a higher achievable strength and better ductility properties, even after heavy total reduction in area, as compared to the wire B of conventional composition. Even when in the proximity of the minimum carbon content for wire for high-tensile applications material A showed to be drawable to a tensile strength level above 2100 N/mm 2 even without patenting and without delamination fractures, but with a ductile fracture made in bending and torsional testing.
EXAMPLE 2
Steel wires were prepared from three groups of wire rods inside the following composition range: C: 0.80%-0.85% ; Mn: 0.40%-0.70% ; Si: 0.20%-0.30%. The groups differed in their sulfur content:
A: less than 0.010% S
B: from 0.010% to 0.020% S
C: from 0.020% to 0.035% S The wire rods were first drawn to patenting diameter d p then patented in the conventional way to a fine pearlitic structure with a tensile strength in the range 1350-1400 N/mm 2 , then coated with a thin brass layer of composition 68% Cu--32% Zn for adhesion to rubber, and finally wet drawn to a final diameter d=0.38 mm. In each group A, B and C, four cases were considered, according to the ratio r=d p /d which is a measure of the degree of cold working and work hardening.
The obtained mechanical properties (average values) are summarized as follows:
TABLE IV__________________________________________________________________________A B Cr R.sub.mZ N.sub.b.sup.(1) N.sub.t R.sub.m Z N.sub.b.sup.(1) N.sub.t R.sub.m Z N.sub.b.sup.(1) N.sub.t__________________________________________________________________________4 252148.2 28.5 56 2570 50.1 29 45 2472 50.1 28 404.5 282545.7 26 50 2845 43.7 26 42 2727 43.7 22 415 298242.5 25 45 2943 41.6 22 35 2953 41.6 19 32.sup.(3)5.5 316842.4 22.5 44 3090 38.7 19 33.sup.(3) 3070 37 17.6 28.sup.(3)6 335536.5 20 34.sup.(3) 3247 35.9 16 30.sup.(3) --.sup.(2) --.sup.(2) --.sup.(2) --.sup.(2)__________________________________________________________________________ .sup.(1) R = 1.25 mm .sup.(2) brittle ruptures in drawingdie .sup.(3) surface delamination
The results show that as a general rule the tested ductility parameters decrease with increasing tensile strength, but more rapidly in the steel compositions with more sulfur content. More specifically, the torsional ductility limit is already reached in the vicinity of 3000 N/mm 2 for material C, and such material could not be drawn up to the highest diameter reduction r =6.
The wires of group A displayed the smoothest deformation strain hardening behavior and achieved the best compromise between the tested ductility parameters and ultimate strength. Only after the highest total reductions in which the strength reached 3400 N/mm 2 , the attained strength became critical, as reflected in the appearance of surface delaminations in the torsion testing.
From these test data it follows that, all other factors being substantially the same, the close control and limitation of the sulfur content is mandatory in order to have the above residual ductility parameters sufficiently high in wire which is drawn to very high tensile strength.
EXAMPLE 3
Four steel wires were tested of about same composition, but differeing in sulfur content:
______________________________________% C % Si % Mn % P % S______________________________________A 0.85 0.26 0.56 0.018 0.024B 0.85 0.24 0.57 0.019 0.017C 0.85 0.25 0.56 0.016 0.012D 0.84 0.23 0.62 0.015 0.008______________________________________
Wire rods of these compositions were drawn in the conventional way into bead wire of diameter 1.05 mm and tensile strength 2300 N/mm 2 . The obtained wires were subsequently artifically aged by heating them up to 150° C. and keeping them at this temperature during 1 hour.
The wires were submitted to the simple torsion test before and after ageing, and the percentage of the wires that do not show a ductile fracture mode was determined. The percentages are given in Table V:
TABLE V______________________________________ A B C D______________________________________before ageing 35 7 0 0after ageing 90 30 8 2______________________________________
This shows that the steel wires with extra low sulfur composition can much more easily meet the specifications in the torsion test, even after heat ageing.
Analogous results were obtained with the same compositions, drawn to hose wire of a diameter of 0.40 mm and tensile strength of more than 2500 N/mm 2 , with the difference that, for this small diameter, the wires had in general to be rejected, irrespective of their fracture mode, because no sufficient number of torsions was reached before wire breakage occurred.
The invention can be applied to all sort of tire cord constructions, either in the bead, or in the carcass or in the belt of the tire. The constructions can for instance be 3+9 constructions of round wires of a diameter of 0.15, 0.175, 0.22, 0.25 or 0.28 mm diameter, or 2 +2 constructions, i.e. constructions according to U.S. patent No. 4,408,444 of round wires of a diameter of 0.20, 0.22, 0.25 or 0.28 mm diameter, or single strand constructions 12×1 or 27×1 of round wires of a diameter of 0.15, 0.175, 0.22 and 0.25 mm, all twisted in the same direction with the same pitch, preferably in the so-called compact configuration, i.e., in a cross-sectional figure which is constituted by a number of circles of which the adjacent ones are tangent to each other, when a network of equilateral triangles is formed by connecting the center point of each circle with lines to the center points of the adjacent circles.
Typical compositions for use in these applications comprise compositions according to Table VI:
TABLE VI______________________________________% C % Mn % Si______________________________________0.85 0.55 0.250.77 0.55 0.220.68 0.75 0.170.80 0.73 0.350.72 0.60 0.20______________________________________
With respect to alloying elements, other than C, Mn and Si, such as Ni, Cr, Co, Mo and Cu, these are limited to amounts at any rate not more than 3%, and preferably to amounts in which they are to be considered as impurities (i.e. less than 0.05%). As to the elements V, Nb, Ti, Al, Ca, Ce, La, Zr, these are limited to amounts to be considered as impurities, preferably to amounts below 0.005%.
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A method of manufacturing a steel wire with high tensile strength having improved bending and torsional ductility properties useful as a reinforcement wire or cord, especially for rubber products such as tires, comprising providing steel comprising less than 0.015%, preferably less than 0.010%, and most preferably less than 0.008% by weight sulfur and drawing said steel beyond normal drawing limits into a wire having a tensile strength in N/mm 2 of at least 2250-1130 log d where d is the wire diameter in millimeters, and optionally, depositing a covering layer of rubber adherable material such as brass on the drawn wire.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is based on a U.S. provisional application filed Jan. 14, 1997, having Ser. No. 60/035,495 now abandoned and priority in that application is claimed for this application.
BACKGROUND OF THE INVENTION
This invention relates to launchers for missiles and, more particularly, to such launchers for missiles which are encapsulated within canisters.
Encapsulating missiles within a canister is desirable because it provides a convenient and safe way to ship, handle and launch the missiles. The prior art canisters were arranged in cells requiring the gases generated by the missile's burning motor to be vented through a common path. This arrangement concentrated stresses and erosion on certain components of the gas management system because such components were subjected to the gases generated by multiple missiles, resulting in a short life for the gas management system as well as frequent and expensive maintenance of such system. The restraint means for the missile, i.e. the means for securing the missile in its associated canister, could fail when the missile was fired. Protection against the hazards associated with such restrained firings was provided in the prior art launchers in the form of a deluge and drain system. Provision for such a system undesirably added to the complexity, cost, maintenance and weight of the launcher. Increased weight is particularly undesirable when the launcher is to be installed aboard a ship. The prior art canisters also required a launching system in which the electronics for the control system located external to the canister were unique to the particular missile in the canister. Consequently, a change in the type of missile within the canister necessitated a change in the control system, making the installation of a new or different missile expensive and delaying the integration of a new missile throughout the fleet.
BRIEF SUMMARY OF THE INVENTION
The present invention is a canister launcher which overcomes the above-described problems and limitations associated with the prior art canister launchers, which provides integral gas management (i.e. self-contained management of the products of combustion resulting from burning of the motor in the missile contained in that particular canister), which provides positive release of the missile from the canister upon ignition of the missile's rocket motor, which prevents restrained firing of the missile within the canister, which eliminates the need for a deluge and drain system normally required in canister launchers to reduce the deleterious effects of, and hazards to the ship and its personnel associated with, restrained firing, which provides a launcher of light weight and corrosion resistance, which provides integral shock mitigation for the missile, which permits mounting of the launcher above deck, which is resistant to the wide range of hostile environmental conditions encountered at sea, which provides an open electronics architecture, which is modular and which requires no changes in the control system to deploy a new missile, and which may economically and readily installed in a variety of ship configurations.
The foregoing advantages of the present invention, and many of the attendant attributes thereof, will become more readily apparent from a perusal of the following description of preferred embodiments and the accompanying drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a missile in a canister, with portions broken away for clarity, constructed according to the present invention;
FIG. 2 is a more detailed view of the upper portion of the canister shown in FIG. 1;
FIG. 3 is a more detailed view of the lower portion of the canister and missile shown in FIG. 1;
FIG. 4 is a view similar to FIG. 3 showing the means for positively releasing the missile from the canister;
FIG. 5 is a top view of the canister and missile shown in FIG. 1;
FIG. 6 is a view of a four cell module according to the present invention capable of holding four canisters as shown in FIG. 1;
FIG. 7 is a more detailed view of the lower portion or base assembly of the module shown in FIG. 6;
FIG. 8 is another view of the base assembly of FIG. 7 showing the dog down linkages for securing the canisters to the base assembly;
FIG. 9 is a more detailed view of the deck assembly portion of the module shown in FIG. 6;
FIG. 10 is another view of the deck assembly shown in FIG. 9;
FIG. 11 is a more detail view of one of the hatch and associated drive assemblies for the deck assembly shown in FIGS. 9 and 10;
FIG. 12 is a block diagram of the electronics for a canister as shown in FIG. 1;
FIG. 13 is a block diagram of the electronics for the four cell module shown in FIG. 6; and
FIG. 14 is a view of another embodiment of the present invention showing an arrangement for mounting a launcher above deck.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1-5, there is shown a canister, indicated generally at 10 , with a missile 12 restrained therein. The particular missile 12 , shown for purposes of illustration, is a TACMS (Tactical Missile System) missile. The canister 10 has a fabricated cylindrical outer tube 14 and generally cylindrical inner tubular member 16 . The member 16 may be actually cylindrical if the fins on the missile do not extend, when folded, beyond the outer periphery of the missile, as in the case of the Tomahawk missile. Because fin pockets are required to accommodate the fins and the hinges mounting the same to the missile, the member 16 is formed of four cylindrical sections 18 separated by and secured to a generally U-shaped members 20 , with the latter having a cross section shaped to function as fin pockets. The tunnels formed by the spacing between the outer tube 14 and the tubular member 16 form uptake passages 17 for the exhaust of gases produced by the motor of the missile 12 . In order to weld or otherwise secure the U-shaped members 20 to the outer tube 14 , cylindrical panels are provided in the outer tube 14 which are not secured to the outer tube 14 until after the U-shaped members 20 are secured to the outer tube 14 . Although the members 20 function as stiffeners and reduce the inward deflection of the sections 18 under the pressure of the gases within the uptake passages, stiffeners 19 are also positioned within the uptake passages 17 , extending along their length, and are secured to the outer tube 14 and to the sections 18 . The stiffeners 19 are first secured to the cylindrical sections 18 and then to the outer tube 14 , which is accomplished by forming a plurality of aligned slots in the outer tube 14 through which tabs on the stiffeners 19 extend and are welded. Fly-out guides 22 are secured to the tubular members 16 to properly direct the missile 12 as it is launched. A circular flange 24 encircles and is secured to the upper end of the outer tube to add structural stability to the upper end of the tube 14 . A similar flange 26 encircles and is secured to the lower end of the outer tube 14 . A hemispherical head 28 is removably secured to the lower flange 26 , preferably by bolts, and seals the lower end of the canister 10 . The inner surface of the hemispherical head 28 , which is formed of stainless steel, is coated with an ablative material to resist the erosion resulting from the flow of high temperature gases produced by the missile's motor. The head 28 serves to turn and redirect such gases through the uptake passages 17 . The sections 18 and the members 20 terminate a short distance above the level of the lower flange 26 to permit free entry of the gases, redirected by the head 28 , into the passages 17 . This arrangement provides integral gas management, i.e. management of the gases entirely within the confines of the canister itself, and is often referred to as a concentric canister launcher (CCL). In order to keep the weight of the canister low and to provide good corrosion resistance, the foregoing components, except for the head 28 and guides 22 , are made of titanium or other appropriate material.
As best seen in FIGS. 3 and 4, the lower end of the missile 12 rests upon a base plate 30 supported by a plurality of shock absorbers 32 , each of which is pinned to a bracket 34 secured to an adjacent U-shaped member 20 . This arrangement provides shock mitigation integral to the canister 10 for the missile 12 . Three levers 36 are pivotally mounted on brackets secured to the base 30 and have projections or dogs on their upper ends that are engageable with complementary recesses formed in the missile 10 . The lower ends of the levers 36 are pinned to links 38 which extend though, and are fulcrumed on, openings in the base plate 30 . The lower end of the links 38 are pinned to a release mechanism 40 , which mechanism includes two tension links 42 pinned to a third link 44 . The third link 44 is a fusible link which separates or comes apart upon exposure to high heat. The two links 42 are shorter than the link 44 in order to position the link 44 directly in the flow of the high temperature gases created upon firing the missile 12 . The dogs on the levers 36 remain engaged with the recesses in the missile, securing the missile 10 to the base plate 30 , as long as the link 44 remains a unitary structure. However, upon exposure to the high temperature gases created upon firing the missile 12 , the link 44 comes apart permitting the dogs to disengage from the missile recesses. Thus, the release mechanism is directly responsive to the firing of the missile and restrained firing is precluded. The link 44 may be made by forming engageable flats on overlapping ends of segments of the link 44 and joining the flats by a means, such as soldering, which fails upon exposure to the high temperatures of the missile's combustion products, but is otherwise structurally sound.
As shown in FIG. 6, four of the canisters may be arranged within a cell, indicated generally at 46 , having a base assembly 48 capable of attachment within a ship, an intermediate structure 50 and an upper deck assembly 52 . The base assembly 48 , as best seen in FIGS. 7 and 8, includes a segmented socket 54 for each of the four canisters 10 having a shape complementary to the hemispherical head 28 for securing the canister 10 from radial movement relative to the base assembly 48 and to assist in properly locating the canister within the cell. For each of the canisters in the cell 46 , four latches 56 , which are commonly called dog down latches, are carried on the base assembly 48 and have projections on their upper ends which engage the lower flange 26 on the canister 10 . Of the four latches, the one adjacent the corner of the cell is connected to a manually actuated lock mechanism which slides the associated latch in a slot angled toward the flange 26 so that the projection thereon engages the top of the flange 26 . The lock mechanism is connected to the other three latches by links 57 . Thus, movement of the lock mechanism will cause all four latches to a position in which the projections thereon engage the upper surface of the lower flange 26 , thereby locking the canister 10 to the base assembly 48 .
The deck assembly 52 , as shown in FIGS. 9-11, which is intended for mounting on the upper deck of a ship, has a hatch 60 for each of the four canisters 10 in the cell 46 . Each hatch 60 has a pair of arms 61 secured thereto with pins 63 extending through brackets 62 secured to the upper surface of the deck assembly 52 . One of the pins 63 is non-rotatably secured to the associated arm and to a crank 64 . A pin 66 pivotally connects a link 68 pinned to the crank 64 , a drag link 70 pivotally connected to the deck assembly 52 and a connecting link 72 . The connecting link 72 is also pinned to an actuating arm 74 which rotates with the output shaft 76 of a worm and wheel drive 78 which is powered by an electric motor 80 . When the hatch 60 is closed the opening in the deck assembly covered thereby is sealed with the pin 66 going over-center, i.e. the pin 66 goes below the line between the pivotal connections of the link 68 to the crank 64 and of the drag link 70 to the deck assembly 52 . With such an over-center arrangement, any force attempting to open the hatch 60 will only cause the hatch to be sealed more tightly. Guide rings 82 are secured within the deck assembly 52 to assist in loading the canister into the cell.
The arrangement of the electronics provides an open architecture that renders the entire system versatile and economical. This is achieved by placing the electronics specific to the type of missile in the canister within the canister and the electronics needed for monitoring and control of the missile on the canister. The cell electronics are enclosed within a protective housing 90 as shown in FIGS. 3 and 4 with an umbilical cord 92 connecting the circuitry within the housing to the missile itself. The connection of the umbilical cord 92 to the missile includes a break-away connector to permit separation there between when the missile is launched. Another housing 94 mounted on each leg of the base assembly 48 contains all of the electronics for control and monitoring of the missile, which are connected to the canister electronics by a cord having a male connector capable of mating with the female connector on the housing 90 . FIG. 13 is a block diagram of the canister electronics in the housing 90 showing its relationship to the missile 12 and the cell electronics in the housing 94 on the associated leg of the base assembly 48 . FIG. 12 is a block diagram of the cell electronics and shows its relationship to the canister electronics and the launcher control panel, the canister electronics, and sensors and control of the hatch motors 80 and hatch heaters necessary for operation of the hatches in cold climates.
Some ships are not physically capable of accepting the launcher below deck, and some missile cannot be launched vertically because they lack the capability of turning into level flight. The present invention is adaptable to overcome either short coming by the arrangement shown in FIG. 14 . In this embodiment, the launcher structure 98 is mounted at an angle to the vertical by the support structure 100 . The lowered height permits mounting the entire launcher above deck, facilitating installation of the launcher on ships that cannot otherwise accommodate such a launcher, and can be used with missiles requiring a low launch angle.
In this embodiment each hatch such as 102 covers a pair of missiles such as 104 and 106 . These missiles are each resident in a canister which is similar to the canister shown in FIG. I et seq. Thus surface 108 is inner tubular member similar in structure and function to the inner tubular member 16 of FIG. 2 . Likewise, the fin pocket 110 of FIG. 14 is similar to the U-shaped fin pocket shown at 20 in FIG. 2 .
Each of the canisters 112 and 114 will have structures identical to those shown for the FIG. 1-3 canisters except that the hatch will be controlled by a single over-center latch operating through and with the hinge 120 . The hatch actuating mechanism will be contained in housing 116 .
Each of the nine missile canisters in this FIG. 14 are identical, thus providing 18 missile capacity from this launcher. It is expected that arrays of between two and any number of missile tubes could be arranged in a structure as shown in FIG. 14 .
The housing 118 may cover the array and also, in this view, covers the apparatus shown in FIG. 7 and FIG. 8 including the electrical connections with housing 94 and the latch mechanism such as 56 .
While various embodiments of the present invention have been shown and described herein, it is to be understood that various changes and modifications may be made without departing from the spirit of the invention, as defined by the scope of the following claims.
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A canister for launching a missile having a cylindrical outer tube with a hemispherical head releaseably secured to its lower end connected through stiffeners to an inner tubular member to form a passage for the gases generated when the missile is fired. A restraint mechanism secures the missile to a base plate, which is itself mounted on shock absorbers, with a release mechanism responsive to the firing of the missile for disabling the restraint mechanism.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 464,410, filed Feb. 7, 1983 now U.S. Pat. No. 4,483,261.
BACKGROUND OF INVENTION
This invention relates to a multiple needle tufting machine, and more particularly to a needle bar assembly for a multiple needle tufting machine.
The conventional needle bars for multiple needle tufting machines are long, continuous, solid bars extending transversely of the machine above the base fabric for the entire width of the fabric to be tufted. A conventional needle bar includes a plurality of needle holes extending vertically through the needle bar and desirably parallel to each other, uniformly spaced at the desired needle gauge. Each needle is inserted through the needle hole in the bottom of the needle bar so that each needle extends substantially the full height, if not the full height, of the needle bar. The needles are secured in position in their respective needle holes by transverse set screws.
The conventional needle bar has always been one of the most difficult parts of a tufting machine to manufacture, since the numerous needle holes must be drilled very accurately in the long needle bar. It is extremely difficult to control the path of the drill bit through a needle bar which is usually 7/8" in depth or height. In the drilling operation, the drill bit often "leads off" in one direction or another at an angle to the vertical. Accordingly, such angular drill holes through the needle bar will not be parallel to each other. Therefore, the elongated needles extending through the angular needle holes would be "off gauge" where the needle holes are not drilled in truly vertical paths. The longer the needle, therefore, the greater the gauge error.
The "leadoff" of the drilling paths for each needle hole may be caused by various factors. A drill bit which is not accurately ground, or a drill bit being forced too rapidly into the metal of the needle bar, or a drill bit striking the more dense or harder portion of the metal in the needle bar, can cause the drill bit to deflect from its truly vertical course. Once the "leadoff" begins, the continuing path of the drill bit will diverge further away from the desired vertical course.
Once the drilling of the conventional needle bar has commenced, it is not possible to determine the path of the drill bit unitl it emerges from the opposite side of the needle bar. In a multiple needle tufting machine having several hundred needles, the gauge errors between the needles caused by the inaccurate drilling of the needle holes can create considerable problems.
Not only does the drilling of the needle holes involve maintaining accurate control of the drilling paths of the drill bits, but occasionally a drill bit will break off in the drilled needle hole, and the broken drill bit cannot be removed without damaging the needle bar.
All of the above problems in the drilling of the needle holes can result in a needle bar which cannot be used and which must be discarded or scrapped.
Normally, it takes approximately 40 man-hours to drill all of the required needle holes in a conventional needle bar of a multiple needle tufting machine.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide in a needle tufting machine an improved needle bar assembly incorporating multiple, modular, needle bar parts that will provide a more accurate needle gauge.
The needle bar assembly made in accordance with this invention, includes a long, continuous, mounting bar which is attached directly to the conventional push rods of the needle drive mechanism of the tufting machine, the mounting bar extending the full width of the fabric to be tufted, or in other words, the same length as the conventional needle bar. The plurality of short needle bar segments in the order of 6-12" in length are designed to be secured by appropriate fastener mechanisms such as bolts, in an end-to-end relationship along, beneath, and to the mounting bar. In each of the needle bar segments, is drilled a plurality of holes at the desired needle gauge. These holes may be in a single straight line, or they may be alternately staggered in a well known manner. The length of the needle bar segments are so limited that the needle gauge will be maintained throughout the length of the needle bar assembly when the needle bar segments are fastened end-to-end beneath the mounting bar.
Because of the combined structure of the mounting bar and the needle bar segments, the height or depth of the needle bar segments, in the order of 1/2", is less than the height or depth of a conventional needle bar. Preferably, the needle bar segments are spaced below the bottom surface of the main portion of the mounting bar so that the needles received within their corresponding needle holes will project above the needle bar segments and engage the bottom or abutment surface of the mounting bar. Because of the lesser depth of the needle bar segments than conventional needle bars, any drilling "leadoffs" or divergences from the true vertical course of the drill bit will be minor. Moreover, because of the relatively short lengths of the needle bar segments, the needle holes may be drilled on an ordinary milling machine on which more accurate spacing can be achieved by moving the short needle bar segment within the travel limits of the milling machine table.
Because of the modular construction of the needle bar assembly made in accordance with this invention, small spacing may be provided between the ends of the needle bar segments in order to permit small lateral adjustments to compensate for any gauge errors and permit the needles to accurately align with the tufting hooks below the fabric.
Moreover, if there are any substantial drilling errors in the needle bar segemnts, then only that needle bar segment which includes the unacceptable drilling error can be discarded without sacrificing the remaining needle bar segments.
Furthermore, because of the modular arrangement of the needle bar segments, an entire set of needle bar segments may be replaced by another set of needle bar segments having a different needle gauge, without removing the continuous mounting bar from the push rods.
The mounting bar and the needle bar segments made in accordance with this invention may include overlapping tongue-and-groove structures secured together by detachable bolt-type fasteners in order to assemble and disassemble the various needle bar segments upon the mounting bar. In one form of the invention, the mounting bar may have an inverted U-shaped cross-section to define a pair of depending legs receivable within corresponding longitudinal recesses formed in the upper surfaces of the corresponding needle bar segments. In another form of the invention, the needle bar segments may have U-shaped transverse cross-sections with the legs projecting upward and receivable in longitudinally extending grooves or recesses formed in the bottom surface of the monolithic or solid elongated continuous mounting bar.
The needle bar assembly made in accordance with this invention can also be adapted for use in dual shiftable needle bars, such as those illustrated in U.S. Pat. No. 4,366,761. In such an arrangement, the dual needle mounting bars may be provided with recesses into which extend the upward projecting portions of corresponding sets of substantially shorter needle bar segments, and secured in place by detachable bolt-type fasteners.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary sectional elevation taken longitudinally along the line 1--1 of FIG. 3, through a portion of a narrow gauge, staggered-needle tufting machine, incorporating a cutpile looper apparatus, and incorporating the needle bar assembly made in accordance with this invention;
FIG. 2 is a fragmentary front elevation of the needle bar assembly, taken along the line 2--2 of FIG. 1;
FIG. 3 is a fragmentary bottom plan view taken along the line 3--3, of FIG. 1, with portions broken away;
FIG. 4 is a sectional elevation taken along the line 4--4, of FIG. 5, of a modified needle bar assembly;
FIG. 5 is a fragmentary section taken along the line 5--5 of FIG. 4, with portions broken away;
FIG. 6 is a sectional elevation of a modified needle bar assembly for a dual shiftable needle bar type tufting machine, taken along the line 6--6 of FIG. 8;
FIG. 7 is a fragmentary front elevation taken along the line 7--7 of FIG. 6;
FIG. 8 is a fragmentary section taken along the line 8--8 of FIG. 6; and
FIG. 9 is a front perspective view of one of the front needle bar segments.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now, to the drawings in more detail, FIG. 1 discloses a cross-section of a needle bar assembly 10 made in accordance with this invention assembled in a conventional multiple-needle tufting machine. The needle bar assembly 10 supports a first row of uniformly spaced front needles 11 and a second row of uniformly spaced rear needles 12 offset preferably mid-way between the front needles 11, to provide a uniform, narrow gauge, staggered needle tufting machine. The needle bar assembly 10 is vertically reciprocated by conventional needle drive means, including a push rod 13 connected to the needle bar assembly 10 by an attachment collar 14. The push rod 13 vertically reciprocates the needle bar assembly 10 to cause the front and rear needles 11 and 12 to move between an upper position above the base fabric 15 to a lower position (FIG. 1) penetrating the base fabric 15, so that the needles will carry yarns, not shown, through the base fabric 15 to form loops of tufting therein. The base fabric 15 is supported upon a needle plate 16 for movement, by means not shown, in the direction of the arrow 17 of FIG. 1, that is longitudinally from front-to-rear of the machine.
The looper apparatus 18 which cooperates with needles 11 and 12 may include a transverse hook bar 20 of unique, or conventional, construction fixed upon a bracket 22 carried by a rocker arm 23 journalled on a rock shaft, not shown. The rocker arms 23 are driven by conventional means, not shown, for limited reciprocal movement in synchronism with the reciprocal movement of the needles 11 and 12. The hook bar 20 supports a plurality of looper hooks 25 and 26 having bills 27 and 28 of different lengths to cooperate with the respective needles 11 and 12 to seize the corresponding loops of yarn formed by the respective needles 11 and 12 below the base fabric 15.
Where cut pile is formed by the needles 11 and 12 and the corresponding looper hooks 25 and 26, a knife 30 is reciprocably supported to cooperate with each hook for cutting the seized loops, in a well known manner.
In the first embodiment of the invention disclosed in FIGS. 1-3, the needle bar assembly 10 includes a continuous elongated needle mounting bar 32 disclosed as having an inverted U-shaped cross-section. The mounting bar includes an upper main body portion 33 having a bottom needle abutment surface 34 and a pair of depending legs 35 and 36 spaced apart in a front-to-rear direction greater than the front-to-rear spacing of the front needles 11 and the rear needles 12. The top surface 37 of the main body portion 33 is connected to the attachment collar 14 of the push rod 13. The mounting bar 32 extends the entire width of the stitching area, or in other words, has at least as great a span as the width of the base fabric 15 moving through the tufting machine. The mounting bar 32 is substantially the same length as a conventional needle bar.
Detachably mounted upon the mounting bar 32 are a plurality of elongated needle bar segments 40 each of substantially shorter length than the overall length of the mounting bar 32. Each needle bar segment 40 may be approximately 6-12" long. The top surface 41 of each needle bar segment 40 is preferably spaced below the abutment surface 34 of the mounting bar 32, and is provided with a pair of grooves or recesses 43 and 44 parallel to each other and extending longitudinally of each corresponding needle bar segment 40. The recesses 43 and 44 have the same front-to-rear spacing and substantially the same front-to-rear dimensions, as the legs 35 and 36 in order to snugly receive the depending legs 35 and 36 within the corresponding recesses 43 and 44. Formed through the height or depth of each needle bar segment 40 are a plurality of elongated needle holes 45 opening through the top surface 41 and the bottom surface 46, parallel to each other, and arranged at the desired needle gauge and spacing, such as the staggered needle arrangement disclosed in FIGS. 1-3. Each needle hole 45 may be drilled in the same manner as conventional needle bars. However, because of the relatively shallow depth or height of the bar segments 40, substantially less drilling is required, and more accurate drilling is obtained.
Each of the needle holes 45 is of a configuration adapted to snugly receive the shank portion 47 of each of the needles 11 and 12. The shank portions 47 may project above the top surface 41 of each needle bar segment 40, as disclosed in FIG. 1, and engage the needle abutment surface 34 of a mounting bar 32. In this manner, the vertical positions of the needles 11 and 12 may be accurately located, and the shank portions 47 may be gripped by the needle holes 45 below the upper ends of the shank portions 47 over a shorter length, to stabilize the needles 11 and 12 as well as needles are stabilized in a conventional needle bar.
Each of the needles 11 and 12 are secured in their respective needle holes 45 by the front and rear set screws 49 and 50 in substantially the same manner as the needles would be secured in a conventional needle bar.
The legs 35 and 36 are secured in their overlapping, dove-tailed, or tongue-and-groove engagement with their corresponding recesses 43 and 44 by means of the transverse threaded fasteners, such as the bolt members 52.
As disclosed in FIG. 2, each bolt 52 may extend through an oversized, oval, or elongated bolt hole 53 in the side of the corresponding needle bar segment 40 before threadely engaging a corresponding threaded hole within the corresponding leg 35 of the mounting bar 32. The oversized hole 53 permits longitudinal or end-to-end adjustment between adjacent needle bar segments 40. The adjacent, opposing ends of the needle bar segments 40 disclosed in FIG. 2 are shown slightly separated, such as by a spacing in the order of 0.008-0.010 inches. Thus, lateral adjustment is permitted between adjacent needle bar segments 40 to correct for any slight errors in the needle gauge, or to permit localized alignment of the needles 11 and 12 with their corresponding hooks 25 and 26.
It will be apparent from the above description that a needle bar assembly 10 has been developed which substantially reduces the cost and time of manufacture, and also provides more accurate needle gauges, and optionally, a needle bar assembly in which the needle gauge may be subject to slight adjustments.
Moreover, the needle bar assembly 10 made in accordance with this invention, permits the use of a single, long mounting bar 32 which may be permanently connected to the push rods 13, and which supports a plurality of replacable and interchangeable needle bar segments, which can be utilized for readily replacing worn parts without discarding an entire single long needle bar. Furthermore, needle gauges of varying sizes may be utilized with the same mounting bar 32 by mere replacement of the entire set of needle bar segments 10 with another set of needle bar segments of different needle gauge.
In the second embodiment of the needle bar assembly 60 disclosed in FIGS. 4 and 5, the cross-sections of the mounting bar 32 and the needle bar segments 40 have been reversed. The structure of the elongated needle mounting bar 62 is of substantially rectangular cross-section and the needle bar segments 70 are each of U-shaped cross-section.
The mounting bars 62 of the needle bar assembly 60 includes a bottom needle abutment surface 64 in which are formed parallel or elongated grooves or recesses 65 and 66. The recesses 65 and 66 are of a spacing and shape to snugly receive the upward projecting legs 75 and 76 from the main body portion 74 of the needle bar segments 70. The top surface 71 of the main body portion 74 of the needle bar segment 70 is spaced below the needle abutment surface 64 to provide additional room for the upward projection of the shank portions 47 of the needles 11 and 12, which abut the bottom surface 64 of the mounting bar 62.
Needle holes 77 are formed in the main body portion 74 to extend entirely through the main body portion 74. The needle holes 77 open through the bottom surface 72 and the top surface 71 and are arranged in the same configuration and gauge as the needles 11 and 12.
The legs 75 and 76 are secured in the recesses 65 and 66 by the bolt members 79 in the same manner as the corresponding legs 35 and 36 are secured in the recesses 43 and 44 of the needle bar assembly 10 by bolt members 52.
The needles 11 and 12 are secured within the needle holes 77 by the set screws 49 and 50.
Otherwise, the structure and function of the needle bar assembly 60 is essentially the same as that of the needle bar assembly 10.
Because, as best disclosed in FIG. 4, each needle bar segment 70 of the needle bar assembly 60 has a lesser front-to-rear dimension than the corresponding dimension of the mounting bar 62, threads of yarn may be fed to the needles 11 and 12 from the yarn feed rolls, not shown, so that they will extend more nearly parallel to the needles 11 and 12 when they are threaded through the needle eyes.
FIGS. 6-9 disclose a modified form of a needle bar assembly 80 especially adapted to be used with dual shiftable needle bars, such as those disclosed in U.S. Pat. No. 4,366,761 of Roy T. Card, issued Jan. 4, 1983.
The needle bar assembly 80 supports a first row of uniformly spaced front needles 11 and a second row of uniformly spaced rear needles 12 offset preferably mid-way between the front needles 11, to provide a uniform, narrow gauge, staggered needle tufting machine. The needle bar assembly 80 is vertically reciprocated by conventional needle drive means, including the push rods 13 connected to the needle bar assembly 80 by attachment collars 14'. The push rods 13 vertically reciprocate the needle bar assembly 80 to cause the front and rear needles 11 and 12 to move in the same manner as the needles 11 and 12 are moved by the needle bar assembly 10 or 60 in FIGS. 1-5, to penetrate the base fabric 15 to form loops of tufting therein.
The looper apparatus 18 which cooperates with the needles 11 and 12 may be of the same construction as the looper apparatus 18, disclosed in FIG. 1, cooperating with the same knives 30.
The needle bar assembly 80 includes a continuous elongated needle bar holder or slide holder 81 fixedly connected to the push rod collars 14'. The needle bar slide holder 81 includes a pair of parallel slideways 82 and 83 for reciprocably and slideably receiving slides 84 and 85 of substantially T-shaped cross-section. Each slide 84 is fixed to a continuous elongated front needle bar or front needle mounting bar 86, while each slide 85 is fixed to a continuous elongated rear needle bar or needle mounting bar 87.
The needle bar holder 81 and the front and rear needle bars 86 and 87 extend the entire width of the stitching area, and are driven, and operate, in the same manner as the dual shiftable needle bar assembly disclosed in U.S. Pat. No. 4,366,761.
Formed in the inner opposed faces of the needle mounting bars 86 and 87 are a pair of elongated recesses 88 and 89. Each of these recesses 88 and 89 is adapted to receive in assembled end-to-end position, a corresponding set of needle bar inserts or segments 90 and 91. Each of the segments 90 and 91 is substantially shorter than the overall length of either of the needle bars 86 or 87.
Moreover, each of the needle bar segments 90 and 91 preferably has an L-shaped cross-section, as best disclosed in FIGS. 6 and 9, including an upper vertical leg portion 92 and a lower foot flange 93. The upper leg portion 92 of each segment 90 and 91 is adapted to be received substantially flush and in snug engagement within each corresponding recess 88 and 89. Each foot flange 93 is provided to limit the upward movement of each needle bar segment 90 and 91 within its corresponding recess 88 and 89 and to seat against the bottom surface of each of the corresponding needle bars 86 and 87.
A plurality of needle holes 95 are formed vertically through the bottom portion of each of the needle bar segments 90 and 91 and are arranged in transverse longitudinal alignment, yet offset from the needle holes in the opposite needle bar segment so that the needles 11 and 12 are arranged in a conventional staggered pattern for each stitch penetration of the base fabric 15.
Each of the needles 11 and 12 is retained in fixed position within a corresponding needle hole 95 by conventional set screws 96 and 97, respectively.
Each of the needle bar segments 90 and 91 is retained in its respective recess 88 and 89 by the threaded bolts 98, in a manner similar to the retention of the needle bar segments 40 and 70 in the respective needle bar assemblies 10 and 60.
Otherwise, the needle bar segments 90 and 91 in the needle bar assembly 80 have substantially the same function and advantages as the needle bar segments 40 and 70 in the corresponding needle bar assemblies 10 and 60.
The bolts 98 may also be provided with elongated, or over-sized, bolt holes, such as the elongated bolt holes 53 disclosed in FIG. 2, for transverse adjustments of the short needle bar segments 90 and 91.
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A needle bar assembly for a multiple needle tufting machine including an elongated continuous mounting bar connected to the push rod of the needle drive mechanism for reciprocal movement, and a plurality of elongated, but substantially shorter, needle bar segments having needle holes for receiving the needles and secured end-to-end along and to the mounting bar, whereby individual needle bar segments may be independently attached and detached to the mounting bar, and longitudinally adjusted if desired. The needle bar assembly also contemplates a pair of needle mounting bars slideably received in a needle bar holder connected to the needle drive mechanism and two sets of substantially shorter needle bar segments secured end-to-end along each of the corresponding needle mounting bars.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from and the benefit of PCT Application No. PCT/EP2007/009368, filed on Oct. 29, 2007; German Patent No. DE 10 2006 051 377.0, filed on Oct. 27, 2006; and German Patent DE 10 2007 016 690.9, filed on Apr. 4, 2007; all entitled “Structural Element for a Vehicle Seat”, which are herein incorporated by reference.
BACKGROUND
[0002] The invention relates to a vehicle seat, in particular a motor vehicle seat with a structural element which in each case comprises a plurality of components, at least some of which are connected to one another. Furthermore, the present invention relates to a method for producing the motor vehicle seat according to the invention.
[0003] The motor vehicle seats according to the invention are known from the prior art. The majority of all of the motor vehicle seats currently mass produced have structural elements which a structure using a very wide variety of steel profiles and sheets. However, motor vehicle seats with structural elements in a lightweight construction, said structural elements being composed of different materials, are also known. Structural elements of this type are disclosed, for example, in DE 10 2004 044 734, DE 697 02 023 T2 and DE 198 26 732 A1. However, said structural elements are currently manufactured differently and in a lower piece number than structural elements made of steel and, as a result, are more expensive to produce.
[0004] It was therefore the object of the present invention to make available a motor vehicle seat which can be made available cost-effectively even in a lightweight construction.
[0005] The object is achieved by a motor vehicle seat with a structural element which in each case comprises a plurality of components, at least some of which are connected to one another, wherein at least one component is available in a plurality of embodiments, and the shape of a component which is connected thereto is configured in such a manner that it remains unchanged irrespective of the embodiment of the components.
SUMMARY
[0006] The present invention relates to a motor vehicle seat which can be located in any row in the particular motor vehicle. It may accordingly be a front seat or a rear seat. The motor vehicle seat according to the invention may provide a seat for one or more individuals. The motor vehicle seat according to the invention may accordingly also be a seat bench.
[0007] According to the invention, the motor vehicle seat has a structural element which is composed of a plurality of components, at least some of which are connected to one another. At least one of said components is available in a plurality of embodiments, for example in a conventional steel construction or in a lightweight construction. However, said component may also be designed differently for different types of connection. For example, this component may have a somewhat different configuration depending on whether it is adhesively bonded or welded to the other component.
[0008] According to the invention, it is now provided that, for example in a steel construction, certain components may be replaced by components in a lightweight construction without the joining components having to be changed. As an alternative or in addition, it can be provided, for example, that one component is configured differently, depending on the type of connection to the other component. As a result, it is possible to realize various embodiments with one and the same structure design on a vehicle platform. Therefore, both a “low cost variant” consisting of steel and a “high end variant” consisting of a hybrid construction can be made available. In addition, different connecting variants may be used. In the case of the hybrid variant, steel components are preferably used with components which are not manufactured from steel, for example a lightweight construction material, such as, for example, plastic, aluminum and/or an aluminum alloy or a combination thereof. The hybrid design here is always significantly lighter than the conventional steel solution. A further great advantage of the motor vehicle seat according to the invention is that, in order to produce the structures, use can be made of virtually the same production equipment in terms of welding robot/systems and apparatuses. As a result, the production costs and the capital costs associated therewith, in particular for the production of the motor vehicle seat in a hybrid construction, could also be significantly reduced.
[0009] The structural element is preferably a backrest frame which constitutes the basic structure for a backrest of a motor vehicle seat. As a rule, a recliner for adjusting the inclination of the backrest, the spring system of the motor vehicle seat, the head restraint and optionally airbags are arranged on the backrest frame. The backrest frame preferably has backrest side parts which are connected to one another by a lower cross piece and/or an upper cross piece. The backrest side parts are preferably three-dimensionally shaped components of any material, for example steel sheet, a lightweight construction material, such as aluminum or plastic, or a combination of said materials, and particularly preferably remain unchanged, irrespective of the embodiment of the cross pieces and/or of the connection of the cross piece to the side part of the backrest. The lower and/or upper cross piece(s) are/is particularly preferably realized in steel or in the form of a lightweight construction. In both cases, the cross pieces are preferably configured as profiles and/or molded parts. The lightweight construction embodiment is preferably an extrudeable profile, particularly preferably a profile which has a lightweight construction material, preferably aluminum, or a molded part, in particular made of lightweight construction material, for example aluminum.
[0010] At least one cross piece and the backrest side parts are in each case preferably connected to one another in a connecting region. Said connection in the connecting region may be an interlocking, frictional and/or material-to-material bonding connection. The interlocking and/or frictional connection take/takes place, for example, by riveting, U welding, press-joining (Tox clinching) or flanging. The material-to-material bonding connection preferably takes place by welding, in particular laser welding, laser hybrid welding, laser bracing or adhesive bonding. The parts are particularly preferably connected to one another by cold metal transfer (CMT) welding.
[0011] In another preferred embodiment, the structural element is the substructure, the seat frame, of a vehicle seat. Said substructure is the basic structure for that part of the vehicle seat on which the vehicle occupant sits. The substructure preferably has two substructure side parts. Said substructure side parts are preferably three-dimensionally shaped components which are particularly preferably formed from steel sheet or from a lightweight construction material, such as aluminum and/or plastic. Said substructure side parts are preferably connected to each other by at least one component. Said component, for example a transverse tube, is preferably realized in steel or in the form of a lightweight construction. In a lightweight construction, the component is preferably at least partially composed of a lightweight construction, material, for example from aluminum.
[0012] The substructure side parts and the component are in each case connected to one another in a connecting region.
[0013] The connection in the connecting region is preferably an interlocking, frictional and/or material-to-material bonding connection. The frictional connection takes place, for example, by riveting, U welding, press-joining (Tox clinching), crimping or flanging. The material-to-material bonding connection preferably takes place by welding, in particular laser welding, laser hybrid welding, laser bracing or adhesive bonding. The parts are particularly preferably connected to one another by cold metal transfer (CMT) welding.
[0014] The connecting region preferably remains unchanged irrespective of the embodiment of the components to be connected and/or of the type of connection. In particular the connecting region which is arranged on the backrest side parts and/or on the substructure side parts particularly preferably remains unchanged. As a result, these can always be made of the same side parts, irrespective of whether the components which connect them are realized in steel or from a lightweight construction material, and/or irrespective of the type of connection. This results in considerable advantages in terms of stock keeping and production.
[0015] The cross pieces and/or the component in a lightweight construction preferably have/has a larger cross section than in the steel embodiment. The connecting region has to be taken into consideration during the design of the same. It has to be constructed in such a manner that there is sufficient space for the component with the largest cross section. For the connection of two parts which are both manufactured from steel or from a lightweight construction material, such as aluminum, if appropriate an adapter has to be provided in order to obtain a suitable connection. As an alternative, a steel part can be widened in the connecting region, for example, by hydroforming.
[0016] The backrest side part preferably has a connecting region. Said connecting region particularly preferably remains unchanged irrespective of the type of connection to the cross piece; i.e. the backrest part can be, for example, welded or adhesively bonded to the cross piece without the backrest part having to be changed.
[0017] The connecting region of the backrest part is particularly preferably dimensioned for an adhesive bonding connection. Since the connecting region for an adhesive bonding connection is somewhat larger than for a welding connection, a cross piece can be arranged in said connecting region by adhesive bonding and by welding without the backrest part having to be changed.
[0018] The cross piece preferably has a connecting region which differs in design depending on the type of connection. All of the cross pieces are particularly preferably initially manufactured in a manner suitable for an adhesive bonding connection. This reduces the stock keeping. If the cross piece is then to be connected to the side part by welding, the cross piece is reworked, in particular by machining or by punching. During the reworking operation, in particular the contact surface of the cross piece is reduced and the cross piece contour provided for a welding connection is increased.
[0019] In a particularly preferred embodiment, the cross pieces are designed in such a manner that they are suitable both for a welding connection and for an adhesive bonding connection to the side part such that they can remain unchanged irrespective of the method of connection. This preferred embodiment of the present invention results in particularly low storage costs. The connection region of the side parts particularly preferably also remains unchanged.
[0020] In a preferred embodiment of the present invention, the side part and the cross piece are connected to each other by adhesive bonding and an interlocking and/or frictional connection, in particular a press-joining. In this case, the interlocking and/or frictional connection serves in particular to fix the side part and the cross piece in relation to each other before, during and/or after the adhesive bonding. In particular, the side part and the cross piece are fixed in their position with respect to each other until the adhesive has hardened. The machine time, in particular, can be reduced as a result. After the adhesive has hardened, the interlocking and/or frictional connection increases the load-bearing capacity of the connection.
[0021] The present invention furthermore relates to a method for producing the structural element according to the invention of a motor vehicle seat, in which a plurality of components are connected to one another by the same technique, irrespective of the particular embodiment of the component.
[0022] With regard to the structural elements, the components and the different embodiments thereof, reference is made to the statements above. This disclosure applies equally to the methods according to the invention.
[0023] According to the invention, use is made of the same connecting techniques, irrespective of which embodiments are involved in the particular component. For example, material-to-material methods of connection which are suitable both for connecting steel to steel and also steel to lightweight construction material are selected. If appropriate, only the parameters of the method of connection are changed, for example, welding parameters, or the preparation of the connection is changed, depending on the material.
[0024] The components are preferably welded or adhesively bonded to one another. Welding takes place in particular by the CMT process, laser hybrid welding or laser brazing.
[0025] The components are preferably connected to one another in an interlocking and/or frictional manner. Said interlocking and/or frictional connection can be connected to a material-to-material bonding connection, in particular adhesive bonding. This results in the advantages mentioned above. An interlocking and/or frictional connection cannot, however, absorb any torque and is preferably used for connecting the cross piece to the side part of the seat part since said cross piece is part of the height adjuster and/or interacts therewith.
[0026] According to a further or a preferred subject matter of the present invention, the connection between the side part and the cross piece takes part from one direction, preferably from the x direction, irrespective of the type of connection. The x direction is the direction close to the forward direction of travel.
[0027] According to a further or a preferred subject matter of the present invention, the components are connected to one another by an interlocking and/or frictional connection before an adhesive has fully hardened.
[0028] According to a further or a preferred subject matter of the invention, the connecting region of the components is converted from an adhesive bonding part into a welding part before the welding operation. This takes place in particular by removal of parts of the adhesive bonding surface, in particular in such a manner that the contour along which welding can take place is increased.
DRAWINGS
[0029] The invention is explained below with reference to an example for a front seat and FIGS. 1 to 12 . Said explanations are merely by way of example and do not restrict the general inventive concept. Said explanations apply equally to all of the subject matter of the present invention.
[0030] FIG. 1 shows a backrest frame.
[0031] FIG. 2 shows the substructure of a motor vehicle seat.
[0032] FIG. 3 shows a further embodiment of the backrest frame.
[0033] FIG. 4 shows two views of the upper cross piece.
[0034] FIG. 5 shows two views of the lower cross piece.
[0035] FIG. 6 shows the upper cross piece in a manner suitable for an adhesive bonding connection.
[0036] FIG. 7 shows an adhesive bonding connection between the backrest side part and the lower cross piece.
[0037] FIG. 8 shows the lower cross piece as an adhesive bonding part and as a welding part.
[0038] FIG. 9 shows the upper cross piece as an adhesive bonding part and as a welding part.
[0039] FIG. 10 shows the upper cross piece which can be used as a welding part and as an adhesive bonding part.
[0040] FIG. 11 shows the lower cross piece which can be used as a welding part and as an adhesive bonding part.
[0041] FIG. 12 shows the connection of the cross piece to the seat side part.
DETAILED DESCRIPTION
[0042] The first exemplary embodiment ( FIG. 1 ) shows a backrest frame 1 comprising two backrest side parts 2 made of high-strength steel, and an upper cross piece 3 and a lower cross piece 4 , both produced from aluminum. The upper and lower cross pieces 3 , 4 are connected by means of a cold metal transfer (CMT) welding process or other connecting techniques, such as adhesive bonding, to the galvanized (necessary for CMT) or plain high-strength backrest side parts 2 . Said welding process permits the aluminum parts to be connected to the galvanized steel components. The intersections at which the cross pieces 3 , 4 are connected to the backrest side parts 2 are designed in a modular manner in terms of structure in such a manner that they permit the optional fitting of aluminum cross pieces 3 , 4 , which customarily have a thicker sheet-metal thickness, or else of cross pieces 3 , 4 composed of steel (smaller material thickness with identical design) without the backrest side parts 2 having to be adapted. This means that, with identical backrest side parts 2 , two variants of a backrest frame 1 can be provided, to be precise the conventional steel/steel embodiment and the steel/aluminum hybrid construction. The method of connection can also be used equally for all of the configurations.
[0043] There can be further possible uses in the substructure 5 (seat part with 2-, 4-, ≧6-directional adjustment) ( FIG. 2 ). The aluminum transverse tubes 6 have a greater cross section than the steel transverse tubes 6 so as to behave in a similar manner in the event of a crash. The substructure side parts 7 are furthermore composed of steel or a lightweight construction material, for example, aluminum.
[0044] The transverse tubes are inserted into bores in the substructure side parts and secured there. In order to ensure that transverse tubes having different diameters can be used, the bore is dimensioned in accordance with the cross section of the largest transverse tube, the aluminum transverse tube. If steel tubes with a smaller cross section are used, the operation can then be carried out with adapter sleeves. The steel tube can also be widened in the connecting region. The rockers 9 are manufactured from light metal.
[0045] FIG. 3 shows a further embodiment of the backrest frame 1 . In the present case the upper cross piece 3 and the lower cross piece 4 are connected to each other by welding, in particular CMT welding. In this case, as indicated by the arrow, the upper and lower cross pieces are inserted in the x direction into the side part and are welded there preferably by means of three weld seams in each case. Said procedure is also undertaken during the adhesive bonding or any other means of connecting the side part to the cross pieces. This avoids the considerably increased outlay on having to move the backrest frame during the machining.
[0046] FIGS. 4 and 5 each show two views of the upper cross piece 3 and the lower cross piece 4 , respectively. It can clearly be seen that both the upper cross piece 3 , in its connecting region 3 ′, and the lower cross piece 4 , in its connecting region 4 ′, have contours 12 along which the welding takes place. Said contours 12 are produced in particular by punching them out. Said punching-out operation increases the length of the contour and therefore the length of the weld seam which is placed along the contour 12 , which increases the stability of the connection to the side rest.
[0047] FIG. 6 shows the upper cross piece 3 which is designed in this case in such a manner that it can be adhesively bonded to the backrest side part 2 in the connecting region 8 . For this purpose, the cross piece 3 preferably has three adhesive bonding surfaces, with the lower adhesive bonding surface particularly preferably being arranged at a right angle to the two upper adhesive bonding surfaces such that the component is completely fixed to the backrest side part in all directions. Said adhesive bond is preferably particularly preferably combined by means of a Tox clinching connection (not shown), i.e. a connection which is obtained by press-joining. Said interlocking and/or frictional connection serves in particular to fix the parts until the adhesive bonding connection has completely cured. However, even thereafter, said interlocking and/or frictional connection increase/increases the load-bearing capacity of the backrest frame.
[0048] FIG. 7 shows the lower cross piece 4 which is adhesively bonded onto the backrest side part by means of the adhesive bonding connecting points 11 . Said connection is also supplemented by a Tox clinching connection (not illustrated). The connecting region 2 ′ of the side part 2 , i.e. the region against which the cross piece 4 bears against the side part 2 , is dimensioned for an adhesive bonding connecting. Since the connecting surface required for an adhesive bonding connection is generally larger than for a welding connection, said region 2 ′ is equally suitable, however, for a welding connection. The same is equally true of the connecting region 2 ′ in which the upper cross piece is arranged on the side part 2 .
[0049] FIG. 8 shows the lower cross piece 4 . The upper illustration shows the cross piece which is suitable in particular for an adhesive bonding connection. The lower illustration shows the cross piece which is suitable in particular for a welding connection. The two cross pieces differ merely by means of the welding contour 12 . Initially, all of the parts are produced in a manner suitable for an adhesive bonding connection. If a cross piece is then to be welded onto the backrest side part, parts are subsequently punched or machined out of the edge region of the cross piece in such a manner that the welding contour 12 is produced.
[0050] FIG. 9 shows the same relationship as FIG. 8 , but for the upper cross piece 3 .
[0051] FIGS. 10 and 11 show the upper and lower cross pieces which are suitable for a welding connection. In this case, the cross pieces 3 , 4 are designed in such a manner that they can be connected without change to the side part 2 irrespective of whether the connection takes place by means of welding or by means of adhesive bonding. A comparison with the cross pieces 3 , 4 in FIGS. 8 and 9 clearly shows that the regions which have been removed from the edge region are smaller than in the case of a cross piece which is suitable only for welding (cf. the lower illustration in FIGS. 8 and 9 ). As a result, the surface available for the adhesive bonding remains comparatively large. The welding contour 12 provided for the welding is not as long as for the welding cross piece according to FIGS. 8 , 9 (lower illustration), but is longer than for a rectilinear contour.
[0052] FIG. 12 schematically shows the connection between a transverse tube 6 and the substructure side part 7 . First of all, a component 13 , which is part of a height adjuster (not illustrated) and/or is connected to a height adjuster, is guided over the transverse tube 6 ( FIG. 12 a ) and is then connected to the tube by crimping. Since the part 13 has interlocking means 14 on its inner side, this results in an axially fixed connection with which torque can also be transmitted. The tube is then connected to the seat side part 7 by conical widening of the edge region of the tube 6 . Said connection is designed in such a manner that the tube 6 can rotate in the side part 7 .
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A motor vehicle seat has a structural element that includes a plurality of components, at least some of which are connected to one another. At least one of the components is available in a plurality of materials, such as steel or a lightweight construction. The shape of the components, however, is configured so that it remains unchanged irrespective of the component material.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/112,510, filed Dec. 14, 1998.
FIELD OF THE INVENTION
The invention is in the field of optical telecommunications, and more particularly, pertains to upgrading an in-service wavelength division multiplexed (WDM) optical communication system including a pair of optical line terminals (OLTs) that reside in the same office and are part of separate WDM networks to form an all optical pass-through from the line side of one OLT of the pair to the line side of the other OLT of the pair.
BACKGROUND OF THE INVENTION
Wavelength division multiplexing (WDM) is an approach for increasing the capacity of existing fiber optic networks. A WDM system employs plural optical signal channels, each channel being assigned a particular channel wavelength. In a WDM system optical signal channels are generated, multiplexed to form an optical signal comprised of the individual optical signal channels, transmitted over a single waveguide, and demultiplexed such that each channel wavelength is individually routed to a designated receiver.
SUMMARY OF THE INVENTION
In typical wavelength division multiplexing systems all wavelengths are constrained to pass through from a source optical node to a predetermined sink optical node.
In view of the above it is an aspect of the invention to selectively pass-through, add or drop individual wavelengths at selected optical nodes.
It is another aspect of the invention to utilize optical line terminals having all-optical pass-through interfaces that provide for continued transmission of optical signals without any intervening electro-optical conversion, and to connect two optical line terminals back-to-back at their respective pass-through interfaces to provide an optical path from the line side interface of the first optical line terminal to the line side interface of the second optical line terminal.
It is yet another aspect of the invention to utilize optical line terminals having a multiplexer/demultiplexer including one or more stages for inputting/outputting individual wavelengths or bands of a predetermined number of wavelengths, or a combination of bands and individual wavelengths.
It is a further aspect of the invention to utilize the optical line terminals to support complex mesh network structures while permitting growth of an in-service network without disrupting network service.
It is yet a further aspect of the invention to provide a wavelength division multiplexed optical communication system including a plurality of optical line terminals, each having a line interface and an all-optical pass-through interface including a plurality of pass-through optical ports and each also including a plurality of local optical ports and an optical multiplexer/demultiplexer for multiplexing/demultiplexing transmitted/received wavelengths. The optical multiplexer/demultiplexer may include one or more stages for inputting/outputting individual wavelengths or bands of a predetermined number of wavelengths, or a combination of bands and individual wavelengths, with at least one of the pass-through optical ports of one of the optical line terminals being connected to at least one of the pass-through optical ports of another optical line terminal to form an optical path from the line side interface of the one of the optical line terminals to the line side interface of the another optical line terminal.
These and other aspects and advantages of the invention will be apparent to those of skill in the art from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an optical line terminal;
FIG. 2 is a flow chart of the control steps executed by the controller 10 of FIG. 1;
FIG. 3 is a block diagram of an optical line terminal having a two-stage multiplexer/demultiplexer;
FIG. 4 is a schematic diagram representative of the optical line terminal of FIG. 1 or FIG. 3;
FIG. 5 is a schematic diagram of two optical line terminals such as in FIG. 4 being connected back-to-back;
FIG. 6 is a diagram illustrating how at least two separate point-to-point WDM systems can be upgraded while in-service to form a merged point-to-point WDM system;
FIG. 7 is a diagram illustrating how at least two separate network WDM systems can be upgraded while in-service to form a merged network WDM system; and
FIG. 8 illustrates a mesh connection between a plurality of optical line terminals.
DETAILED DESCRIPTION
FIG. 1 is a block diagram of an optical line terminal (OLT) 2 which is the basic element of the present embodiment. The OLT 2 has an input/output line interface 4 which is connected to an external fiber facility and transmits/receives an optical signal having N optical wavelengths, for example 32 wavelengths, on a single optical fiber which is multiplexed/demultiplexed by a multiplexer/demultiplexer 6 , which outputs demultiplexed wavelengths λ 1 -λN on individual optical fibers. The respective wavelengths λ 1 -λN are sent either to a peer OLT via a pass-through port or to client equipment via a transponder and a local port. The client equipment includes SONET equipment, add/drop multiplexers, cross-connect switches, internet protocol (IP) routers, asynchronous transfer mode switches (ATM) and the like.
As employed herein an optical signal is generally intended to encompass wavelengths in the range of approximately 300 nanometers to approximately 2000 nanometers (UV to far IR). This range of wavelengths can be accommodated by the preferred type of optical conductor (a fiber optic), which typically operates in the range of approximately 800 nanometers to approximately 1600 nanometers.
Consider λ 1 which is provided to a 1×2 switch 8 which is controlled by a control signal, having at least N states, from a controller 10 . The controller 10 responds to a command, from a management system (not shown), at a terminal 12 to provide the control signal at a terminal 14 and then to control terminal 16 of switch 8 to position the switch 8 in a first or second position. When in the first position, λ 1 is provided to a transponder 18 which transmits λ 1 to a client apparatus 20 via a local port 19 . When in the second position λ 1 is provided to a pass-through port 22 to a corresponding pass-through port in a peer OLT 24 . The control signal is also provided to output terminal 15 , and then to control terminal 16 of a corresponding switch 8 in peer OLT 24 to route λ 1 to the corresponding multiplexer/demultiplexer 6 . If it is desired to send λ 1 to both client apparatus 20 and peer OLT 24 , an optical splitter can be used in place of the switch 8 .
Switch 26 selects λ 1 coming from the opposite direction in response to a control signal at terminal 28 from controller 10 to position switch 26 in a first or second position. When in the first position, λ 1 is received from client 20 via local port 19 and transponder 18 , and when in the second position λ 1 is received from peer OLT 24 via pass-through port 22 , and then is provided to multiplexer/demultiplex 6 to be multiplexed with the other received wavelengths λ 2 -λN.
A wavelength can be directly passed-through to a peer OLT rather than being sent to a client apparatus. For example, λ 2 is directly sent to, and received from, peer OLT 30 via pass-through port 32 .
A 1×N switch can be used to send/receive a wavelength to/from one of N−1 peer OLTs or a client apparatus. For example, 1×N switch 34 under control of a control signal, having at least N states, provided to terminal 36 from controller 10 sends λ 3 to either peer OLT 38 via pass-through port 40 , or peer OLT 42 via pass-through port 44 , or peer OLT 46 via pass-through port 48 or client apparatus 50 via transponder 52 and local port 53 . Reception of λ 3 in the opposite direction is controlled by N×1 switch 54 under control of a control signal provided to terminal 56 from controller 10 , and than is provided to multiplexer/demultiplexer 6 to be multiplexed with the other received wavelengths.
As discussed above, a wavelength can be passed-through to a peer OLT via a pass-through port or can be optically switched to a client apparatus via a local port. λN is shown as being directly passed through to, or received from, peer OLT 60 via pass-through port 62 .
FIG. 2 is a flow chart of the steps performed by the controller 10 of FIG. 1 to control the 1×2 switches 8 and 26 , and the 1×N switches 34 and 54 to route the respective wavelengths λ 1 -λN.
In step S 101 the controller 10 waits for a command from a management system such as a computer (not shown). At step S 102 a determination is made as to whether or not the command is a switch control signal to either pass-through the wavelength via a pass-through port to a peer OLT or drop/add the wavelength locally at/from a client apparatus via a transponder and a local port. If the answer is no, the command is handled by another interface (not shown) at step S 103 . If the answer is yes, a signal is sent to switch A (for example switch 8 or 34 ) to move switch A to transmit position X (the selected position) at step S 104 , and at S 105 a signal is sent to switch B (for example switch 26 or 54 ) to move switch B to receive position X (the selected position). At step 106 the control signal at terminal 15 of controller 10 is sent to the peer OLT to set its switches A and B in a corresponding manner. A loop-back is then made to step S 101 to wait for the next command.
In the multiplexer/demultiplexer 6 of FIG. 1, 32 wavelengths on a single optical fiber received at line interface 4 are demultiplexed into 32 individual wavelengths λ 1 -λ 32 . However, according to another aspect of the invention the 32 wavelengths can be demultiplexed into bands, for example four bands of 8 wavelengths each, by a first multiplexer, and the resultant four bands can be processed by the OLT. According to another aspect of the invention at least one of the four bands of wavelengths can be demultiplexed by a second multiplexer/demultiplexer into its individual wave lengths such that the OLT can process the individual wavelengths of the at least one band and the remaining ones of the four bands.
FIG. 3 is a block diagram illustrating a modular OLT 200 having two stages of multiplexing/demultiplexing. The operation of the OLT 200 is described with respect to the demultiplexing operation; however, it is to be understood that the multiplexing is merely the reverse operation. It is to be noted that the 1×2 switches and 1×N switches shown in FIG. 1 are not included in FIG. 3 in order to simplify the drawing. However, it is to be understood that in practice such switches may be utilized in the practice of the invention. The OLT terminal 200 has an input/output line interface 202 which is connected to an external fiber facility and receives on a single optical fiber N, for example 32, wavelengths which are demultiplexed by a multiplexer/demultiplexer 204 , which is situated on a first modular card, into M, for example 4, bands of 8 wavelengths each. The first band 206 (λ 1 -λ 8 ) is demultiplexed into its 8 individual wavelengths by a multiplexer/demultiplexer 208 , which is situated on a second modular card, with each such wavelength being provided to a pass-through port (P) or a local port (L) via transponder (T). Each of the pass-through ports (P) is situated on a different modular card, and each of the transponder (T) and its associated local port (P) are situated together on yet another modular card. Although direct connections are shown, as discussed above the respective wavelengths may be selectively switched to either of a local port (L) via transponder (T), or a pass-through port (P) as described with respect to FIG. 1 .
The second band 210 (λ 9 -λ 16 ) is provided directly to a pass-through port (P), and the third band 212 (λ 17 -λ 24 ) is provided directly to a pass-through port (P).
The fourth band 214 (λ 25 -λ 32 ) is demultiplexed into its 8 individual wavelengths by a multiplexer/demultiplexer 216 , which is situated on a modular card 217 , with each such wavelength being provided to a pass-through port (P) or a local port (L) via a transponder (T). Again, switching may be used to select a connection to either P or T.
FIG. 4 is a simplified schematic diagram representative of the OLT 2 shown in FIG. 1 or the OLT 200 of FIG. 3 . However, it is to be noted that for simplicity only 16 wavelengths are utilized. The OLT 300 interfaces and operates in a bidirectional manner as discussed in detail with respect to FIGS. 1 and 3. The line interface 302 is adapted for wavelength division multiplexed (WDM) optical communication signals of the highest relative order, in this example 16 wavelengths λ 1 -λ 16 , corresponding to the N optical wavelengths on a single optical fiber which are applied to input/output line interfaces 4 and 202 of OLT 2 (FIG. 1) and OLT 200 (FIG. 3 ), respectively. The pass-through interface connected to the lines WL 1 - 4 , WL 5 - 8 , WL 9 - 12 and WL 13 - 16 corresponds to the respective pass-through ports, and the local-interface connected to the lines labeled 16 local ports correspond to the local ports connected to the respective transponders, where wavelengths from or to client equipment are added or dropped.
FIG. 5 illustrates two OLTs 300 A and 300 B as shown in FIG. 4 connected in a back-to-back relationship by way of their respective all-optical pass-through interfaces. Thus, it is seen that the connection results in an optical add/drop multiplexer (OADM) functionality without requiring intermediate electro-optical conversion (OEO) of the communicated optical signals. As discussed above, the add/drop feature is achieved at the 16 local ports of each OLT, where channels (wavelengths) can be added or dropped by a manual configuration, or via add/drop switching, as controlled by switches 8 and 26 of FIG. 1, to achieve a switchable add/drop multiplexer.
The pass-through may be accomplished using single conductors and/or ribbon connectors that pass multiple individual channels (wavelengths) in one cable. The pass-through connections between OLTS 300 A and 300 B is preferably made using ribbon connectors/cables.
FIG. 6 illustrates three separate in-service WDM point-to-point optical communication systems A, B and C which are not initially interconnected. WDM system A includes optical nodes 400 and 402 which are optically connected via their respective line interfaces, with at least optical node 402 being an OLT. WDM system B includes optical nodes 404 and 406 which are optically connected via their respective line interfaces, with at least optical node 404 being an OLT. WDM system C includes optical nodes 408 and 410 which are optically connected via their respective line interfaces, with at least optical node 408 being an OLT.
As discussed above, the three separate WDM systems are not initially interconnected. However, any two of the three WDM systems, or all three of the WDM systems, may be interconnected by connecting respective OLTs of the separate WDM system back-to-back at respective pass-through ports as shown in FIG. 5, without disrupting service. For example, WDM system A may be connected to WDM system B by directly optically connecting pass-through ports of the OLT of node 402 to pass-through ports of the OLT of node 404 via optical fibers 416 and 418 . WDM system A may also be connected to WDM system C by directly optically connecting pass-through optical ports of the OLT of node 402 to pass-through ports of the OLT of node 408 via optical fibers 420 and 422 . Thus, an all optical path is provided from optical node 400 of WDM system A to optical node 406 of WDM system B, and likewise an all optical path is provided from optical node 400 of WDM system A to optical node 410 of WDM system C, resulting in a merger of WDM systems A, B and C without disrupting service. At the back-side of the respective optical nodes, lines with a box are indicative of local ports (L) to which client equipment is normally connected.
FIG. 7 illustrates three separate in-service WDM network optical communication systems D, E and F which are not initially interconnected. WDM system D includes optical nodes 500 and 502 which are optically connected via their respective line interfaces through an optical network 503 , with at least optical node 502 being an OLT. WDM system E includes optical nodes 504 and 506 which are optically connected via their respective line interfaces through an optical network 507 , with at least optical node 504 being an OLT. WDM system F includes optical nodes 508 and 510 which are optically connected via their respective line interfaces through an optical network 511 , with at least optical node 508 being an OLT.
As discussed above, the three separate WDM optical networks are not initially interconnected. However, any two of the three WDM optical networks, or all three of the WDM optical networks may be interconnected by connecting respective OLTs of the separate WDM optical networks back-to-back at respective pass-through ports as shown in FIG. 5, without disrupting service. For example, WDM optical network D may be connected to WDM optical network E by directly optically connecting pass-through ports of the OLT of node 502 to pass-through ports of the OLT of node 504 via optical fibers 516 and 518 . WDM system D may also be connected to WDM optical network F by directly optically connecting pass-through optical ports of the OLT of node 502 to pass-through ports of the OLT of node 508 via optical fibers 520 and 522 . Thus, an all optical path is provided from optical node 500 of WDM optical network D to optical node 506 of WDM optical network E, and likewise an all optical path is provided from optical node 500 of WDM optical network D to optical node 510 of WDM optical network F, resulting in a merger of WDM network optical communication systems D, E and F without disrupting service. At the back-side of the respective optical nodes, lines with a box are indicative of local ports (L) to which client equipment is normally connected.
FIG. 8 illustrates how OLTs can be connected in more complex ways to achieve greater functionality, such as, for example, limited cross-connection capabilities. Specifically, OLT 600 and OLT 602 are connected back-to-back to form a first OADM, OLT 604 and OLT 606 are connected back-to-back to form a second OADM, OLT 600 and OLT 606 are connected back-to-back to form a third OADM and OLT 602 and OLT 604 are connected back-to-back to form a fourth OADM. OLT 600 , OLT 602 and OLT 604 each have add/drop switching capability, whereas OLT 606 has no switching capability.
The arrangement shown in FIG. 8 illustrates how a group of OLTs in an office, which may be part of separate WDM networks, can be coupled to form different OADMs on an individual channel or per band basis. Wavelengths 1 , 2 , 3 and 4 (channels 1 , 2 , 3 and 4 ) are connected between pass-through optical ports of OLT 600 and OLT 602 via optical fiber 603 and are also connected between pass-through optical ports of OLT 604 and OLT 606 via optical fiber 607 . Wavelengths 5 , 6 , 7 and 8 (channels 5 , 6 , 7 and 8 ) are connected between pass-through optical ports of OLT 600 and OLT 606 via optical fiber 608 and are also connected between pass-through optical ports of OLT 602 and OLT 604 via optical fiber 609 . Wavelengths 9 , 10 , 11 and 12 (channels 9 , 10 , 11 and 12 ) can be separated into individual channels that are connected between local ports of the respective OLTs. For example, channel 9 is directly connected between a local port of OLT 600 and a local port of OLT 602 via optical fiber 610 , and channel 10 is directly connected between a local port of OLT 600 and a local port of OLT 606 via optical fiber 612 . To simplifiy the drawing, no connections are shown for wavelengths 11 and 12 ; however, they may be connected in a like manner. The local ports may also be connected to client equipment as discussed above. It is to be noted that the connection configuration of FIG. 8 does not constitute a plain patch-panel form of connectivity, insofar as it allows for switching of channels without manual reconfigurations.
In summary, the methods and apparatus of the present invention allow upgrading of a wavelength division multiplexed optical communication system including a pair of OLTs that reside in the same office or facility and are part of separate WDM networks (whether point-to-point links or more advanced networks) to form an OADM. Such upgrade is accomplished without service disruption to the network by appropriate connection of the OLTs through the pass-through interfaces.
Although certain embodiments of the invention have been described and illustrated herein, it will be readily apparent to those of ordinary skill in the art that a number of modifications and substitutions can be made to the preferred example methods and apparatus disclosed and described herein without departing from the true spirit and scope of the invention.
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A wavelength division multiplexed optical communication system includes a plurality of optical line terminals which may be part of separate in service networks, each having a line interface and an all-optical pass-through interface including a plurality of pass-through optical ports, and each also including a plurality of local optical ports which are connectable to client equipment and an optical multiplexer/demultiplexer for multiplexing/demultiplexing optical wavelengths. The optical multiplexer/demultiplexer may include one or more stages for inputting/outputting individual wavelengths or bands of a predetermined number of wavelengths, or a combination of bands and individual wavelengths. At least one of the pass-through optical ports of an optical line terminal of one network may be connected to at least one of the pass-through optical ports of an optical line terminal of another network to form an optical path from the line interface of the optical line terminal of the one network to the line interface of the optical line terminal of the another network to form a merged network. The use of such optical line terminals allows the upgrading and merging of the separate networks while in service.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims priority to U.S. Provisional Patent Application No. 60/304,058 filed on Jul. 9, 2001.
BACKGROUND OF INVENTION
1. Field of the Invention
This invention relates to polycrystalline diamond compacts (PDC) used primarily in the oil and gas industry for drilling. More specifically, this invention relates to polycrystalline diamond cutters that utilize a substrate interface design that comprises a network of closed features that extend from the face of the substrate into the superabrasive layer.
2. Description of Related Art
Polycrystalline diamond compacts (PDC) often form the cutting structure of down hole tools, including drill bits (fixed cutter, roller cone and percussion bits), reamers and stabilizers in the oil and gas industry. A variety of PDC devices, specifically substrate interface designs have been described and are well known in the art. Generally, these devices do not have interface designs that include a network of closed shaped features that share common walls.
A polycrystalline diamond compact (PDC) can be manufactured by a number of methods that are well known in the art. The typical process consists of essentially placing a substrate adjacent to a layer of diamond crystals in a refractory metal can. A back can is then positioned over the substrate and is sealed to form a can assembly. The can assembly is then placed into a cell made of an extrudible material such as pyrophyllite or talc. The cell is then subjected to conditions necessary for diamond-to-diamond bonding or sintering in a high pressure/high temperature press. This detail is provided to familiarize the reader with the PDC sintering technology. For more information regarding the manufacture of PDC cutters the reader is referred to U.S. Pat. No. 3,745,623, which is hereby incorporated by reference in its entirety for the material contained therein.
There are a variety of U.S. patent documents that are helpful in providing a reader with general background information regarding PDC cutter design and manufacture. The reader is referred to the following U.S. patent documents, each of which is hereby incorporated by reference in its entirety for the material contained therein: U.S. Pat. Nos. 4,527,998, 4,539,018, 4,772,294, 4,941,891, 5,370,717, 5,384,470, 5,469,927, 5,560,754, 5,711,702, 5,871,060, 5,848,348, 5,890,552, 6,011,248, 6,063,333, 6,068,071, and 6,189,634.
SUMMARY OF INVENTION
Polycrystalline diamond compacts (PDC) are frequently used as the cutting structure on drill bits used to bore through geological formations. It is not unusual for PDC cutters to be subjected to loads down hole that exceed the working mechanical strength of the PDC (also referred to herein as the “insert”) and failures can occur. A most common type of failure is delamination and spallation of the diamond table. This type of failure is typically due to excessive stress loading caused by tool vibration and/or drilling inter-bedded hard formations. Residual stresses in the PDC can also drastically reduce the working load of a PDC, which in turn limits the magnitude of loads that can be applied before failure. Typically, the most harmful residual stresses are located on the outer diameter of the cutter just above the interface to the diamond table. These particular stresses encourage cracks to propagate parallel to the interface and are believed to be the source of most delamination failures. It is desirable to minimize all harmful residual tensile stresses and to maximize the compressive stresses in the diamond table.
The geometry of the substrate or interface design can significantly affect the performance of a PDC insert. Through different interface shapes and sizes the residual stresses of a PDC can be controlled. Residual stresses are inherently part of nearly all PDC products and tend to increase with increasing diamond thickness. These stresses arise from the difference in thermal expansion between the diamond layer and the substrate after sintering at extremely high pressures and temperatures. These stresses can be detrimental to the cutter, leading to delamination of the diamond and premature failure. This inherent property of PDC can be beneficial if the stresses are managed properly. Through interface design, residual compressive stresses can be created in the diamond table to increase toughness and diamond attachment strength. With an ever-increasing trend toward thick diamond PDC, it is now more critical than ever to design substrate interfaces that manage residual stresses to minimize premature failure tendencies.
This invention, in its present embodiment, significantly reduces residual tensile stresses on the outer diameter of the cutter, thereby significantly reducing tensile stresses on the outer diameter of the cutter, and therefore, significantly reducing the tendency to delaminate. The present embodiments of the invention have a tungsten carbide substrate that includes multiple closed features that define cavities and protrude into the diamond table. The closed features of one present embodiment illustrated herein share common walls and resemble a honeycomb geometry. This illustrated embodiment having interconnected closed features in its interface works to manipulate the residual stresses to provide the diamond table with reinforcing compressive stresses, while minimizing harmful outer diameter tensile stresses. This invention has many potential embodiments. Each of these embodiments may incorporate one or more of the following objects, however, because of the envisioned many possible embodiments, it is not anticipated that all embodiments will incorporate all of the following objects. Therefore, the limitations of this invention are to be found in the claims and should not include the following or any other potential objects.
Therefore, it is an object of this invention to provide a PDC with an enhanced residual stress distribution.
It is a further object of this invention to provide a PDC with an interface geometry that has a network of protrusions that are closed in form and that defines cavities and that share common walls that favorably manipulates the residual stresses.
It is a further object of this invention to provide a PDC that increases the strength and working life of a thick diamond table despite the corresponding increase in external diamond tensile stresses.
It is a further object of this invention to provide a PDC that has increased resistance to delamination by providing a mechanical locking device that includes an interface of non-planar networked closed features.
It is a further object of this invention to provide a PDC that has increased diamond attachment strength provided by an interface that has in increased surface area for bonding.
It is a further object of this invention to provide a PDC that exposes multiple diamond surfaces and new cutting edges, as wear progresses, to maintain a sharp cutting action.
It is a further object of this invention to provide a PDC with increased toughness by varying the height of the features across the interface to maintain constant or optimum substrate to diamond volumes.
Additional objects, advantages and other novel features of this invention will be set forth in part in the description that follows and in part will be come apparent to those skilled in the art upon examination of the following description or may be learned with the practice of the invention. Still other objects of the present invention will be come readily apparent to those skilled in the art from the following description wherein there is shown and described several preferred embodiments of this invention, simply by way of illustration of several of the various modes of the invention. As it will be realized, this invention is capable of other different embodiments and its several details and specific features are capable of modification in various aspects without departing from the invention. Accordingly, the objects, drawings and descriptions should be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings, incorporated in and forming a part of the specification, illustrate present preferred embodiments of the present invention. Some, although not all, alternative embodiments are described in the following description. In the drawings:
FIG. 1 depicts a first present interface pattern of a closed network of features, which are hexagonal protrusions with common walls that encompass a hexagonal cavity that resembles a honeycomb.
FIGS. 2 , 3 and 4 depict alternative interface patterns that include various geometric shaped protrusions with common walls defining cavities within.
FIG. 5 depicts a top view of a substrate with a network of closed square features. The interface design of this embodiment also includes a peripheral recessed ring.
FIGS. 6 , 7 , 8 , 9 , 10 and 11 depict alternative cross-sectional views of various PDC designs with closed network features that either protrude from or recess into the face of the substrate.
FIG. 12 depicts an embodiment of the invention with a large wear flat that exposes a number of diamond surfaces and cutting edges.
FIGS. 13 and 14 depict alternative embodiments of the substrate interface design. These designs include hexagonal protrusions that extend out from the face of the substrate and define a peripheral ring. Internal cavity depths decrease as they approach the center of the substrate. The protrusions define a surface that can be flat, concave or convex.
FIG. 15 depicts a present embodiment of the substrate interface design. This design includes hexagonal protrusions that extend out from the face of the substrate and define a peripheral ring. The internal depths decrease as they approach the center of the substrate. The protrusions of this embodiment define a surface that is flat.
Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings.
DETAILED DESCRIPTION
This invention is intended primarily for use as the cutting structure on earth boring devices used in oil and gas exploration, drilling, mining, excavating and the like. The mechanical and thermal properties of polycrystalline diamond make it an ideal material for cutting tools. However, like most hard materials, diamond is brittle and relatively weak under tensile loading. This is why it is so beneficial to make PDC designs that can manage the residual stresses associated with the large thermal expansion mismatch between the diamond layer and the substrate. Designs that minimize tensile stresses and maximize the compressive stresses in diamond are particularly desirable. The presence or absence of either of these residual stresses is a major determinant for significantly improving or weakening the working strength of the PDC. This invention by providing the benefits of increased attachment strength and a plurality of cutting edges is advantageous because it manipulates the residual stresses to a favorable condition to appreciably increase the working life of the cutter.
FIG. 1 shows the present preferred interface pattern 100 of the closed network of features, which in this embodiment are hexagonal protrusions 103 a–e with common walls 102 a–e that encompass hexagonal cavities 101 a–e that together resembles a honeycomb. The cavities 101 a–e are provided to receive the diamond table to provide a transition from the substrate to the diamond table to soften the stress gradient across the interface. It has been determined that along with residual stresses, the diamond-carbide interface attachment strength is directly related to the dynamic toughness of the PDC. The network of closed features provided by the interface pattern 100 increases the attachment strength of the diamond and thereby increases the toughness of the PDC. These closed features form cavities 101 a–e to act as mechanical locks to increase the attachment strength of the diamond table to the substrate. Due to the difference in thermal expansion between the substrate and the diamond layer, the substrate will typically contract more than the diamond layer. This causes the closed network of features of the interface pattern 100 to clamp down or pinch the enclosed diamond forming a mechanical lock that increases the attachment strength between the diamond layer and the substrate. This network of closed features of the interface pattern 100 also provides a substantial increase in surface area compared to more traditional planar interface designs. With increased surface area more chemical bonds are formed between the substrate and the diamond layer also increasing the attachment strength.
The thickness of walls 102 a–e of the protrusions can vary depending on the desired stress state. In some embodiments, the wall 102 a–e thickness can be uniform throughout the pattern 100 , or can vary across the pattern 100 depending on the desired stresses. The wall 102 a–e thickness of the present embodiment is between 0.015″ and 0.030″ and is uniform throughout the network 100 .
FIGS. 2 , 3 and 4 show a variety of alternative protrusion shapes that can be used in alternative networks of closed features 200 , 300 , 400 .
FIG. 2 shows a first alternative interface pattern 200 that includes a series of square protrusions 203 a–f with common walls 202 a–f defining square cavities 201 a–f within.
FIG. 3 shows a second alternative interface pattern 300 that includes triangular protrusions 303 a–f with common walls 302 a–f defining triangular cavities 301 a–f within.
FIG. 4 shows a third alternative interface pattern 400 that includes both diamond shaped protrusions 403 a–e and triangular protrusions 406 a–d that share common walls 402 a–e , 405 a–d and that define diamond shaped cavities 401 a–e and triangular cavities 404 a–d within.
Each of these FIGS. 1–4 are provided to show examples of different geometries. Naturally, a wide variety different geometries are envisioned and can be substituted without departing from the concept of this invention. Such other geometries include, but are not necessarily limited to other polygon shapes, circles, conics, ovals, abstract shapes or combinations thereof.
FIG. 5 shows a top view 500 of a substrate 501 with a network of closed square features 502 . The interface design 503 includes a circular portion 504 and peripheral ring 505 that can be varied in width and depth depending on desired stress conditions. The network of closed features 502 can include more than a circular portion 504 and may include polygons, conics, ovals, abstract shapes and combinations thereof.
FIG. 6 shows a cross-sectional view 600 of a PDC with a constant depth closed network design 601 that protrudes from the face 602 of the substrate 603 . Protrusions 604 define a peripheral ring 605 of thick diamond 606 . The diamond 606 fills the cavities 607 to provide a transition between the diamond 606 and the substrate 603 to soften the stress gradient across the interface 608 and to increase the attachment strength between the diamond 606 and the substrate 603 . The closed features of the network design 601 are represented to include a draft angled wall 609 for manufacturing ease but are not limited to obtuse angled walls 609 and can include vertical and acute angled walls relative to the substrate center axis 610 . The polycrystalline diamond 606 region is bonded to the substrate 603 typically through a high temperature/high pressure sintering process, although in alternative embodiments bonding can be accomplished by brazing or by chemical vapor deposition or the like. Also, alternatively cubic boron nitride (CBN) or other superabrasive materials can be substituted for the polycrystalline diamond 606 without departing from the concept of this invention. The preferred substrate 603 material is made of tungsten carbide, although in alternative embodiments, such materials as titanium carbide, tantalum carbide, vanadium carbide, niobium carbide, hafnium carbide, zirconium carbide, or alloys thereof can be used in the substrate 603 .
FIG. 7 shows a cross-sectional view 700 of a first alternative PDC design with a variable depth closed network design 701 that protrudes from the face 702 of the substrate 703 . Protrusions 704 extend generally across the face 702 of the substrate 703 . The diamond 706 fills the cavities 707 to provide a transition between the diamond 706 and the substrate 703 to soften the stress gradient across the interface 708 and to increase the attachment strength between the diamond 706 and the substrate 703 . The closed features of the network design 701 are represented to include a draft angled wall 709 for manufacturing ease but are not limited to obtuse angled walls 709 and can include vertical and acute angled walls relative to the substrate center axis 710 . The polycrystalline diamond 706 region is bonded to the substrate 703 typically through a high temperature/high pressure sintering process, although in alternative embodiments bonding can be accomplished by brazing or by chemical vapor deposition or the like. Also, alternatively cubic boron nitride (CBN) or other superabrasive materials can be substituted for the polycrystalline diamond 706 without departing from the concept of this invention. The preferred substrate 703 material is made of tungsten carbide, although in alternative embodiments, such materials as titanium carbide, tantalum carbide, vanadium carbide, niobium carbide, hafnium carbide, zirconium carbide, or alloys thereof can be used in the substrate 703 .
FIG. 8 shows a cross-sectional view 800 of a second alternative PDC design with an alternative variable depth closed network design 801 that recesses into the face 802 of the substrate 803 . The recesses 804 extend generally across the face 802 of the substrate 803 and in this embodiment the depth of the recesses 804 decrease at they 804 approach the center axis 810 of the substrate 803 . The diamond 806 fills the recesses 804 to provide a transition between the diamond 806 and the substrate 803 to soften the stress gradient across the interface 808 and to increase the attachment strength between the diamond 806 and the substrate 803 . Although in this shown embodiment 800 , the recess 804 bottom geometry is depicted as constant throughout the network 801 while the recess 804 opening size increases with depth, in alternative embodiments straight walled recesses 804 can be substituted so that both the recess 804 bottom and opening can remain constant. The closed features of the network design 801 are represented to include a draft angled wall 809 for manufacturing ease but are not limited to obtuse angled walls 809 and can include vertical and acute angled walls relative to the substrate center axis 810 . The polycrystalline diamond 806 region is bonded to the substrate 803 typically through a high temperature/high pressure sintering process, although in alternative embodiments bonding can be accomplished by brazing or by chemical vapor deposition or the like. Also, alternatively cubic boron nitride (CBN) or other superabrasive materials can be substituted for the polycrystalline diamond 806 without departing from the concept of this invention. The preferred substrate 803 material is made of tungsten carbide, although in alternative embodiments, such materials as titanium carbide, tantalum carbide, vanadium carbide, niobium carbide, hafnium carbide, zirconium carbide, or alloys thereof can be used in the substrate 803 .
FIG. 9 shows a cross-sectional view 900 of a third alternative PDC with an alternative variable depth closed network design 901 that protrudes from the face 902 of the substrate 903 . Protrusions 904 define a peripheral ring 905 of thick diamond 906 . The diamond 906 fills the cavities 907 to provide a transition between the diamond 906 and the substrate 903 to soften the stress gradient across the interface 908 and to increase the attachment strength between the diamond 906 and the substrate 903 . The closed features of the network design 901 are represented to have a top surface 911 that is generally concave and the protrusions include a draft angled walls 909 for manufacturing ease but are not limited to obtuse angled walls 909 and can include vertical and acute angled walls relative to the substrate center axis 910 . Alternatively, it is envisioned that the top surface 911 can be flat, convex or combinations thereof. The polycrystalline diamond 906 region is bonded to the substrate 903 typically through a high temperature/high pressure sintering process, although in alternative embodiments bonding can be accomplished by brazing or by chemical vapor deposition or the like. Also, alternatively cubic boron nitride (CBN) or other superabrasive materials can be substituted for the polycrystalline diamond 906 without departing from the concept of this invention. The preferred substrate 903 material is made of tungsten carbide, although in alternative embodiments, such materials as titanium carbide, tantalum carbide, vanadium carbide, niobium carbide, hafnium carbide, zirconium carbide, or alloys thereof can be used in the substrate 903 .
FIG. 10 shows a cross-sectional view 1000 of a fourth alternative PDC with a variable depth closed network design 1001 that recesses 1004 into the face 1002 of the substrate 1003 . The recesses 1004 define a peripheral ring 1005 of thick diamond 1006 . The diamond 1006 also fills the recesses 1007 to provide a transition between the diamond 1006 and the substrate 1003 to soften the stress gradient across the interface 1008 and to increase the attachment strength between the diamond 1006 and the substrate 1003 . The closed features of the network design 1001 are represented to include a draft angled wall 1009 for manufacturing ease but are not limited to obtuse angled walls 1009 and can include vertical and acute angled walls relative to the substrate center axis 1010 . The polycrystalline diamond 1006 region is bonded to the substrate 1003 typically through a high temperature/high pressure sintering process, although in alternative embodiments bonding can be accomplished by brazing or by chemical vapor deposition or the like. Also, alternatively cubic boron nitride (CBN) or other superabrasive materials can be substituted for the polycrystalline diamond 1006 without departing from the concept of this invention. The preferred substrate 1003 material is made of tungsten carbide, although in alternative embodiments, such materials as titanium carbide, tantalum carbide, vanadium carbide, niobium carbide, hafnium carbide, zirconium carbide, or alloys thereof can be used in the substrate 1003 .
FIG. 11 shows a cross-sectional view 1100 of a fifth alternative PDC with a variable depth closed network design 1101 that protrudes from the face 1102 of the substrate 1103 . Protrusions 1104 define a peripheral ring 1105 of thick diamond 1106 . The diamond 1106 fills the cavities 1107 to provide a transition between the diamond 1106 and the substrate 1103 to soften the stress gradient across the interface 1108 and to increase the attachment strength between the diamond 1106 and the substrate 1103 . The closed features of the network design 1101 are represented to include a draft angled wall 1109 for manufacturing ease but are not limited to obtuse angled walls 1109 and can include vertical and acute angled walls relative to the substrate center axis 1110 . The polycrystalline diamond 1106 region is bonded to the substrate 1103 typically through a high temperature/high pressure sintering process, although in alternative embodiments bonding can be accomplished by brazing or by chemical vapor deposition or the like. Also, alternatively cubic boron nitride (CBN) or other superabrasive materials can be substituted for the polycrystalline diamond 1106 without departing from the concept of this invention. The preferred substrate 1103 material is made of tungsten carbide, although in alternative embodiments, such materials as titanium carbide, tantalum carbide, vanadium carbide, niobium carbide, hafnium carbide, zirconium carbide, or alloys thereof can be used in the substrate 1103 .
FIG. 12 shows an embodiment of this invention 1200 with a large wear flat 1201 in both the diamond layer 1205 and the substrate 1201 that has exposed a plurality of diamond surfaces 1202 and cutting edges 1203 . This FIG. 12 is representative of a typical extended wear flat that can be seen on typical used PDC inserts. Generally, as extended wear flats 1201 are produced the drilling efficiency of a PDC insert drops dramatically. Instead of a sharp edge to bite and shear the formation, an extended wear flat acts as a bearing surface that will not engage the formation to be cut unless increased force is applied to the drilling assembly. Maintaining a sharp cutter or edge is preferred for efficient drilling. With this embodiment of the invention, as wear progresses into the network cavities, new diamond surfaces 1202 and cutting edges 1203 are exposed, further enhancing drilling efficiency.
FIGS. 13 and 14 depict alternative embodiments 1300 , 1400 of the substrate interface design 1301 , 1401 . As can be seen, these design 1301 , 1401 also have hexagonal protrusions 1302 , 1402 that extend out from the face 1303 , 1403 of the substrate 1304 , 1404 and define a peripheral ring 1305 , 1405 . The internal cavity 1306 , 1406 depths decrease as they approach the center 1307 , 1407 of the substrate 1304 , 1404 . The protrusions 1302 in FIG. 13 provide a generally concave interface surface 1308 , while the protrusions 1402 in FIG. 14 provide a generally convex interface surface 1408 . In alternative embodiments, the interface surface could be flat or a combination of flat, concave and convex.
FIGS. 15 a, b, c, d, e and f show several views of the present substrate interface design of this invention. Hexagonal protrusions 1501 extend out from the face 1502 of the substrate 1507 and define a peripheral ring 1503 . The protrusions 1501 define a surface 1513 that is flat. The internal cavity 1504 depths decrease as they approach the center 1505 of the substrate 1507 . The cavity's 1504 bottom hole shape 1506 follows the profile 1509 of a dome that protrudes from the surface 1508 of the substrate 1507 . This domed profile 1509 allows the diamond volume to gradually increase as it moves toward the perimeter 1510 of the PDC 1500 . The closed features of the hexagonal protrusions 1501 include a draft angle 1511 for conventional powdered metallurgy pressing techniques. Polycrystalline diamond 1512 is bonded to the substrate 1507 typically through a high temperature/high pressure sintering process. Polycrystalline diamond, although the preferred material for the superhard surface, may alternatively be substituted with cubic boron nitride (CBN) or any other appropriate superhard material. The preferred substrate 1507 is composed of tungsten carbide, although alterative materials such as titanium carbide, tantalum carbide, vanadium carbide, niobium carbide, hafnium carbide, zirconium carbide, or alloys thereof can be substituted without departing from the concept of this invention.
The described preferred and alternative embodiments of this disclosure are to be considered in all respects only as illustrative of the current best modes of the invention known to the inventors and not as restrictive. Alternative embodiments of the invention, including a combination of one or more of the features of the foregoing PDC devices should be considered within the scope of this invention. The appended claims define the scope of this invention. All processes and devices that come within the meaning and range of equivalency of the claims are to be considered as being within the scope of this patent.
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A superhard compact having an improved superabrasive-substrate interface region design for use in drilling bits, cutting tools and wire dies and the like. This compact is designed to provide an interface design to manipulate residual stresses to enhance the working the strength of the compact. The compact is provided with a network on interface features that share common walls to form cavities.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a suction recovery apparatus for an ink jet recording apparatus, and in particular to a suction recovery apparatus for easily and reliably recovering from unsatisfactory ink discharge, for example, unsatisfactory discharge during interchange of the main tank.
2. Description of the Prior Art
An ink jet recording apparatus has the possibility of giving rise to ink leakage from the nozzle during the transportation or long-time non-use thereof and therefore, the nozzle must be capped. Also, in an ink jet recording apparatus, ink may sometimes fail to be discharged due to impact forces or paper powder and at such time, it is necessary to provide suction through the end of the nozzle.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a suction recovery apparatus for an ink jet printer which is easy to operate for suction recovery.
It is another object of the present invention to enable the suction recovery operation to be accomplished by one touch.
It is still another object of the present invention to enable the suction recovery operation to be accomplished by a light operating force.
Other objects of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of the present invention.
FIG. 2 is a side view of the embodiment.
FIG. 3 illustrates a lever for constituting another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2 which show an embodiment of the present invention, the forward end of a cap holder 1 has integrally attached thereto an elastic cap 1B for hermetically sealing a nozzle (not shown) located at one end of an ink jet recording head 2. The recording head 2 is movable along guides 3 in the direction of arrow A. A head guide 1c is also integrally attached to the forward end of the cap holder 1 and, when the holder 1 moves in the direction of arrow B, the sloping surfaces on the opposite sides of the head guide the head 2 so that the nozzle is accurately hermetically sealed by the elastic cap 1B. The cap holder 1 is held on a bed 4 so as to be slidable only in directions perpendicular to the guides 3, i.e., the direction B and counter-B direction. A pin 1A is projectedly provided on a side of the cap holder 1 and is engaged by a cam slot 7 in a lever 5. This engagement relation may be reversed, that is, a slot may be formed in the holder and a pin may be provided on the lever. The lever 5 is rotatably supported on the support shaft 6 of the strut 4A of the bed 4. The cap holder 1 is movable in the direction B or the counter-B direction by pivotal movement of the lever 5 on the basis of the engagement between the pin 1A and the cam slot 7. Designated by 8 is a coil spring held between the rear wall 4B of the bed 4 and the rearward end of the cap holder 1 so that the pin 1A is normally in contact with the inner surface of the cam slot to prevent backlash of the bed and the cap holder. Denoted by 9 is a piston type negative pressure suction device which is manually operated negative pressure generating means and which is fixed to the bed 4. The suction device 9 generates a negative pressure by the piston lever 10 thereof being depressed by a lever pressing portion 5A projectedly provided on the underside of the lever 5. An ink sucking tube 11 is connected between the suction device 9 and the elastic cap 1B and sucks ink and air from the nozzle of the recording head 2 with the aid of the negative pressure generated by the suction device 9, thereby releasing the unsatisfactory discharge of the nozzle. Designated by 5B is the operating portion of the lever.
Referring to FIG. 2, a grooved pulley 12 radially formed with grooves 12A is integrally attached to the lever 5 so that pivoal movement of the lever 5 may be effected in a click-like fashion. A resilient pawl 4C fixed to the bed 4 is resiliently fitted in a groove 12A of the grooved pulley 12 to pivot the lever 5 in a click-like fashion and stop the lever 5 in its pivoted position.
Operation of the suction recovery apparatus of the above-described construction will now be described. When the lever 5 is first pivoted in the direction of arrow C about the shaft 6, the pin 1A integral with the holder 1 is guided by the slot cam 7 of the lever and advances in the direction of arrow B, i.e., toward the head 2. In this manner, the elastic cap 1B is firmly urged against the nozzle of the head 2 by the spring 8 and the nozzle portion is hermetically sealed by the elastic cap 1B. In this state, when the lever operating portion 5B is further depressed in the direction of arrow C, the piston 10 is depressed and the interior of the suction device 9 assumes a negative pressure, so that ink, bubbles, etc. are discharged from the nozzle through the tube 11 connected to the elastic cap 1B and dust or the like near the nozzle is sucked and removed, whereby discharge is recovered. During this suction recovery operation, the pin 1A engages a slot cam portion 7A of the same radius and therefore, the holder 1 does not move back and forth and the nozzle is maintained hermetically sealed. The piston 10 is depressed to a position indicated by a dotted line and then liberated, whereupon it is returned to the position indicated by solid line by a return spring (not shown) within the apparatus. By the return force of this spring, the lever 5 is also returned to its position of FIG. 2. After the interior of the tube assumes the atmospheric pressure in a short time, the lever operating portion 5B is rotated in the counter-C direction, whereupon the lever pressing portion 5A becomes disengaged from the piston and the hermetic sealing of the nozzle is released, whereafter the pin 1A of the holder comes into engagement with the slot cam lock portion 7B. This state is shown in FIG. 1, wherein the shaft 6, the pin 1A of the holder and the slot cam lock portion 7B are on a horizontal line, whereby the advancing force of the holder 1 toward the head by the spring 8 is blocked. With the cap opened, the recording head 2 moves and effects printing. This series of lever operations are effected in the position of FIG. 1 wherein a side surface of the recording head is controlled by a damper 14 provided on a side plate 13, after unsatisfactory discharge of the ink jet recording apparatus has been confirmed. Since the lever operating portion 5B is more distant from the shaft 6 than the pressing portion 5A, the force required for operation may be lower and the suction recovery operation can be accomplished by a light force.
FIG. 3 shows a lever 15 for constituting another embodiment of the present invention. In FIG. 3, a gear 16 meshing with the pinion gear of a motor which is a rotative drive source is integrally secured to a pivot shaft 15B held by the strut 4A. The gear 16 of the lever 15 meshes with a negative pressure generating gear and generates a negative pressure upon rotation of the lever 15, and such negative pressure sucks the end of the nozzle. If the angle of rotation of the slot cam 7 is selected to a great value, the reduction ratio of the gear can also be selected to a great value and the motor load can be decreased.
According to the present invention, as has been described above, the negative pressure for the hermetic sealing of the nozzle and the suction of ink can be generated simply by operating a single lever once and thus, a suction recovery apparatus which requires a low operating force and which is easy to operate can be provided. Also, if a gear is provided on a portion of a single lever, automation of the ink jet negative pressure suction device by motor control will become possible.
What I claim is:
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A suction recovery apparatus comprises a capping unit for hermetically sealing the end of a recording head for discharging ink, a unit for mounting the capping unit movement toward the recording head, a negative pressure generating unit for generating a negative pressure, and a lever rotatable about an axis for moving the capping unit toward the recording head by rotation in one direction to hermetically seal the end of the head and causing the negative pressure generating unit to generate a negative pressure which sucks the end of the recording head.
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This application is a Continuation of Application Ser. No. 07/933,432, Aug. 8, 1992, now abandoned.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to highly sensitive positive photoresist compositions which are mixtures of certain partially substituted polymeric materials and cationic photoinitiators. In particular, there are provided photoresist compositions with greatly improved sensitivity without deterioration of their processability. These compositions which may be conveniently developed with alkaline developers display increased sensitivity to ultraviolet (UV), electron beam (E-beam) and X-ray radiation, are thermally stable at temperatures up to about 165° C., adhere readily to silicon dioxide and silicon nitride layers on a substrate, and may be treated with organometallic reagents (e.g., silylating agents) without the necessity of any post development baking. The films formed may be processed with very little image shrinkage on exposure and development and provide essentially crack-free resist layers. The partially substituted polymeric materials comprise recurrent structures having alkaline soluble groups pendent to the polymeric backbone, a portion of which groups have been substituted with (protected by) acid labile groups.
2. Background of the Invention
The fabrication of semiconductor devices requires the use of resist compositions which maintain imaged patterns during a processing. As the need to increase semiconductor circuit density has dictated a movement from very large scale integration (VLSI) devices to ultra-large scale integration (ULSI) devices, the demands for submicron photolithography with sensitivity to produce and maintain ultra-fine tolerances become more critical.
Chemically amplified resist systems having a polymer and sensitizer combination which generate an initial acid from the sensitizer and additional acid from the polymer provide increased sensitivity to UV, e-beam and x-ray radiation.
In Ito et al., U.S. Pat. No. 4,491,628, resists sensitive to ultraviolet (UV), electron beam and X-ray radiation capable of forming either positive or negative tone patterns dependent upon the choice of developers were disclosed. Such resist compositions are formulated from a polymer having recurrent acid labile groups (such as tertbutyl esters and tertbutyl carbonates) which undergo efficient acidolysis to effect a change in polarity (solubility) and a photo-initiator which generates acid upon radiolysis. The polymer may be a copolymer which includes polymers having recurrent acid labile groups. When being used to form positive images the Ito materials have possibility drawbacks that are directly related to the completeness of removal of the acid labile group on the film composition. These factors relate to skin formation, shrinkage, cracking and poor adhesion which require delicate control to overcome.
In Ito et al., U.S. Pat. No. 4,552,833, there is provided a process for generating negative images wherein a film of a polymer having masked functionalities is coated onto a substrate, the film is imagewise exposed, the exposed film is treated with an organometallic reagent, and the treated film is developed with an oxygen plasma. That disclosure contemplates the dry development of polymers similar to those disclosed in U.S. Pat. No. 4,491,628. The dry development process avoids changes in film compositions that lead to processing complications
In Chiong et al., U.S. Pat. No. 4,613,398, still other processes are disclosed entailing the removal of acid labile protecting groups from pendent alkaline soluble groups on a resist polymer such as hydroxyl, amine, carboxyl, phenol, or imide NH which are capable of reacting with the organometallic reagent. Upon silylation and further processing negative images are obtained.
In U.S. Ser. No. 922,657, filed Oct. 24, 1986 now abandoned and assigned to the assignee of the present application, there are described certain highly sensitive resists that achieve high autodecomposition temperatures due to the presence of secondary carbonium ion forming acid labile substituent groups on polymers having pendent carbonate or carbonate-like groups.
Ito, J. Polymer Science Part A, 24, 2971-80 (1986) discloses effects of p-hydroxystvrene groups in the thermolysis of poly(p-t-butyloxycarbonyloxy styrene) and devises a method to make such substituted polymer via a copolymerization of butyloxycarbonyloxy styrene with formyloxy styrene followed by photo-fries decomposition to convert the formyloxystyrene units to hydroxystyrene units.
SUMMARY OF THE INVENTION
In accordance with the present invention, highly sensitive positive photoresist compositions are made by combining a polymeric material having functional groups pendent thereto which contribute to the solubility of the polymer in alkaline developers, a portion of which functional groups are substituted with masking or protecting acid labile groups which inhibit the solubility of the polymer, and a photo-initiator compound which generates a strong acid upon radiolysis which is able to cleave or remove the acid labile groups from the polymer to unmask or deprotect functional sites. From 15 to 40 percent of the pendent functional groups are masked or protected with acid labile groups. The preferred protecting groups will also generate acid when they are cleaved or removed and cause additional cleavage or removal of masking as protecting groups, furthering the formation of a latent image. The most preferred protecting group-functional group structure is tert-butyl carbonate of a phenol. On acid generated decomposition, it is believed that the mechanism includes formation of a phenoxycarbonyloxy ion and a tertiary carbonium ion which further decompose to provide phenol, carbon dioxide, isobutene and proton (H+) fragments, the latter being available for further deprotecting of the polymer. Other protecting croups which generate a proton such as the secondary alkyl substituted moieties as disclosed in U.S. Ser. No. 922,657, the disclosure of which is hereby incorporated by reference into this application, may also be used, however, such groups are generally more tightly bound to the groups on the polymeric material functional groups and do not provide as much sensitivity as do the tertbutyl carbonates of phenols.
It has been surprisingly found that a polymer having from 15 to 40 percent substitution with acid labile protecting groups exhibits far more sensitivity than a polymer which is essentially fully protected. This is especially surprising since the fully unprotected polymer provides verb limited resolution and image discrimination to a positive tone.
Polymer backbones having pendent aromatic groups provide the thermal and dimensional stability which are desired in order to provide a material which may be applied to a substrate in a uniformly thin coating, which may be baked to remove solvent and which after imaging and patterning provides chemical resistance in subsequent process steps.
The preferred polymer backbone is polystyrene having substituent functional groups on the aromatic ring to impart aqueous alkaline solubility to the polymer. These groups not only must provide solubility, but they must be maskable with a blocking or protective group that is acid removable in response to the radiolysis of the acid generating sensitizer. The functional groups ideally should be one which does not adversely interact with the semiconductor processing environment. For that reason phenolic groups are most preferred.
The partially substituted polymeric materials are not the result of a copolymerization of monomeric materials, but rather result from side chain substitution of homopolymers.
The homopolymers may be prepared in accordance with the methods set forth in Ito et al. U.S. Pat. No. 4,491,628, the disclosure of which is incorporated herein by reference. Those methods include phase transfer reactions, free radical polymerization and cationic polymerization to provide p-tert-butyloxy-carbonyloxy styrene and p-tert-butyloxycarbonylox-α-methyl styrene.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a infrared spectrum showing the progress of decarbonation of the polymer.
FIG. 2 is a correlation between infrared absorbance and mole percent p-hydroxystvrene in the polymer.
FIG. 3 is a graph of absorbance in a 1 cm path-length cell of a 0.02% diglyme solution made with the polymer of the invention.
FIG. 4 is a comparative spectral representation of 1.4 μm resist films of various composition.
DETAILED DESCRIPTION
In accordance with the present invention the substituted polymers were prepared as follows:
EXAMPLE 1
Synthesis of poly-(p-Hydroxystyrene-p-tert-butoxycarbonyloxystyrene)
300 grams of poly p-tertbutoxycarbonyloxystyrene with a molecular weight of 15,000 was dissolved in 1500 ml of 1,2 dimethoxyethane and the solution was heated to 60.0° C. To the stirred solution was added dropwise 20.0 g of concentrated H 2 SO 4 . The solution is kept at 60° C. for 3-4 hours to convert 75 mole percent of the p-tertbutoxycarbonyloxystyrcne groups to p-hydroxystyrene. The reaction was followed by IR of the reaction liquid. The IR peak ratio of the hydroxyl (OH) group peak (3400 cm -1 ) to the carbonate group peak (1750 cm -1 ) was used as the monitor to obtain the desired ratio for conversion to a 75 mole percent p-hydroxystyrene (see FIGS. 1 and 2). The mole percent of p-hydroxsystvrene can also be determined on the final product by UV 286 nm absorbance of a 0.02 weight percent solution in diglyme (corrected for diglyme absorbance). The ratio of the absorbance of the partially substituted to the absorbance of a 0.01% p-hydroxystyrene at 286 nm is used, see FIG. 3. The p-hydroxystyrene is made by the complete conversion (acidolysis) of the initial tertbutoxycarbonyloxystyrene polymer. After the desired tertbutoxycarbonyloxystyrene conversion was determined from the IR monitor, the reaction is quenched by the addition of a solution of potassium carbonate (125 g/250 ml water). The decanted liquid from the reaction is precipitated into a ten-fold ratio of water containing 0.05 M ammonium acetate and the product washed several times with water. The product was dried overnight in vacuum at 50° C. and checked for p-hydroxy styrene content by UV analysis.
EXAMPLE 2
Two substituted polymer compositions were prepared by solution phase acidolysis of the tertbutoxycarbonyloxystyrene polymer having a weight-average molecular weight of about 15000 as described in Example 1.
The first composition contained about 60 mole % tertbutoxycarbonyloxystyrene and 40 mole % p-hydroxy-styrene and the second composition was about 23 mole % tertbutoxycarbonyloxy styrene and 77 mole % p-hydroxy-styrene as determined by UV spectroscopy. These substituted polymers were formulated in propylene glycol methyl ether acetate with 5% (based on weight of solids) triphenylsulfonium hexafluroantimonate salt and were spin coated on silicon wafers to give film thicknesses of about 1.3 microns. Following a 115° C. 15 minute bake, the resists were imagewise exposed on a Perkin Elmer projection aligner in the UV-2 mode (240-300 nm) at doses ranging from 1-100 mJ/cm 2 . Post exposure conversion was done at 90° C. for 90 seconds on a hot plate. The resists were developed at times ranging from 30 seconds to 5 minutes in an aqueous 0.27 N tetramethyl ammonium hydroxide developer solution at room temperature. Alpha step surface profile measurements of undeveloped films showed that the first film had 18% film shrinkage while the second resist gave only 7% shrinkage. The terthutoxycarbonyloxystyrene homopolymer control gave 33% film shrinkage. Inspection of the developed images showed that the tertbutoxycarbonyloxy styrene polymer control had cracked extensively after only 30 seconds of development. Gross adhesion loss was also noted. The first resist showed a low level of cracking failure after 30 seconds and no adhesion failure. The second resist showed neither cracking nor adhesion failure for up to 5 minutes developing time.
Scanning electron microscope inspection of final images showed that the control was underdeveloped at 60 seconds. Longer developed times could not be evaluated due to poor adhesion and cracking. The first resist gave nearly 1 to 1 mask replication after 30 mJ exposure with 30 second development time. Nearly vertical profiles were obtained, with a slight bread-loaf appearance. The second resist required a higher exposure dose due to the higher optical density in the 240-300 nm range. At 100 mJ for 120 seconds development time, the second resist gave sidewall having 70-80° angles and no trace of bread-loaf. The first and second resists were capable of resolving the smallest masked feature of 0.75 micron.
FIG. 4 shows UV spectra at 1.4 micron films of the first and second resists as well as of a fully protected control resist. These curves show that the incorporation p-hydroxystyrene into the film increases its optical density in the 240-300 nm range. Such incorporation accounts for increased sensitivity and shallower image profiles obtained with the 77% substituted polymers of the second resist.
EXAMPLE 3
One mole of a p-tert-bit,loxycarbonyloxy styrene polymer (BCS) having a molecular weight of 15,000 was dissolved in a 20 weight percent solution of glyme. The solution was then heated under a nitrogen atmosphere to 60° C. To the stirred solution, 0.25 mole of concentrated sulfuric acid was added dropwise and the progress of the reaction was monitored by IR spectroscopy until 78 mole percent of the tert-butyloxycarbonyl (PC) groups were removed and the polymer had 22 percent BC substitution and 78 percent hydroxyl substitution. The reaction was quenched with an excess of ammonium hydroxide and ammonium sulfate was filtered off. The polymer solution was precipitated from a solution of excess ammonium acetate, was washed with water, filtered and dried overnight at 60° C. in a vacuum.
EXAMPLE 4
A p-tert-butyloxycarbonyloxy styrene (BCS) polymer having a molecular weight of 15,000 was heated in nitrogen at 160° C. for two hours. Samples were taken and analyzed for t-butylcarbonyl (BC) content from between 50 mole and 0 mole percent BC remaining. In all cases, the polymer solution in propylene glycol acetate was cloudy and could not be filtered through a 0.2 μm Millipore filter. A sample having 22 mole % tert-butyloxycarbonyloxy styrene and 78 role % p-hydroxy styrene was isolated.
EXAMPLE 5
A poly p-hydroxystyrene polymer having a molecular weight of 11,000 reacted with a solution of ditertiarybutylcarbonate in glyme with triethylamine as a catalyst. The reaction product was precipitated in hydrochloric acid, was stirred with ammonium acetate and was washed with water. IR and UV analysis characterized the polymer as containing 22 mole percent of tert-butyloxy carbonyl groups.
EXAMPLE 6
Preparation of the substituted polymer by copolymerization of p-hydroxystvrene and p-t-butyloxy-carbonyloxystyrene monomers was not attempted due to inherent instability of p-hydroxystyrene monomers.
EXAMPLE 7
Polymers having an average mole % composition of 22% tert-butyloxycarbonylo-,y styrene and 78% p-hydroxystyrene derived by the synthetic methods of Examples 3-5 and a control using the BCS starting material of Example 3 were formulated into resists with 7 percent triphenyl sulfonium hexafluoroantimonate sensitizer in a propylene glycol methyl ether acetate. The films were cast onto substrates, were baked at 95° C. for five minutes, were exposed in deep UV radiation at 254 nm, were post exposure baked at 95° C. for ninety seconds, and were developed in an aqueous 0.27 N totramethylammonium hydroxide developer solution.
The sensitivity of each resist was determined by measuring step wedge thickness remaining using a criterion of 95 percent of unexposed film remaining while the exposed area was developed at a given dose. The results are shown in Table I.
TABLE I______________________________________Source of UV Sensitivity, Polymer in Resist Dose in mJ/cm.sup.2______________________________________Example 3 5 Example 4 25* Example 5 45 Control 30**______________________________________ *Many insoluble particles or residues in image **Images were cracked and unusable
The causes for differences in sensitivity of the resist compositions have polymers having the same ratio of t-butyloxycarbonyloxy groups to hydroxy groups is not understood. The noted differences are reproducible.
Further comparison between the resist made from the Example 3 polymer and a control polymer of p-tert-butyloxycarbonyloxystyrene prepared in accordance with U.S. Pat. No. 4,491,628 yielded the following data:
TABLE II______________________________________ Polymer in ResistProperty Control Example 3______________________________________Sensitivity UV photo speed 30 mJ/cm.sup.2 5 mJ/cm.sup.2 E-beam dose 10 μc/cm.sup.2 3 μc/cm.sup.2 X-ray dose 150 mJ/cm.sup.2 100 mJ/cm.sup.2 On set of thermal flow 90° C. 165° C. Post silylatable No* *Yes Image shrinkage 37% 7% (after DUV hardening) Cracking in developer Yes No Adhesion to Si, Poor Good Si.sub.3 N.sub.4 surfaces RIE erosion 35% 10% Base developable Cracked Excellent, no cracks UV hardenable Yes with Yes shrinkage______________________________________ *requires flood UV exposure/baking before silylation
Example 8
Another series of polymers were prepared in accordance with the method of Example 3 and were incorporated into resists in accordance with the method of Example 7. The properties resists containing these polymers and the control were compared.
TABLE III______________________________________Mole % BC in Polymer 100 (control) 64 36 20 16______________________________________Shrinkage 37 18 8 7 7 (percent) Crack Devel- Severe Moder. None None None opment Adhesion Poor Fair Excel. Excel. Excel. Resistance Excel. Excel. Excel. Excel. Poor to Alkali Image Dis- Severe Severe Slight Unde- Unde- tortion tect- tect- able able______________________________________
Only the preferred embodiments of the invention have been described above and one skilled in the art will recognize that numerous substitutions, modifications and alterations are permissible without departing from the spirit and the scope of the invention, as set forth in the following claims.
|
Positive resists sensitive to UV, electron beam, and x-ray radiation which are alkaline developable are formulated from a polymer material comprising recurrent structures having alkaline soluble groups pendent to the polymer backbone, a portion of which groups are substituted with acid labile groups.
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This is a National Phase Application in the United States of International Patent Application No. PCT/JP2012/004559 filed Jul. 17, 2012, which claims priority on Japanese Patent Application No. 2011-194285, filed Sep. 6, 2011. The entire disclosures of the above patent applications are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
Technical Field
The present invention relates to an improvement in a raw material vaporizing and supplying apparatus for semiconductor manufacturing equipment using so-called metalorganic chemical vapor deposition (hereinafter, referred to as MOCVD), and, also, to a raw material vaporizing and supplying apparatus equipped with a raw material concentration detection mechanism, capable of controlling a raw material concentration of a raw material mixed gas supplied to a process chamber highly accurately and quickly, and also capable of displaying the raw material gas concentration in real time.
Description of the Related Art
Conventionally, as this type of raw material vaporizing and supplying apparatus for semiconductor manufacturing equipment, a raw material vaporizing and supplying apparatus which utilized a so-called bubbling method has been used in many applications. In vaporizing and supplying of a raw material according to the bubbling method, there has been a strong demand for, such as, realizing significant downsizing of the raw material vaporizing and supplying apparatus, an increased supply quantity of a raw material, quick and highly accurate control of a mixture ratio of carrier gas and raw material gas, and direct display of a raw material gas concentration in the mixed gas supplied to a chamber.
Therefore, various types of research and development have been made for the bubbling-type raw material vaporizing and supplying apparatus. For example, techniques in the fields of controlling a flow rate of a mixed gas supplied to a process chamber and a raw material gas concentration in the mixed gas are disclosed in Japanese Published Unexamined Patent Application Publication No. H07-118862, Japanese Patent No. 4605790, etc.
FIG. 6 is a drawing that describes the structure of a reaction gas control method described in Japanese Published Unexamined Patent Application Publication No. H07-118862 given above. In FIG. 6 , reference numeral 31 denotes a closed tank, 32 denotes a heater, 33 denotes a mass flow controller, 34 denotes an injection pipe, 35 denotes an ejection pipe, 36 denotes a mass flow meter, L 0 denotes a liquid raw material (TEOS, or tetraethyl orthosilicate), G K denotes a carrier gas (N 2 ), G m denotes a mixed gas (G+G K ), G denotes a raw material gas, Q 1 denotes a carrier gas flow rate, Q 2 denotes a raw material gas flow rate, Q S denotes a mixed gas flow rate, 37 denotes a flow rate setting circuit, 38 a denotes a concentration calculation circuit, 38 b denotes a concentration setting circuit, 38 c denotes an electric current control circuit, Q S0 denotes a set flow rate, and K S0 denotes a set concentration.
The present invention is to control a temperature of the liquid raw material L 0 , thereby regulating a produced flow rate Q 2 of a raw material gas G to keep the concentration of the raw material gas G in a mixed gas G m constant. More specifically, computation is made for the produced flow rate Q 2 of the raw material gas with reference to a mixed gas flow rate Q S from the mass flow meter 36 and a carrier gas flow rate Q 1 from the mass flow controller 33 .
Further, the thus computed Q 2 (the produced flow rate of the raw material gas) is used to determine Q 2 /Q S , thereby computing a raw material gas concentration K S in the mixed gas G m .
The thus computed raw material gas concentration K S is input into the concentration setting circuit 38 b and by comparing with a set concentration K S0 , a difference between them (K S0 −K S ) is subjected to feedback to the electric current control circuit 38 c . Where such a relationship of K S0 >K S is obtained, the heater 32 is operated so as to raise its temperature, thereby increasing the produced flow rate Q 2 of the raw material gas G. Where such a relationship of K S0 <K S is obtained, the heater is operated so as to lower its temperature, thereby decreasing the produced flow rate Q 2 .
Further, the mixed gas flow rate Q S from the mass flow meter 36 is compared with the set mixed gas flow rate Q S0 on the flow rate setting circuit 37 , thereby regulating the flow rate Q 1 from a mass flow controller so that a difference between them becomes zero.
However, the method for regulating the raw material gas concentration as shown in FIG. 6 increases the produced flow rate Q 2 of a raw material gas by heating the liquid raw material L 0 , (or decreases the produced flow rate Q 2 of the raw material gas by lowering a temperature of the liquid raw material L 0 ). Therefore, there is a problem that the method is very low in response characteristics with respect to regulation of concentration and extremely low in response characteristics with respect to a decrease in concentration of the raw material gas.
Further, the mass flow meter (thermo-flowmeter) 36 undergoes a great fluctuation in measured flow rate value when a type of mixed gas G m or a mixture ratio thereof is changed. Therefore, the method shown in FIG. 6 has such a problem that, irrespective of whether a type of mixed gas G m is changed or the type is the same, a great change in a mixture ratio (concentration of raw material gas) will result in a drastic decrease in the measuring accuracy of a flow rate Q S .
Still further, the change in temperature of heating the liquid raw material L 0 will raise a pressure inside the closed tank 31 , thereby inevitably resulting in a fluctuation in primary side pressure of the mass flow meter 36 . As a result, the mass flow meter 36 will have an error in the measured flow rate value, thus revealing a problem of decreasing the control accuracy of a flow rate and concentration of raw material gas.
On the other hand, FIG. 7 is a drawing which shows the structure of a raw material gas supplying apparatus of Patent No. 4605790 which has been described above. The apparatus is able to supply a mixed gas having a predetermined concentration of raw material gas to a process chamber, with a flow rate thereof being controlled highly accurately with high responsive characteristics.
In FIG. 7 , reference numeral 21 denotes a closed tank, 22 denotes a constant temperature device, 23 denotes a mass flow controller, 24 denotes an injection pipe, 25 denotes an ejection pipe, 26 denotes an automatic pressure regulator for the closed tank, 26 a denotes an arithmetic and control unit, 26 b denotes a control valve, L 0 denotes a liquid raw material, G K denotes a carrier gas, Q 1 denotes a carrier gas flow rate, G denotes a raw material gas, G m denotes a mixed gas (G+G K ), and Q S denotes a mixed gas flow rate.
In the raw material gas supplying apparatus, first, the constant temperature device 22 is used to heat the closed tank 21 , a main body of the automatic pressure regulator 26 for the closed tank and a piping line L to a predetermined temperature. Thereby, an internal space of the closed tank 21 is filled with saturated steam (raw material gas) G of a raw material.
Further, the carrier gas G K at a flow rate Q 1 controlled by the mass flow controller 23 is released from a bottom of the closed tank 21 . A mixed gas G m of the carrier gas G K and the saturated steam (or vapor) G of the raw material is supplied through the control valve 26 b of the automatic pressure regulating device 26 to outside (process chamber).
The mixed gas G m is regulated for the flow rate Q S by controlling a pressure of the mixed gas in the closed tank 21 by the automatic pressure regulator 26 . A set flow rate Q S0 is compared with a computation flow rate Q S computed with reference to measurement values obtained from a pressure gauge P 0 and a temperature gauge T 0 at an arithmetic and control unit 26 a of the automatic pressure regulator 26 . And, the control valve 26 b is opened and closed so that a difference between them (Q S0 −Q S ) becomes zero, thereby controlling a flow rate Q S of supplying the mixed gas G m to a set flow rate Q S0 .
The raw material gas supplying apparatus shown in FIG. 7 is able to supply the mixed gas G m having a constant raw material gas concentration which is determined in response to a heating temperature of the liquid raw material L 0 by regulating an internal pressure of the closed tank, with a flow rate thereof controlled highly accurately with high response characteristics, thereby providing excellent effects of controlling a flow rate of the mixed gas having a predetermined and constant raw material gas concentration.
Although the raw material gas supplying apparatus is able to measure a flow rate Q S of the mixed gas G m highly accurately and with high response characteristics, it has a basic problem that the mixed gas G m is not measured for a raw material gas concentration highly accurately and cannot display a measurement value thereof. As a matter of course, if a heating temperature of the closed tank 21 , a flow rate of the carrier gas G K , a level height of the raw material liquid L 0 , etc., are determined, it is possible to estimate a raw material gas concentration K S in the mixed gas G m to some extent. However, a technique has not yet been developed that a raw material gas concentration of the mixed gas G m supplied to a process chamber can be continuously and automatically measured and displayed without using a complicated and expensive concentration meter, etc., in a less expensive and economical manner.
CITATION LIST
Patent Document
Patent Document 1: Japanese Published Unexamined Patent Application Publication No. H07-118862
Patent Document 2: Japanese Patent No. 4605790
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
The main object of the present invention is to solve problems of the raw material vaporizing and supplying apparatus described in Japanese Published Unexamined Patent Application Publication No. H07-118862 and Japanese Patent No. 4605790. That is, the former case has the following problems, for example. (A) The raw material vaporizing and supplying apparatus is increased or (decreased) in produced flow rate Q of a raw material gas by heating or cooling a liquid raw material L 0 , thereby regulating a raw material gas concentration K S in a mixed gas G m . Thus, the apparatus is relatively low in response characteristics for controlling the raw material gas concentration and also required to have expensive additional equipment for increasing the response characteristics. Thereby, the raw material gas supplying apparatus has increased manufacturing costs and dimensions. (B) Where the mixed gas G m is changed in the type of mixed gas or the mixture ratio thereof, the mass flow meter undergoes a great fluctuation in the measured flow rate value. Then, a mixed gas flow rate Q S is decreased in accuracy of measurement, resulting in a great decrease in accuracy of computing the raw material gas concentration K S . (C) Change in heating temperature will result in a fluctuation in pressure in the closed tank 31 . Thereby, the mass flow meter 35 has decreased accuracy of measurement to decrease the accuracy of computing a measurement value of the flow rate Q S and the raw material concentration K S . Further, the latter case has the following problem, for example. (A) It is not possible to measure a raw material gas concentration in the mixed gas G m highly accurately and display the concentration in real time. Therefore, the present invention seeks to provide a raw material vaporizing and supplying apparatus equipped with a raw material concentration detection mechanism in which the raw material gas concentration K S in a mixed gas G m of carrier gas G K and raw material gas G supplied to a process chamber is measured and displayed continuously and automatically Furthermore, in place of a concentration meter, etc., high in cost and complicated in structure, a device low in cost and simple in structure can be used for extremely economical control and display of the raw material gas concentration in the mixed gas G m .
Means for Solving the Problems
The invention according to the first aspect is a raw material vaporizing and supplying apparatus which supplies a carrier gas G K into a source tank 5 through a mass flow controller 3 to release the carrier gas G K from inside the source tank 5 and also supplies into a process chamber a mixed gas G S composed of the carrier gas G K and saturated steam G of a raw material 4 produced by keeping the source tank 5 at a constant temperature by a constant temperature unit 6 , and the raw material vaporizing and supplying apparatus in which an automatic pressure regulating device 8 and a mass flow meter 9 are installed on a flow-out passage of the mixed gas G S from the source tank 5 , the automatic pressure regulating device 8 is controlled so as to open and close a control valve 8 a , thereby controlling an internal pressure P 0 of the source tank 5 to a predetermined value, individual detection values of a flow rate Q 1 of the carrier gas G K by the mass flow controller 3 , the internal pressure P 0 of the tank and a flow rate Q S of the mixed gas G S by the mass flow meter 9 are input into a raw material concentration arithmetic unit 10 , the raw material concentration arithmetic unit 10 is used to compute a raw material flow rate Q 2 based on Q 2 =Q S ×P M0 /P 0 (however, P M0 is a saturated steam pressure of the raw material steam G at a temperature of t° C. in the source tank), and a raw material concentration K of the mixed gas G S supplied to the process chamber is computed and displayed in terms of K=Q 2 /Q S with reference to the raw material flow rate Q 2 .
The invention according to the second aspect is the invention according to the first aspect, in which a storage device of saturated steam pressure data of the raw material in the source tank 5 is installed on the raw material concentration arithmetic unit 10 and also detection signals of an internal pressure P 0 of the source tank 5 and a temperature t from the automatic pressure regulating device 8 are input into the raw material concentration arithmetic unit 10 .
The invention according to the third aspect is a raw material vaporizing and supplying apparatus which supplies a carrier gas G K into a source tank 5 through a mass flow controller 3 to release the carrier gas G K from inside the source tank 5 and also supplies to a process chamber a mixed gas G S composed of the carrier gas G K and saturated steam G of a raw material 4 produced by keeping the source tank 5 at a constant temperature by a constant temperature unit 6 , and the raw material vaporizing and supplying apparatus in which an automatic pressure regulating device 8 and a mass flow meter 9 are installed on a flow-out passage of the mixed gas G S from the source tank 5 , the automatic pressure regulating device 8 is controlled so as to open and close a control valve 8 a , thereby controlling an internal pressure P 0 of the source tank 5 to a predetermined value, individual detection values of a flow rate Q 1 of the carrier gas G K by the mass flow controller 3 , the internal pressure P 0 of the tank and a flow rate Q S of the mixed gas G S from the mass flow meter 9 are input into a raw material concentration arithmetic unit 10 , and the raw material concentration arithmetic unit 10 is used to determine a raw material flow rate Q 2 based on Q 2 =CF×Q S ′−Q 1 (however, CF is a conversion factor of the mixed gas Q 2 ), and a raw material concentration K of the mixed gas G S supplied to the process chamber is computed and displayed based on K=Q 2 /(Q 1 +Q 2 ) with reference to the raw material flow rate Q 2 .
The invention according to the fourth aspect is the invention according to the third aspect, in which a conversion factor CF of the mixed gas Q S is given as 1/CF=C/CF A +(1−C)/CF B (however, CF A is a conversion factor of the carrier gas G K , CF B is a conversion factor of the raw material gas G, and C is a volume ratio of carrier gas (Q 1 /(Q 1 +Q 2 )).
The invention according to the fifth aspect is the invention according to the first aspect or the third aspect, in which the raw material concentration detection unit 10 , a flow rate arithmetic and control unit 3 b of the mass flow controller 3 , a pressure arithmetic and control unit 8 b of the automatic control device and a flow rate arithmetic and control unit 9 b of the mass flow meter 9 are arranged so as to be assembled in an integrated manner.
The invention according to the sixth aspect is the invention according to the third aspect, in which the raw material concentration arithmetic unit 10 is provided with a storage device of individual data on conversion factors of the raw material gas G in the source tank and conversion factors of the carrier gas G K .
The invention according to the seventh aspect is the invention according to any one of the first aspect to the sixth aspect, in which the mass flow meter 9 is installed on the downstream side of the automatic pressure regulating device 8 .
The invention according to the eighth aspect is the invention according to any one of the first aspect to the sixth aspect, in which the mass flow meter 9 is installed on the upstream side of the automatic pressure regulating device 8 .
The invention according to the ninth aspect is the invention according to any one of the first aspect to the sixth aspect, in which the automatic pressure regulating device 8 is a pressure regulating device which has a temperature detector T, a pressure detector P, a control valve 8 a installed on the downstream side from the pressure detector P and a pressure arithmetic and control unit 8 b.
The invention according to the tenth aspect is an invention in which the mass flow meter 9 is installed between the pressure detector P and the control valve 8 a.
In the present invention, the raw material vaporizing and supplying apparatus is arranged so that a flow rate Q 1 of supplying the carrier gas G K from the mass flow controller 3 , a flow rate Q S of supplying the mixed gas G S from the mass flow meter 9 and an internal pressure of the tank from the automatic pressure regulating device 8 in the source tank, etc., are input into the raw material concentration arithmetic unit 10 , and the mixed gas G S is supplied to the chamber at a constant pressure and, at the same time, a raw material gas concentration K in the thus supplied mixed gas G S is computed and displayed on the raw material concentration arithmetic unit 10 in real time. Therefore, the mixed gas G S can be supplied at a more stable raw material concentration K. It is also possible to display the raw material concentration K of the mixed gas G S in a digital form and carry out stable process treatment which is high in quality.
Further, it is acceptable that the raw material concentration arithmetic unit 10 is simply added. Thereby, as compared with a case where the above-described expensive gas concentration meter is used, the raw material gas concentration K in the mixed gas G S can be detected and displayed reliably and in a less-expensive manner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a systematic diagram which shows the structure of a raw material vaporizing and supplying apparatus equipped with a raw material concentration detection mechanism according to a first embodiment of the present invention.
FIG. 2 is a drawing which describes test equipment used for studying a relationship between a raw material gas flow rate Q 2 , a mixed gas flow rate Q S , a carrier gas flow rate Q 1 , a source tank pressure P 0 and a source tank temperature t.
FIG. 3 is a drawing which shows a relationship between the internal pressure P 0 of the tank, the mixed gas flow rate Q S , the raw material gas flow rate Q 2 and the tank temperature t measured by using the test equipment given in FIG. 2 , in which (a) shows a state of change in the mixed gas flow rate Q S and (b) shows a state of change in the raw material gas flow rate Q 2 .
FIG. 4 is a line drawing which shows a relationship between a measurement value, with the carrier gas flow rate Q 1 kept constant (mixed gas flow rate Q S −carrier gas flow rate Q 1 ) and the raw material gas flow rate Q 2 calculated with reference to Formula (2).
FIG. 5 is a schematic diagram which shows a system of supplying a raw material gas.
FIG. 6 is a drawing which describes one example of a conventional raw material vaporizing and supplying apparatus according to the bubbling method (Japanese Published Unexamined Patent Application Publication No. H07-118862).
FIG. 7 is a drawing which describes another example of a conventional raw material vaporizing and supplying apparatus according to the bubbling method (Japanese Patent No. 4605790).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a systematic diagram which shows the structure of a raw material vaporizing and supplying apparatus equipped with a raw material concentration detection mechanism according to the first embodiment of the present invention.
In FIG. 1 , reference numeral 1 denotes a carrier gas supply source, 2 denotes a decompression unit, 3 denotes a thermal type mass flow control system (mass flow controller), 4 denotes a raw material (organometallic compound (MO material), etc.), 5 denotes a source tank, 6 denotes a constant temperature unit, 7 denotes an induction pipe, 8 denotes an automatic pressure regulating device in the source tank, 9 denotes a mass flow meter, 10 denotes a raw material concentration arithmetic unit, Q 1 denotes a carrier gas flow rate of Ar, etc., Q 2 denotes a flow rate of the raw material saturated steam (raw material gas flow rate), Q S denotes a mixed gas flow rate of the carrier gas flow rate Q 1 and the raw material steam flow rate Q 2 , P denotes a pressure detector of the mixed gas G S , T denotes a temperature detector of the mixed gas G S , 3 a denotes a sensor unit of the mass flow controller, 8 a denotes a piezoelectric element driving control valve, 9 a denotes a sensor unit of the mass flow meter, and 9 b denotes an arithmetic and control unit of the mass flow meter 9 a . The mass flow controller 3 is made up of the sensor unit 3 a and a flow rate arithmetic and control unit 3 b of the sensor unit 3 a . The automatic pressure regulator 8 of the source tank is made up of the control valve 8 a , a pressure arithmetic and control unit 8 b , the pressure detector P and the temperature detector T.
It is noted that N 2 is generally used as the carrier gas G K . However, the carrier gas G K is not limited to N 2 but includes various types of gas such as H 2 and Ar. Further, the raw material includes an organometallic compound (MO material) but shall not be limited to an organometallic material. The raw material also includes any liquid and solid materials as long as they are capable of attaining a predetermined saturated steam pressure in a source tank.
The mass flow controller 3 is publicly known and, therefore, a detailed description thereof will be omitted here. The automatic pressure regulating device 8 of the source tank is also publicly known in Japanese Patent No. 4605790, etc., with a detailed description thereof omitted here.
Further, in FIG. 1 , reference numeral G K denotes a carrier gas, G denotes raw material steam (raw material gas), G S denotes a mixed gas, P 0 denotes an internal pressure of the source tank (kPa abs.), P M0 denotes a raw material steam pressure in the source tank (kPa abs.), 3 e denotes a flow rate display signal, 8 d denotes a control valve control signal, 8 c denotes a pressure detection signal, 8 f denotes a temperature detection signal, 8 e denotes a pressure display signal, 9 c denotes a mixed gas flow rate detection signal, and 9 e denotes a mixed gas flow rate display signal. The display signal 3 e of the flow rate Q 1 of the carrier gas G K and the display signal 9 e of the flow rate Q S of the mixed gas G S from the mass flow meter 9 are input into the raw material concentration arithmetic unit 10 , and a raw material gas concentration K in the mixed gas G S is computed and displayed here. It is noted that 10 K denotes a raw material concentration display signal.
It is noted that in the embodiment shown in FIG. 1 , the flow rate arithmetic and control unit 3 b of the mass flow controller 3 , the pressure arithmetic and control unit 8 b of the automatic pressure regulating device 8 , the flow rate arithmetic and control unit 9 b of the mass flow meter 9 and the raw material concentration arithmetic unit 10 are formed on a single substrate in an integrated manner. As a matter of course, it is also acceptable that the control units 3 b , 8 b , 9 b and the raw material concentration arithmetic unit 10 are individually installed.
Next, a description will be given of operation of the raw material vaporizing and supplying apparatus.
In the raw material vaporizing and supplying apparatus, first, a pressure PG 1 of the carrier gas G K supplied into the source tank 5 is set so as to give a predetermined pressure value by the decompression unit 2 and a supplying flow rate Q 1 thereof is also set so as to give a predetermined value by the thermal type mass flow control system 3 (mass flow controller).
Further, the constant temperature unit 6 is operated to keep parts in constant temperature excluding the source tank 5 , the arithmetic and control unit 8 b of the automatic pressure regulating device 8 , etc.
As described so far, the supply quantity Q 1 of the carrier gas G K is kept at a set value by the thermal type mass flow control system 3 , the temperature of the source tank 5 is kept at a set value, and the internal pressure P 0 of the source tank 5 is kept at a set value by the automatic pressure regulating device 8 , respectively. Thereby, the mixed gas G S with a constant flow rate is allowed to flow into the mass flow meter 9 at a fixed mixture ratio through the control valve 8 a , and the flow rate Q S of the mixed gas G S is measured here with high accuracy.
Further, the source tank 5 , the control valve 8 a of the automatic pressure regulating device 8 , etc., are kept at constant temperature. Therefore, a pressure P M0 of the raw material saturated steam G in the source tank 5 is kept stable and the internal pressure P 0 of the source tank 5 is controlled so as to give a set value by the automatic pressure regulating device 8 . It is, thereby, possible to measure and display the raw material gas concentration K in the mixed gas G S on the raw material concentration arithmetic unit 10 as described later, while the concentration K of the raw material gas G in the mixed gas G S is kept stable.
And, in the raw material vaporizing and supplying apparatus shown in FIG. 1 , where the internal pressure of the source tank is given as P 0 (kPa abs.), the raw material steam pressure is given as P M0 , the flow rate of the carrier gas G K , is given as Q 1 (sccm), the flow rate of the mixed gas G S supplied to the chamber is given as Q 2 (sccm) and the flow rate of the raw material steam G is given as Q 2 (sccm), the flow rate Q S of supplying the mixed gas G S to the chamber is expressed as Q S =Q 1 +Q 2 (sccm).
That is, the raw material flow rate Q 2 is proportional to the raw material steam pressure P M0 in the source tank, and the flow rate of supplying the mixed gas G S , that is, Q S =Q 1 +Q 2 , is proportional to the internal pressure P 0 of the source tank. Therefore, the following relationship is obtained. Raw material flow rate Q 2 : mixed gas supplying flow rate Q S =raw material steam pressure P M0 : internal pressure P 0 of source tank.
That is,
[Formula 1]
Q 2 ×P 0 =Q S ×P M0 (1)
With reference to Formula 1, the raw material flow rate Q 2 is expressed as follows:
[Formula 2]
Q 2 =Q S ×P M0 /P 0 (2)
As apparent from Formula 2 given above, the raw material flow rate Q 2 is determined by the mixed gas flow rate Q S , the source tank pressure P 0 and the raw material steam pressure (partial pressure) P M0 . Further, the internal pressure P 0 of source tank is determined by the temperature t in the source tank.
In other words, the raw material concentration K in the mixed gas G S is determined by parameters such as the carrier gas flow rate Q 1 , the internal pressure P 0 of source tank and the temperature t in the source tank.
In FIG. 1 , the mass flow meter 9 is installed on the downstream side of the automatic pressure regulating device 8 . It is acceptable that their positions are exchanged so that the automatic pressure regulating device 8 is installed on the downstream side of the mass flow meter 9 . It is also acceptable that the mass flow meter 9 is installed between the pressure detector P and the control valve 8 a.
As shown in FIG. 1 , where the automatic pressure regulating device 8 is installed on the upstream side of the mass flow meter 9 , a control pressure of the automatic pressure regulating device 8 is in agreement with an internal pressure of the source tank. It is, therefore, possible to control the internal pressure of the source tank accurately. However, such a problem is posed that a supply pressure of the mass flow meter 9 is influenced by a secondary side (process chamber side).
On the other hand, where the mass flow meter 9 is installed on the upstream side of the automatic pressure regulating device 8 , the mass flow meter 9 is in a range of pressure control by the automatic pressure regulating device 8 . Thus, the mass flow meter 9 is made stable in supply pressure, thus enabling highly accurate measurement of a flow rate. However, the mass flow meter 9 undergoes pressure loss, thereby causing a difference between the control pressure of the automatic pressure regulating device 8 and the internal pressure of the source tank.
Further, where the mass flow meter 9 is installed between the pressure detector P and the control valve 8 a , the control pressure of the automatic pressure regulating device 8 is in agreement with the internal pressure of the source tank and the mass flow meter 9 is also in a range of pressure controlled by the automatic pressure regulating device 8 . Therefore, the mass flow meter 9 is made stable in supply pressure, enabling highly accurate measurement of a flow rate. However, such a problem is posed that the mass flow meter 9 causes pressure loss between the pressure detector P and the control valve 8 a, thereby affecting the response characteristics for pressure control.
FIG. 2 is a drawing which describes test equipment used for confirming the establishment of a relationship between Formula 1 and Formula 2 given above. Acetone (steam pressure curve is close to that of TMGa) was used as the raw material 4 , a water bath was used as the constant temperature unit 6 and N 2 was used as the carrier gas G K . A relationship between the internal pressure P 0 of the tank and the flow rate Q S of the mixed gas G S was regulated, with the tank temperature t given as a parameter (−10° C., 0° C., 10° C., 20° C.).
FIG. 3 shows results of the test carried out by using the test equipment of FIG. 2 . Further, Table 1 below shows results obtained by using Formula 2 to compute the raw material gas flow rate Q 2 of the raw material acetone.
TABLE 1
Raw material acetone: Carrier gas N 2 (50 sccm)
Temperature of
constant temperature
water bath (° C.)
Internal pressure P 0 of tank (kPa abs) and
Measure-
raw material flow rate Q (sccm)
Setting
ment
120
150
180
210
240
270
300
20
19.4
12.43
9.56
7.70
6.44
5.59
4.92
4.36
10
9.8
7.34
5.68
4.67
3.94
3.42
3.02
2.69
0
−0.5
4.12
3.25
2.67
2.27
1.99
1.77
1.57
−10
−11.0
2.21
1.74
1.44
1.23
1.08
0.96
0.86
Table 2 shows comparison between steam pressure of acetone as a raw material and steam pressure of TMGa (trimethyl gallium) as a generally-used MO material. Since these two substances are remarkably approximate in steam pressure, calculation values obtained by using acetone in Table 1 can be said to indicate those of TMGa used as a raw material.
TABLE 2
kPa
Torr
Steam pressure of acetone
−10
5.39
40.4
0
9.36
70.2
10
15.53
116.5
20
24.74
185.6
30
38.03
285.3
40
56.64
424.9
50
81.98
615.1
Steam pressure of TMGa
−10
5.20
39.0
0
8.97
67.3
10
14.91
111.8
20
23.92
179.4
30
37.21
279.1
40
56.26
422.0
50
82.93
622.0
FIG. 4 is a drawing which shows a relationship of a difference between an N 2 converted detection flow rate Q S ′ of the mixed gas G S and the carrier gas flow rate Q 1 , Q S ′−Q 1 which are measured by using a mass flow meter installed on the test equipment of FIG. 2 , with a carrier gas flow rate (Q 1 ) kept constant and the tank temperature t (−10° C. to 20° C.) given as a parameter (that is, an N 2 converted raw material gas flow rate Q 2 ′=Q S ′−Q 1 ) with respect to an acetone flow rate (Q 2 sccm) calculated with reference to Formula (2). In this drawing, (a) covers a case where the carrier gas flow rate Q 1 is equal to 50 sccm, (b) covers a case where Q 1 is equal to 100 sccm and (c) covers a case where Q 1 is equal to 10 sccm.
As apparent from (a) to (c) in FIG. 4 as well, there is found a direct proportional relationship between a measurement value (mixed gas flow rate Q S ′−carrier gas flow rate Q 1 ) by using the mass flow meter and a calculated acetone flow rate Q 2 . As a result, the carrier gas flow rate Q 1 is measured by using the mass flow controller 3 and the mixed gas flow rate Q S is measured by using the mass flow meter 9 , respectively, to determine Q S −Q 1 . Thereby, it is possible to calculate the raw material gas flow rate Q 2 .
Next, a description will be given of calculation of a raw material gas flow rate Q 2 and a concentration K of the raw material gas G in the mixed gas Gs.
Where a raw material gas supply system is expressed as given in FIG. 5 and where a raw material gas G at a flow rate Q 2 equivalent to a concentration K and a carrier gas G K (N 2 ) at a flow rate Q 1 (that is, Q 2 +Q 1 sccm) are supplied to the mass flow meter 9 to give a detection flow rate (N 2 -based conversion) of mixed gas Gs at this time as Q S ′ (sccm), the raw material gas flow rate Q 2 and the raw material gas concentration K in the mixed gas can be obtained with reference to the formulae given below.
[Formula 3]
Raw material gas flow rate Q 2 (sccm)= CF of mixed gas×detected flow rate (N 2 -based conversion) Q S ′ (sccm)−carrier gas flow rate Q 1 (sccm) (3)
[Formula 4]
Raw material gas concentration K =Raw material gas flow rate Q 2 (sccm)/Carrier gas flow rate Q 1 (sccm)+Raw material gas flow rate Q 2 (sccm) (4)
CF given in Formula (3) above is a conversion factor of the so-called mixed gas Gs in a thermal type mass flow meter and can be obtained with reference to Formula (5) below.
[Formula 5]
1 /CF=C/CF A +(1 −C )/ CF B (5)
However, in Formula (5), CF A denotes a conversion factor of gas A, CF B denotes a conversion factor of gas B, C denotes a volume ratio (concentration) of the gas A and (1−C) denotes a volume ratio (concentration) of the gas B (“Flow rate measurement: A to Z,” compiled by the Japan Measuring Instruments Federation, published by Kogyogijutsusha (pp. 176 to 178).
Now, in FIG. 5 , where CF A of the carrier gas G K (N 2 ) is given as 1 and CF B of the raw material gas G is given as α, the concentration of the raw material gas is expressed as Q 2 /(Q 1 +Q 2 ) and the concentration of the carrier gas is expressed as Q 1 /(Q 1 +Q 2 ). Thus, CF of the mixed gas Q 2 is expressed by Formula (5) as follows.
1 CF = 1 1 × Q 1 Q 1 + Q 2 + 1 α · Q 2 Q 1 + Q 2 = α Q 1 + Q 2 α ( Q 1 + Q 2 ) [ Formula 6 ]
Thus, the following formula is obtained.
CF
=
α
(
Q
1
+
Q
2
)
α
Q
1
+
Q
2
[
Formula
7
]
Therefore, the N 2 converted detection flow rate Q S ′ of the mixed gas G S detected by the mass flow meter 9 is expressed as follows.
Qs
’
=
Q
1
+
Q
2
CF
=
(
Q
1
+
Q
2
)
×
(
α
Q
1
+
Q
2
)
/
α
(
Q
1
+
Q
2
)
=
(
α
Q
1
+
Q
2
)
/
α
=
Q
1
+
Q
2
α
[
Formula
8
]
Thereby, the flow rate Q 2 of the raw material gas G is expressed as Q 2 =α(Q S ′−Q 1 ). However, in this case, α is a conversion factor of the raw material gas G.
Table 3 below shows results obtained by comparing a raw material gas flow rate Q 2 calculated by using a conversion factor CF determined with reference to Formula (5) above with a raw material gas flow rate Q 2 computed by using Formula (1) and Formula (2). It is found that a value calculated with reference to Formula (1) and Formula (2) is well in agreement with a value calculated with reference to Formula (5).
It is noted that in Table 1, acetone is supplied as a raw material gas G and N 2 is supplied as a carrier gas G K at a flow rate Q 1 =500 sccm and calculation is made, with the temperature t given as a parameter. The raw material gas flow rate Q 2 determined with reference to a pressure ratio between Formula (1) and Formula (2) and the raw material gas flow rate Q 2 determined with reference to a conversion factor CF according to Formula (5) are approximate in flow rate value with each other.
TABLE 3
CF of acetone: 0.341, Constant temperature water bath set at 20° C., Flow rate of N 2 , 50 sccm
RT
° C.
24.0
24.0
23.9
23.9
24.0
24.1
23.9
Tank temperature
° C.
19.2
19.4
19.3
19.3
19.4
19.5
19.4
Acetone steam
KPa
23.9
24.0
24.0
23.9
24.1
24.1
24.0
pressure
abs
Flow rate of N 2
sccm
50.1
50.1
50.1
50.1
50.1
50.1
50.1
Internal pressure of
KPa
120
150
180
210
240
270
300
tank
abs
Concentration
%
19.9%
16.0%
13.3%
11.4%
10.0%
8.39%
8.0%
Detection flow
AVE
sccm
88.4
79.6
73.9
70.2
67.6
65.4
63.8
rate of mixed
MAX
sccm
89.1
80.2
74.7
70.7
68.2
66.0
64.4
gas G s
MIN
sccm
87.8
78.9
73.2
69.6
67.1
64.9
63.3
(N 2 -based
conversion): Q s ′
Raw material gas flow
sccm
38.3
29.5
23.8
20.1
17.5
15.3
13.7
rate (N 2 -based
conversion) Q 2 ′
Calculated acetone
sccm
12.43
9.56
7.70
6.44
5.59
4.92
4.32
flow rate (Formula 2)
Mixed gas CF
—
0.869
0.894
0.912
0.925
0.934
0.941
0.947
Measured acetone
sccm
13.08
10.05
8.13
6.86
5.98
5.23
4.68
flow rate (Formula 5)
Table 4, Table 5 and Table 6 below respectively show cases in which an acetone flow rate determined by using a pressure ratio (Formula (1) and Formula (2)) is compared with an acetone flow rate determined by using a conversion factor CF (Formula 5), with a flow rate Q 1 of N 2 as a carrier gas G K being changed.
TABLE 4
Flow rate of N 2 : 100 sccm
Internal pressure P 0 of tank
kPaabs
120
150
180
210
240
270
300
100 sccm 20° C.
Partial
sccm
24.99
19.06
15.46
13.00
11.19
9.83
8.76
pressure
acetone flow
rate
CF acetone
sccm
25.91
19.83
16.06
13.60
11.63
10.22
9.10
flow rate
100 sccm 10° C.
Partial
sccm
14.46
11.34
9.30
7.87
6.80
6.03
5.37
pressure
acetone flow
rate
CF acetone
sccm
14.99
11.67
9.55
8.08
6.98
6.18
5.55
flow rate
100 sccm 0° C.
Partial
sccm
8.30
6.61
5.38
4.62
4.01
3.59
3.21
pressure
acetone flow
rate
CF acetone
sccm
8.42
6.64
5.48
4.64
4.02
3.59
3.25
flow rate
100 sccm −10° C.
Partial
sccm
4.36
3.46
2.84
2.43
2.12
1.88
1.70
pressure
acetone flow
rate
CF acetone
sccm
4.37
3.43
2.80
2.42
2.06
1.87
1.67
flow rate
TABLE 5
Flow rate of N 2 : 50 sccm
Internal pressure P 0 of tank
kPaabs
120
150
180
210
240
270
300
50 sccm 20° C.
Partial
sccm
12.43
9.56
7.70
6.44
5.59
4.92
4.36
pressure
acetone flow
rate
CF acetone
sccm
13.08
10.05
8.13
6.86
5.98
5.23
4.68
flow rate
50 sccm 10° C.
Partial
sccm
7.34
5.68
4.67
3.94
3.42
3.02
2.69
pressure
acetone flow
rate
CF acetone
sccm
7.69
6.01
4.93
4.18
3.64
3.24
2.88
flow rate
50 sccm 0° C.
Partial
sccm
4.12
3.25
2.67
2.27
1.99
1.77
1.57
pressure
acetone flow
rate
CF acetone
sccm
4.39
3.43
2.83
2.42
2.12
1.86
1.69
flow rate
50 sccm −10° C.
Partial
sccm
2.21
1.74
1.44
1.23
1.08
0.96
0.86
pressure
acetone flow
rate
CF acetone
sccm
2.35
1.91
1.53
1.33
1.17
1.08
0.94
flowrate
TABLE 6
Flow rate of N 2 : 10 sccm
Internal pressure P 0 of tank
kPaabs
120
150
180
210
240
270
300
10 sccm 20° C.
Partial
sccm
2.53
1.93
1.56
1.30
1.13
0.99
0.88
pressure
acetone flow
rate
CF acetone
sccm
2.84
2.21
1.80
1.53
1.35
1.18
1.05
flow rate
10 sccm 10° C.
Partial
sccm
1.48
1.16
0.94
0.80
0.69
0.61
0.54
pressure
acetone flow
rate
CF acetone
sccm
1.68
1.34
1.11
0.96
0.86
0.76
0.70
flow rate
10 sccm 0° C.
Partial
sccm
0.83
0.65
0.54
0.48
0.40
0.35
0.32
pressure
acetone flow
rate
CF acetone
sccm
0.93
0.73
0.60
0.54
0.46
0.42
0.38
flow rate
10 sccm −10° C.
Partial
sccm
0.45
0.35
0.29
0.25
0.22
0.19
0.17
pressure
acetone flow
rate
CF acetone
sccm
0.55
0.50
0.50
0.41
0.34
0.30
0.30
flow rate
As apparent from the above description as well, where a partial pressure method based on Formula (1) and Formula (2) is used to determine a raw material gas steam flow rate Q 2 and a raw material gas steam concentration K, as a matter of course, a steam pressure curve of raw material (a relationship between the temperature t and steam pressure P M0 ) is required, in addition to a measured flow rate value Q 1 from the mass flow controller 3 , a measurement value of internal pressure P 0 of the tank from the automatic pressure regulating device 8 and a measured flow rate Q S ′ from the mass flow meter 9 as shown in FIG. 1 . Further, the raw material concentration arithmetic unit 10 shown in FIG. 1 is required to store in advance a curve which covers the temperature t of the raw material 4 and the steam P M0 .
Further, also in a case where a CF method according to Formula (5) is used to determine a raw material gas flow rate Q 2 and a raw material gas steam concentration K, it is desirable that conversion factors CFs for various types of raw material gas and various types of mixed gas G S are in advance prepared in a table form.
As a matter of course, the raw material gas steam flow rate Q 2 and the raw material gas steam concentration K which have been described previously are all computed and displayed, etc., on the raw material concentration arithmetic unit 10 shown in FIG. 1 by using a CPU, etc.
Further, as a matter of course, the raw material gas steam concentration K can be raised or lowered by controlling a tank pressure P 0 and/or a tank temperature t.
INDUSTRIAL APPLICABILITY
The present invention is applicable not only to a raw material vaporizing and supplying apparatus used in a MOCVD method and a CVD method but also applicable to any liquid supplying apparatus arranged so as to supply gas from a pressurized storage source to a process chamber in plants for manufacturing semiconductors and chemicals.
DESCRIPTION OF REFERENCE SYMBOLS
1 : carrier gas supply source
2 : decompression unit
3 : mass flow control system
3 a: sensor unit of mass flow controller
3 b: flow rate arithmetic and control unit of mass flow controller
3 e: flow rate display signal
4 : raw material (MO material such as organometallic compound)
5 : source tank (container)
6 : constant temperature unit
7 : induction pipe
8 : automatic pressure regulating device in source tank
8 a: control valve
8 b: pressure arithmetic and control unit
8 c: pressure detection signal
8 d: control valve control signal
8 e: pressure display signal
8 f: temperature detection signal
9 : mass flow meter
9 a: sensor unit of mass flow meter
9 b: arithmetic and control unit of mass flow meter
9 c: mixed gas flow rate detection signal
9 e: display signal of mixed gas flow rate
10 : raw material concentration arithmetic unit
10 K : concentration detection signal
CF: conversion factor of mixed gas
CF A : conversion factor of gas A
CF B : conversion factor of gas B
C: volume ratio of gas A
G K : carrier gas
G: raw material gas
G S : mixed gas
P 0 : internal pressure of source tank
P M0 : raw material steam partial pressure in source tank
Q 1 : carrier gas flow rate
Q S : mixed gas flow rate
Q S ′: detection flow rate of mass flow meter (N 2 -based conversion)
Q 2 : raw material gas flow rate
Q 2 ′: raw material gas flow rate (N 2 -based conversion)
K: raw material gas steam concentration
P: pressure gauge
T: temperature gauge
t: tank temperature (raw material temperature)
|
An apparatus able to regulate a raw material concentration, in a mixed gas of carrier gas and raw material gas, accurately and stably to supply the mixed gas to a process chamber, with a flow rate controlled highly accurately, thereby detecting a vapor concentration of the raw material gas in the mixed gas easily and highly accurately and displaying the concentration in real time without using an expensive concentration meter, etc.
| 5
|
BACKGROUND OF THE INVENTION
The present invention relates to improved method and device for carrying out loggings in an activated nonflowing production well which provides improved measurements.
Various embodiments of a production log method and device for a nonflowing well requiring, for its bringing in, the implementing of activation means and notably for deflected wells, are described in French patent applications FR 2,637,939 and 89/04,225. This method and this device are particularly suitable for wells intended for producing oil containing effluents. It allows determination of the most favourable well portions notably when the wells pass through heterogeneous reservoirs producing oil, but also water and gas. The equipment of a well generally comprises a casing that is kept in position through cementing. A liner perforated on at least part of its length, which is an extension of the casing, is arranged in the total zone intended for the production. This liner can be possibly cemented, the cemented annular space being fitted with passageways linking the production zone to the liner. A flow string consisting of connected successive sections and fitted with centering elements is taken down into the liner. Sealing means are arranged in the annular space between the string and the liner in order to canalize in the string the total effluents produced by the production zone. The well being nonflowing, activation means are associated with the string and taken down into the well to suck up the effluents. These activation means comprise a pump which is driven by an electric or hydraulic motor.
The logging device comprises at least one set of measuring instruments arranged at the base of the flow string in order to measure the features of part of the flows sucked up by the pump. Sealing means are arranged around the string in order to separate in two parts the pipe or liner and to limit the measurements carried out to the effluents coming from only one of these two parts. The device may also comprise two measuring sets to measure separately the features of the flows coming from the two opposite parts of the pipe and homogenization means to mix up the effluents in case of a polyphase production, in order to improve the preciseness of the measurements carried out on the flows. By lengthening or shortening the string, the logging device is displaced in order to perform measurements on the effluents flowing out of the formation in various places of the well towards the inlet of the pump.
One problem still remains which distorts the measurements on the features of the flows. It is the more or less considerable pressure drop caused by each set of measuring instruments located in the flows flowing from the activated production zone, which has the effect of acting upon the flow rates measured in each place of the producing zone. According to whether the effluents come from upstream or downstream of said set, the flowing pressures are different. Besides, because of these pressure drops, an ill-defined part of the effluents tends to bypass the measuring instruments in case of a non cemented liner, and the resulting leak rates are not measured. It is therefore advisable to be able to correct this pressure drop so that the flow rates measured all along the pipe correspond to a substantially constant flowing pressure.
SUMMARY OF THE INVENTION
The improved method according to this invention allows, by avoiding the drawbacks mentioned above, production logs to be obtained in a nonflowing well going through a subterranean zone producing effluents, this well being equipped for the production of these effluents by means of a pipe perforated in a part crossing said subterranean zone. The method comprises the use of a flow string connected with a surface installation, means for closing an annular space between the pipe and the flow string, in order to isolate in relation to one another the two parts of the pipe on either side, pumping means to activate the production of the well through said string and at least one set of measuring instruments operating on at least part of the produced effluents, arranged close to the lower end of the string.
The method also comprises the use of secondary pumping means in order to raise the pressure of the effluents before the effluents are measured in order to take into account the pressure drop undergone by the effluents while the effluents flow through each set of measuring instruments.
The method comprises, for example, the compression of only a part of the produced effluents in order to compensate for said pressure drop.
The method may also comprise the measuring of the variations of the flow rate of the effluents entering each measuring set, according to the overpressure applied by the secondary pumping means, in order to determine the variations of the amounts of effluents going from one side to the other side of the closing means between the well and said perforated pipe.
The improved device according to the invention provides production logs in a nonflowing well going through a subterranean zone producing effluents, this well being equipped for the production of these effluents by means of a pipe perforated in its part passing through said subterranean zone. The device comprises a flow string connected with a surface installation, means for closing the annular space between the pipe and the flow string, in order to isolate, in relation to each other, the two parts of the pipe on either side, pumping means for activating the production of the well through said string and means for measuring at least part of the produced effluents, arranged close to the lower end of the string. It also comprises secondary pumping means with an adjustable flow rate or pressure gain in order to compress at least part of the produced effluents before the effluents are measured, and pressure pick-ups arranged at the inlet of said secondary pumping means and at the outlet of the measuring means.
The secondary pumping means comprise for example, a pump driven by a synchronous motor supplied by an alternating-current generator arranged at the surface, by means of an electric cable.
The secondary pumping means comprise, for example, a positive-displacement pump whose output varies in a well-known way according to its engine speed, and a driving motor whose rotating speed can be adjusted with precision.
According to one embodiment of the invention, the measuring means comprise only one set of instruments to measure the features of the effluents produced on one side of said closing means, said set being associated with secondary pumping means.
According to another embodiment, the device according to the invention comprises two sets of measuring instruments to measure separately the features of the effluents respectively produced in the two parts of the well on either side of the closing means, at least one of these two sets being associated with secondary pumping means.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the method and the device according to the invention will be clear from the following description procedures, given by way of non limitative examples, with reference to the accompanying drawings in which:
FIG. 1 shows an activation and measuring set taken down into a production well fitted with a cemented casing;
FIG. 2 shows an analogous set taken down into a well equipped with a non cemented casing;
FIG. 3 shows the activation and measuring set without a secondary pumping means;
FIG. 4 shows a diagram of the pressures between the inlet and the outlet of the measuring set shown in FIG. 3;
FIG. 5 shows the activation and measuring set combined with secondary pumping means;
FIG. 6 shows an example of a pressure diagram modified by the presence of the secondary pumping means in case of a total compensation for the pressure drop resulting from the passing of the effluents through the set of measuring instruments;
FIG. 7 and 8, respectively, correspond to FIG. 5 and 6 in case of a pressure drop under compensation; and
FIG. 9 and 10, respectively, correspond to FIG. 5 and 6 in case of a pressure drop overcompensation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the production well 1 diagrammatically shown in FIG. 1 or FIG. 2, fluid flow features are to be measured in connection with the formation along the producing part of the well, and these measurements should provide an account of the variations of certain features between different spots of the production zone that is crossed by the well. Well 1 comprises a substantially vertical part 2 and a part 3, substantially horizontal or inclined in relation to the vertical, in which the oil production is carried out under normal operating conditions. In its non producing part, the well is fitted with a casing 4 ending in a shoe 5.
A pipe or liner 6 perforated on at least part of its length is arranged in this production zone. Pipe 6 may be cemented in the well (FIG. 1) or not be cemented (FIG. 2), as the case may be. The flows of fluid coming from the surrounding geologic formation take place during the activation through the perforations of the pipe and/or of the annular space between it and the well.
A string 8 preferably equipped with protectors or centralizers 9 in the deflected and horizontal part of the well is taken down into the well. Means for activating the production, such as a pump 10 and a set of instruments 11 to perform measurements on the flows of fluid outside the formation, such as the flow rate in relation to the curvilinear abscissa along the perforated pipe or the nature of the effluents oil, gas or water, etc, are arranged in this string.
Pump 10 is activated (FIG. 1) by an electric motor supplied by a multiline cable 12 passing through the annular zone 13 located between the string 8 and the casing 4, as well as through the annular zone 14 between the string 8 and the pipe 6. Multiline cable 12 is unwound from a cable drum at the surface (not shown) as the parts that constitute the string 8 are assembled and therefore as the pump 10 is taken down into the well.
The pump may also be supplied with power by a multiline cable 15 (FIG. 2) located within the string 8 and connected to the motor by a bottomhole connector 16 of the delayed connection type such as it is described in French patent 2,544,013. This cable 15 enters the string 8 through a side-entry sub 17.
The wall of the tubular string 8 is solid until the wall reaches the location of pump 10. Here the wall is provided with ports 18 in the space left between the pump and the set of instruments 11. Sealing means 19 of the cup type are, for example, arranged around the string 8 in order to separate from one another the upstream flow coming from part 20 of the formation which is furthest from the surface and the downstream flow coming from the opposite part 21 of the formation.
The upstream flow passes through the set of instruments 11 and, with the downstream flow entering through ports 18, it is collected by pump 10 and discharged towards the surface installation. By adding or removing a certain number of elements from string 8, the set of instruments 11 is displaced to a new location in the well and a series of local measurings can be performed, as described in the French patent applications cited above.
One drawback of this type of installation is the pressure drop Δp undergone by the effluents as the effluents flow through the set of instruments 11 (FIG. 3).
At the outlet of the set of instruments 11 taken as a reference (x=0), the pressure Pav is lower than the pressure Pam at the inlet of the latter at the abscissa x=L (FIG. 4). When pipe 6 is not cemented in the well (FIG. 2), part of the flow coming from the upstream zone 20 tends, because of this pressure drop which may be considerable, to bypass this set of instruments 11 and directly enter the downstream zone by flowing through ports 18. The measurements performed with the set of instruments 11 are therefore not very representative of the real flow rate coming from the upstream zone 20.
The method according to the invention allows to correct the anomalies resulting from this uncontrolled leak rate. It essentially consists in raising the pressure of the upstream effluents entering measuring set 11 enough to compensate for the pressure drop the effluents undergo while flowing through the set. To that effect, a pump 22 driven by variable-speed motor means and controlled from the surface installation is fastened to the end part of the string. It may be, for example, a two-phase or a three-phase electric motor supplied from the surface installation by means of a line included in cable 12 or 15 and connected to an alternating-current generator with a variable frequency (not shown). While changing the frequency of the current, it is possible to modify the rotating speed of pump 22 and thereby to increase or decrease its outlet pressure on demand. Pressure pick-ups 23, 24 are respectively arranged close to the inlet of pump 22 and close to the outlet of the set of measuring instruments 11.
The method according to the invention therefore essentially consists in adjusting the rotating speed of the pump so that the upstream effluents at the pressure Pam1 (abscissa L2) are brought (FIG. 6) up to a pressure PS1=Pam1+Δp before these effluents flow through the measuring instruments.
Because of the pressure drop Δp inherent in the measuring instruments, the pressure of the upstream effluents equals pressure Pam1 towards the inlet of pump 10.
A positive-displacement pump 22 driven by a motor with a variable rotating speed and precisely adjustable on a wide variation range (of the direct-current motor type) is preferably used, and the rotating speed of this pump gives the value of the flow rate of the effluents flowing through it. The flow rate Qam1 entering the positive-displacement pump at abscissa L2 is measured in this case.
Using a pump 22 of this type makes it possible to carry out measurements of leak rates when the effluents bypass the sets of measuring instruments by flowing between perforated pipe 6 and the wall of the well.
If the overpressure imposed by the positive-displacement pump 22 is decreased, the new pressure at its outlet being PS2<PS1, by modifying the adjustment of the main pump 10 in order to maintain a constant pressure Pam1, the pressure drop Δp is compensated only partly and part of the effluents escape towards ports 18 (FIG. 7, 8) and the inlet of lift pump 10 by flowing through the small space between pipe 6 and the well. Leak rate QF2 is determined by comparing the new flow rate Qam2 of the effluents flowing through positive-displacement pump 22 with the previous one Qam1:
QF2=Qam1-Qam2
If the overpressure imposed by positive-displacement pump 22 is increased, with an outlet pressure of P3>P1, and also if the adjustment of the main pump 10 is modified in order to maintain a constant pressure Pam1, part of the effluents coming from downstream (FIG. 9, 10) will bypass the measuring set 11 by flowing between perforated pipe 6 and well 1 and also enter positive-displacement pump 22. In this case, the leak rate QF3 can also be determined by comparing the new flow rate Qam3 and flow rate Qam1:
QF3=Qam3-Qam1
The variation of the rotating speed of pump 22 therefore enables determination of the extent of the leak rates as well as their direction of flow.
The embodiment that is heretofore described only relates to the measurements performed on the upstream effluents after a compression compensating for the pressure drop. It is within the scope of the invention, as it is described in the French patent applications cited above, to measure also the downstream effluents with a second set of instruments. In this case, a previous compression of the effluents coming from the downstream zone is carried out in the same way in another positive-displacement pump of the same type as pump 22, in order to compensate for the pressure drop undergone while flowing through the second set of measuring instruments.
It is also within the scope of the invention to replace the asynchronous electric motor driving positive-displacement pump 22 by a hydraulic motor, a direct-current motor with or without brushes, etc.
|
The method involves introducing a pumping and measuring set into a production well fitted with a pipe or liner perforated in a part extending through a producing zone. This set is fastened to the end of a flow string and comprises an activation pump and at least one set for measuring the produced effluents. The improvement essentially consists in using secondary pumping means such as a positive-displacement type pump, for example, in order to suppress the pressure drop undergone by the effluents during passage through the measuring zone, which distorts the measured values and causes parasitic flows by bypassing between the liner and the wall of well. The extent of these leak rates can be measured through a variation of the flow rate of the positive-displacement pump.
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BACKGROUND OF THE INVENTION
The present invention relates to a fluid heater system, and particularly to a single tank fluid heater system with an exterior temperature sensor.
Instantaneous water heating systems have long been used in applications including, for example, dishwashing in commercial food establishments. There is a tight control window in which the water outlet temperature must be maintained in order to provide safe and consistent operation within a predetermined operating temperature range for a specific application. Maintaining the water outlet temperature within this tight control has been an ongoing problem for this type of heater.
U.S. Pat. No. 4,638,944 (the '944 patent), which is incorporated herein by reference, is directed to one solution to the temperature control problem. Specifically, the '944 patent addressed the problem of temperature control in a compact, high volume point of use instantaneous water heating system by using two individual water heaters, each with an "instantaneous" burner, heat exchanger, and an exterior temperature sensor. The burners of the instantaneous heaters would alternate between high and low heat asynchronously. The '944 system provides a consistently controlled outlet temperature by averaging four variables: the temperature within the lower portion of the accumulator tank measured by a thermostat therein; the temperature at the outlet of the first heat exchanger; the temperature at the outlet of the second heat exchanger; and the water flow through the entire unit.
The use of the dual heaters operating asynchronously as described in the '944 patent helped to permit the use of a smaller-sized accumulator tank adjacent the use point, since no large accumulator volume is required to smooth out water temperature fluctuations. However, to properly control temperatures, dual heaters were absolutely necessary because the burners known at that time were not capable of actual instantaneous heating requiring a short heat up time period. Further, the temperature sensors that existed at the time at which the '944 patent was applied for were neither quick nor accurate over time, resulting in poor reliability.
Although the '944 system contemplates a single auxiliary heater, the advantages associated with temperature control would be decreased, because the dual heaters are needed for averaging and accuracy.
What is needed, therefore, is a point of use instantaneous water heating system that is able to provide hot water on demand at a temperature within a predetermined tight control window.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to a heating system that takes advantage of the improvements in technology related to heaters and temperature sensors. Preferably, a single, quick, accurate external temperature sensor and a single, quick, accurate instantaneous heater, such as an IR gas burner, can be used to create a heater system that is more reliable, requires less field service, and has lower costs associated with parts, assembly, and calibration than previously known systems. The heating system of the present invention also eliminates the need for averaging variables to control output temperature.
Specifically, a fluid heating system of the present invention preferably includes a fluid source, a use point for intermittently demanding fluid from the fluid source, at least one instantaneous IR gas heater, and a temperature sensor positioned external to the heater. The instantaneous IR gas heater is preferably interposed operatively between the fluid source and the use point for heating fluid from the fluid source instantaneously and delivering fluid substantially immediately after heating to the use point during periods of demand. The temperature sensor preferably controls the regulation of the heater in response to output fluid temperature.
The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE is a schematic diagram of an exemplary point of use instantaneous water heating system constructed according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The water heating system of the present invention provides hot water to a use point 10 from a relatively small accumulator tank 12. The accumulator tank 12 is fed by an ancillary, high-energy instantaneous water heater 14 heated by an internal IR gas burner 16. The IR gas burner 16 may be a ceramic fiber type as provided by Solaronics, Inc. or another suitable IR gas burner. Water is provided to the ancillary water heater by one or more pressure boosting pumps such as pump 18, connected to a water input line 20 leading from a standard hot water heater 22 which is a source of water for the system. Water is also recirculated from the accumulator 12 through line 36 and pump 18 to the heater.
The accumulator tank 12 includes an interior baffle 24 which is a wall or partition separating a top portion 26 of the accumulator tank 12 from a bottom portion 28. The baffle 24 will create temperature stratification of the water held within the accumulator tank 12. In general, the hotter water which is fed to the accumulator tank from the heater 14 through line 30 will be concentrated in the top portion of the tank 26, whereas the bottom portion of the tank 28 will be a zone of relatively low temperature (although it will normally be hotter than water from the standard water heater 22). This would normally be the case even without the baffle 24 since the hotter water tends to rise to the top; however, the baffle 24 increases the degree of stratification of the water temperature, creating two distinct zones instead of a gradual temperature gradient and reducing thermosyphon currents which tend to equalize tank temperatures. The baffle 24 has an aperture 32 which allows fluid communication through a tee fitting 33 between the top portion 26 and the bottom portion 28. Disposed close to the aperture 32 is a conventional microprocessor-controlled thermostat 34. Thermostat 34, which may be either above or below the baffle 24, controls the operation of pump 18. The accumulator tank recirculation line 62 leads from the zone of relatively low temperature in the bottom portion 28 of the accumulator to the water input line 20 through an optional restriction 38 or similar valving arrangement.
The heater 14 is heated by an IR gas burner 16 located within 9 heat exchanger. The IR gas burner 16 receives gas from gas source 40 of natural gas, LPG, or LNG. Gas source 40 is controlled by respective modulating valve arrangements consisting of a valve 42a and a restriction 46b, as well as by the primary valve 42c. The primary valve 42c is controlled in response to a decreased temperature in the accumulator sensed by thermostat 34. The modulating valve 42a is controlled by temperature sensor 54 located immediately external to the heater at the output 50 of the heater, and modulates the gas supply by opening in response to output water temperature decreasing below a predetermined limit, and closing in response to output water temperature increasing above a predetermined limit. When the modulating valve 42a is closed, a reduced flow of gas is permitted through restriction 42b. Thermostat 34 deactivates the pump 18 in response to sufficiently high water temperature sensed at the accumulator thermostat 34, and also deactivates heater 14 by closing primary valve 42c. The heater also includes a conventional pressure and temperature safety relief valve 58 which may be located in the heater output line 30 and/or the accumulator tank 12.
There are two fundamental modes of operation of the system. In both cases, however, it is important that water at a predetermined temperature be available for instantaneous use at the use point 10. In the first mode of operation, which may be termed the "no-demand" mode, there is little or no demand at the use point 10 and the system must, by recirculation, maintain the temperature of the water in the accumulator tank 12 so as to be ready for instantaneous use. In the second, or "demand," mode of operation there is constant or intermittent demand at the use point 10, and there is little or no recirculation in the accumulator tank 12.
In either case, the thermostat 34 is set to actuate pump 18 at a predetermined minimum temperature lower than the desired temperature of the water to be delivered to the use point 10. This is because of the low position of the thermostat 34 in the tank and the fact that there will always be stratification of the temperature of the water held within the accumulator tank. When the thermostat 34 senses the accumulator water temperature dropping below the predetermined minimum, either due to normal accumulator heat loss or due to demand at the use point 10 while the pump 18 is deactivated (the latter drawing cooler water into the bottom of the accumulator through recirculation conduit 36 while hot water is discharged to the use point from the top of the accumulator through pipe 53), it actuates pump 18. The pump draws water from either recirculation line 36 or input line 20, or a combination of both, depending upon water pressure in and flow through the tank 12 (which in turn depends on the presence or absence of demand at the use point). Restriction 38 serves to create priority of flow from the standard water heater 22 over that recirculating from the tank 12. However, during periods of no demand when the pump 18 is activated, the pressure in line 36, even with restriction 38, will be higher than the pressure in line 20, and therefore the pump 18 will draw water from recirculation line 36. On the other hand, in the "demand" mode the pressure in the tank 12 will not normally be enough to override the pressure from the standard water heater 22, and water will be drawn from the standard heater 22 until demand ceases. This priority arrangement, the placement and setting of the thermostat 34, and the baffle 24, all contribute toward insuring that the heater 14 always receives the lowest temperature water available so as to minimize the danger of super heating.
When pump 18 is actuated by thermostat 34, water is pumped into line 62. Gas ignition control is energized and valve 42c is opened, providing gas for ignition. Thereafter gas flow is modulated by valve 42a in response to heater output temperature sensor 54 to maintain the output temperatures from the heater within the desired range. Water is pumped into heater 14 by pump 18 where it is heated substantially instantaneously by IR gas burner 16, and is then supplied through heater output line 50 to the water input line 30 of accumulator tank 12. In the "no demand" mode, the heated water is stored in the tank 12, replacing cooler water recirculated back to the heater 14 through line 36. In contrast, in the "demand" mode, the heated water is immediately transferred to the use point 10 through line 53 due to its proximity to the line 30. (In the demand mode, the water could alternatively be transferred directly through a line such as 30a, bypassing the accumulator tank 12 and rendering line 53 unnecessary.)
One of the crucial features of the water heating system of the present invention is the accuracy of the temperature control. Accordingly, like thermostat 34, output temperature sensor 54 is a conventional micro-processor controlled thermostat. Using a single external output temperature sensor has many advantages. Specifically, the more reliable temperature sensor allows valve 42a to cycle much more rapidly, providing closer temperature control comparable to that obtainable from the rapidly cycling IR gas burner 16. Moreover, the temperature sensor requires less field service, and has lower costs associated with parts, assembly, and calibration.
It should be noted that the system described above with a single ancillary water heater may be fitted with one or more additional ancillary water heaters. If two water heaters are used, the dual ancillary water heaters would function in much the same manner as the dual water heaters described in the '944 patent, the disclosure of which is incorporated herein by reference.
The system described above utilizes water as the fluid to be used at the use point 10. However, this system may be used for any fluid which may have to be heated and made available for instantaneous use, and is therefore not limited to applications calling for water.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims that follow.
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An instantaneous fluid heating system includes a fluid source, a use point for intermittently demanding fluid from the fluid source, an instantaneous IR gas heater, and a temperature sensor positioned external to the heater. The instantaneous IR gas heater is interposed operatively between the fluid source and the use point. The temperature sensor controls the regulation of the heater in response to output fluid temperature.
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FIELD
The present disclosure relates to a method for balancing a propshaft assembly.
BACKGROUND
This section provides background information related to the present disclosure which is not necessarily prior art.
Various techniques are known for balancing propshaft assemblies, including the welding or adhesive bonding of weights to the propshaft assembly at one or more locations that are identified when the propshaft is rotated about its longitudinal axis. While such processes are suited for their intended purpose, there remains a need in the art for an improved propshaft balancing technique.
For example, a significant delay time is needed when balance weights are welded to a metallic tube of a propshaft to permit the weld to cool and solidify. A longer delay is typically required for adhesive curing when adhesive materials are employed to bond a balance weight to a metallic tube of a propshaft assembly. Such delays can be disadvantageous in high volume production as they tend to limit throughput through the equipment that is used to check the rotational balance of a propshaft assembly. Moreover, as the equipment that is used to check the rotational balance of a propshaft assembly can be very expensive, it would be desirable to improve capacity (when increased capacity is desired) without the need for purchasing additional balance checking equipment. Accordingly, an improved method for balancing a propshaft assembly is needed in the art.
SUMMARY
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
In one form, the present disclosure provides a method that includes: providing a thin-walled tube; forming first and second sets of balancing holes radially through the thin-walled tube, wherein the balancing holes of the first set of balancing holes are spaced circumferentially apart from one another in a first predetermined manner and wherein the balancing holes of the second set of balancing hole are spaced circumferentially apart from one another in a second predetermined manner; coupling universal joints to opposite ends of the thin-walled tube after the first and second sets of balancing holes have been formed radially through the thin-walled tube; circumferentially relating at least one rotational imbalance to one of the balancing holes of the first and second sets of balancing holes; determining an imbalance correction to correct for the at least one rotational imbalance, the imbalance correction comprising a set of correction weights and a mapping of the correction weights to the balancing holes of the first and second sets of balancing holes, the mapping of the correction weights matching a specific one of the balance weights to a specific one of the balance holes of the first and second sets of balance holes, wherein each specific one of the correction weights has a mass that is tailored to the specific one of the balance holes; and installing the specific ones of the correction weights according to the mapping to form a balanced shaft assembly.
In another form, the present disclosure provides a method that includes: providing a first quantity (n) of thin-walled tubes; forming a second quantity (n+1) of sets of balancing holes in the first quantity (n) of thin-walled tubes, wherein the second quantity (n+1) is one (1) more than the first quantity (n), each set of balancing holes comprising balancing holes that are spaced circumferentially apart from one another in a predetermined manner; coupling universal joints to opposite ends of each of the thin-walled tubes after the sets of balancing holes have been formed radially through the thin-walled tubes to form a shaft assembly, the universal joints coupling each of the thin-walled tubes to one another; circumferentially relating at least one rotational imbalance of the shaft assembly to at least one set of the balancing holes; determining an imbalance correction to correct for the at least one rotational imbalance, the imbalance correction comprising a set of correction weights and a mapping of the correction weights to the balancing holes of the at least one set of balancing holes, the mapping of the correction weights matching a specific one of the balance weights to a specific one of the balance holes of the second quantity (n+1) of sets of balancing holes, wherein each specific one of the correction weights has a mass that is tailored to the specific one of the balance holes; and installing the specific ones of the correction weights according to the mapping to form a balanced shaft assembly.
In still another form, the present disclosure provides a method that includes: providing a thin-walled tube; coupling first and second universal joints to opposite ends of the thin-walled tube, the first universal joint having a first yoke portion that is welded to a first end of the thin-walled tube, the second universal joint having a second yoke portion that is welded to a second end of the thin-walled tube, each of the first and second yoke portions having a plurality of discrete added mass sections; circumferentially relating at least one rotational imbalance to the added mass sections of the first and second yoke portions; determining an imbalance correction to correct for the at least one rotational imbalance, the imbalance correction comprising a set of mass reductions and a mapping of the mass reductions to the added mass sections, the mapping of the mass reductions matching a specific one of the mass reductions to a specific one of the added mass sections such that a mass of each specific one of the mass reductions is tailored to the specific one of the added mass sections; and machining the specific ones of the added mass sections to remove material corresponding to the mapping of the mass reductions to the added mass sections to thereby form a balanced shaft assembly.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is a partly sectioned side elevation view of a first propshaft assembly constructed in accordance with the teachings of the present disclosure;
FIG. 2 is a side elevation view of a portion of the first propshaft assembly of FIG. 1 , illustrating a thin-walled tube in more detail;
FIG. 3 is a section view taken along the line 3 - 3 of FIG. 2 ;
FIG. 4 is a section view taken along the line 4 - 4 of FIG. 2 ;
FIG. 5 is a partial lateral section view of the first propshaft assembly taken through the tube illustrating a first manner for coupling a correction weight to the tube;
FIG. 6 is a view similar to that of FIG. 5 but illustrating a second manner for coupling a correction weight to the tube;
FIG. 7 is a partly sectioned side elevation view of a second propshaft assembly constructed in accordance with the teachings of the present disclosure;
FIG. 8 is a section view taken along the line 8 - 8 of a portion of the second propshaft assembly of FIG. 7 , the view illustrating the construction of a second tube;
FIG. 9 is a partly sectioned side elevation view of a third propshaft assembly constructed in accordance with the teachings of the present disclosure; and
FIG. 10 is a section view taken along the line 10 - 10 of FIG. 9 .
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
With reference to FIG. 1 of the drawings, a propshaft assembly constructed in accordance with the teachings of the present disclosure is generally indicated by reference numeral 10 . The propshaft assembly 10 comprises a tube 12 , a first universal joint 14 , a second universal joint 16 , and a set of correction weights 18 . The first and second universal joints 14 and 16 can be any type of universal joint, such as a Cardan joint.
With reference to FIGS. 2 and 3 , the tube 12 can be a relatively thin-walled tube that can be formed of a suitable material, such as aluminum or steel. First and second sets of balancing holes 20 and 22 , respectively, can be formed in the tube 12 . The first set of balancing holes 20 can comprise a predetermined first quantity of balancing holes 24 , such as three or four holes, that can be spaced circumferentially about the tube 12 at a first predetermined circumferential spacing (e.g., a first spacing angle A 1 ) and located at a first radial offset 30 from a predetermined radial datum 32 and a first longitudinal offset 34 from a predetermined longitudinal datum 36 . For example, the first spacing angle A 1 can be 120 degrees in a situation where the first quantity of balancing holes 24 is three in number, and can be 90 degrees in a situation where the first quantity of balancing holes 24 is four in number. Those of skill in the art will appreciate, however, that the balancing holes 24 of the first set of balancing holes 20 can be spaced apart from one another in any desired manner and that a spacing angle that is common to all of the balancing holes 24 of the first set of balancing holes 20 need not be employed.
With reference to FIGS. 2 and 4 , the second set of balancing holes 22 can comprise a predetermined second quantity of balancing holes 24 , such as three or four balancing holes 24 , that can be spaced circumferentially about the tube 12 at a second predetermined circumferential spacing (e.g., a second spacing angle A 2 ) and located at a second radial offset 38 from the predetermined radial datum 32 and a second longitudinal offset 40 from the predetermined longitudinal datum 36 . For example, the second spacing angle A 2 can be 120 degrees in a situation where the second quantity of balancing holes 24 is three in number, and can be 90 degrees in a situation where the second quantity of balancing holes 24 is four in number. Those of skill in the art will appreciate, however, that the balancing holes 24 of the second set of balancing holes 22 can be spaced apart from one another in any desired manner and that a spacing angle that is common to all of the balancing holes 24 of the second set of balancing holes 22 need not be employed. Those of skill in the art will further appreciate that the second quantity of balancing holes 24 can be equal to or different from the first quantity of balancing holes 24 . The second predetermined circumferential spacing can be equal to or different from the first predetermined circumferential spacing (e.g., the first spacing angle can be equal to or different from the second spacing angle). The first and second radial offsets 30 and 38 can be equal so that the balancing holes 24 of the first and second sets of balancing holes 20 and 22 can be disposed in lines that are parallel to a longitudinal axis 42 of the tube 12 . In situations where the quantity of balancing holes 24 of the second set of balancing holes 22 is equal to the quantity of balancing holes 24 of the first set of balancing holes 20 , the first and second spacing angles can be equal. The first and second longitudinal offsets 34 and 40 can be different so as to place balancing holes 24 of the first and second sets of balancing holes 20 and 22 at opposite ends of the tube 12 . The balancing holes 24 of the first and second sets of balancing holes 20 and 22 can be deburred on one or both circumferential sides of the tube 12 .
Returning to FIG. 1 , the first universal joint 14 can comprise a first end cap 50 , a first yoke 52 , a second yoke 54 , a first bearing system 56 and a slip coupling 58 . The first end cap 50 can be fixedly coupled to a first end of the tube 12 and configured to close or substantially close the first end of the tube 12 . In the particular example provided, the first end cap 50 is welded to the first end of the tube 12 . The first yoke 52 can comprise a pair of yoke arms that can be fixedly coupled (e.g., integrally formed) with the first end cap 50 . The second yoke 54 can comprise a pair of yoke arms that can be fixedly coupled (e.g., integrally formed) with the slip coupling 58 . The slip coupling 58 can be configured to slidably but non-rotatably engage a power transmitting shaft, such as an output shaft (not shown) of a transmission (not shown). The first bearing system 56 can comprise a cross-trunnion (not specifically shown), a plurality of bearing assemblies (not specifically shown) and a plurality of bearing retainers (not specifically shown). The cross-trunnion is conventional in its configuration and defines four trunnions (not specifically shown) that are circumferentially spaced apart from one another at ninety degree intervals. Each of the bearing assemblies can comprise a bearing cup (not specifically shown), which is configured to be received in a cup aperture (not specifically shown) in an associated one of the yoke arms, and a plurality of bearing elements (not specifically shown) that can be disposed between an inside surface of the bearing cup and a surface of a corresponding one of the trunnions. Prior to coupling the first universal joint 14 to the tube 12 , the first universal joint 14 can be oriented in a desired manner relative to the predetermined radial datum 32 or to one of the balancing holes 24 of the first and second sets of balancing holes 20 and 22 .
The second universal joint 16 can comprise a second end cap 60 , a third yoke 62 , a fourth yoke 64 , a second bearing system 66 and a yoke flange 68 . The second end cap 60 can be fixedly coupled to a second end of the tube 12 and configured to close or substantially close the second end of the tube 12 . In the particular example provided, the second end cap 60 is welded to the second end of the tube 12 . The third yoke 62 can comprise a pair of yoke arms that can be fixedly coupled (e.g., integrally formed) with the second end cap 60 . The fourth yoke 64 can comprise a pair of yoke arms that can be fixedly coupled (e.g., integrally formed) with the yoke flange 68 . The yoke flange 68 can be configured to be fixedly but removably coupled to a power transmitting shaft, such as an input pinion (not shown) of an axle assembly (not shown). The second bearing system 66 can comprise a cross-trunnion (not specifically shown), a plurality of bearing assemblies (not specifically shown) and a plurality of bearing retainers (not specifically shown). The cross-trunnion is conventional in its configuration and defines four trunnions (not specifically shown) that are circumferentially spaced apart from one another at ninety degree intervals. Each of the bearing assemblies can comprise a bearing cup (not specifically shown), which is configured to be received in a cup aperture (not specifically shown) in an associated one of the yoke arms, and a plurality of bearing elements (not specifically shown) that can be disposed between an inside surface of the bearing cup and a surface of a corresponding one of the trunnions. Prior to coupling the second universal joint 16 to the tube 12 , the second universal joint 16 can be oriented in a desired manner relative to the predetermined radial datum 32 or to one of the balancing holes 24 of the first and second sets of balancing holes 20 and 22 .
With reference to FIGS. 1 and 2 , the set of correction weights 18 can comprise a plurality of correction weights 70 that are coupled to the tube 12 at locations corresponding to the locations of the balancing holes 24 of the first and second sets of balancing holes 20 and 22 . The mass of each of the correction weights 70 is selected based upon the location of the balancing hole 24 of the first and second sets of balancing holes 20 and 22 and the magnitude and location of the rotational imbalance of the propshaft assembly 10 . More specifically, each of the correction weights 70 is configured to be matched to a specific one of the balancing holes 24 so that the set of correction weights 18 cooperate to form an imbalance correction that at least substantially cancels out a rotational imbalance of the propshaft assembly 10 prior to the installation of the set of correction weights 18 (hereafter referred to as “the unbalanced propshaft assembly”).
In this regard, at least one rotational imbalance of the unbalanced propshaft assembly is determined and is circumferentially related to at least one of the balancing holes 24 of the first and second sets of balancing holes 20 and 22 . An imbalance correction is determined to correct for the at least one rotational imbalance. The imbalance correction comprises the set of correction weights 18 and a mapping of the correction weights 70 to the balancing holes 24 of the first and second sets of balancing holes 20 and 22 . The mapping of the correction weights 70 to the balancing holes 24 of the first and second sets of balancing holes 20 and 22 matches a specific one of the correction weights 70 to a specific one of the balancing holes 24 of the first and second sets of balancing holes 20 and 22 so that each of the correction weights 70 has a mass that is tailored to the location on the unbalanced propshaft assembly that corresponds to the specific one of the balancing holes 24 . It will be appreciated that the mapping is configured to provide a location of each of the correction weights 70 in a predetermined manner relative to the predetermined radial datum 32 and the predetermined longitudinal datum 36 .
Minimally, each correction weight 70 can comprise a fastener 80 that is configured to be received into the balancing hole 24 and sealingly engaged to the tube 12 . The fasteners 80 can be any type of fastener, and can be secured to the tube 12 via permanent deformation of the fastener 80 as shown in FIG. 5 , which depicts the fastener 80 as a rivet, or through resilient (elastic) deformation of the fastener 80 as shown in FIG. 6 , which depicts the fastener 80 as having at least one resilient element 86 that is configured to be pushed through the thin-walled tube 12 such that the resilient element(s) 86 of each fastener is/are engaged to an interior surface 88 of the thin-walled tube 12 to thereby secure the fasteners 80 to the thin-walled tube 12 . Returning to FIGS. 1 and 2 , the fastener 80 can alternatively be a threaded fastener that is configured to threadably engage the tube 12 and configured to substantially seal a corresponding one of the balancing holes 24 . In the particular example provided, the threaded fasteners comprise self-tapping fasteners that are removably coupled to the tube 12 .
Each correction weight 70 may additionally comprise a mass member 90 that can be secured to the tube 12 via the fastener 80 . The mass member 90 can have a mass that is sized or selected based upon the location of its associated balancing hole 24 and the magnitude and location of the rotational imbalance of the propshaft assembly 10 . In situations where the mass member 90 is selected, those of skill in the art will appreciate that the mass member 90 could be selected from a group of mass members 90 having different but predetermined masses (e.g., the group of mass members 90 can comprise a mass member 90 having a mass of 5 grams, a mass member 90 having a mass of 10 grams, a mass member 90 having a mass of 15 grams and a mass member 90 having a mass of 20 grams).
Generally speaking, the masses of the correction weights 70 (i.e., the fasteners 80 and the mass members 90 ) is configured to create an imbalance correction that will at least substantially cancel out the rotational imbalance of the unbalanced propshaft assembly. The use of threaded fasteners as the fasteners 80 that secure the mass members 90 to the tube 12 is advantageous in that it permits disassembly of one or more of the correction weights 70 in the event that it is necessary to modify the correction imbalance. Moreover, the use of threaded fasteners permits the propshaft assembly 10 to be rotationally balanced after the tube 12 and the first and second universal joints 14 and 16 have been painted.
Accordingly, a method for balancing the unbalanced propshaft assembly can comprise: providing a thin-walled tube 12 ; forming first and second sets of balancing holes 20 and 22 radially through the thin-walled tube 12 , wherein the balancing holes 24 of the first set of balancing holes 20 are spaced circumferentially apart from one another in a first predetermined manner and wherein the balancing holes 24 of the second set of balancing holes 22 are spaced circumferentially apart from one another in a second predetermined manner; coupling first and second universal joints 14 and 16 to opposite ends of the thin-walled tube 12 after the first and second sets of balancing holes 20 and 22 have been formed radially through the thin-walled tube 12 ; circumferentially relating at least one rotational imbalance to one of the balancing holes 24 of the first and second sets of balancing holes 20 and 22 ; determining an imbalance correction to correct for the at least one rotational imbalance, the imbalance correction comprising a set of correction weights 18 and a mapping of the set of correction weights 18 to the balancing holes 24 of the first and second sets of balancing holes 20 and 22 , the mapping of the set of correction weights 18 matching a specific one of the correction weights 70 to a specific one of the balancing holes 24 of the first and second sets of balancing holes 20 and 22 , wherein each specific one of the correction weights 70 has a mass that is tailored to the specific one of the balancing holes 24 ; and installing the specific ones of the correction weights 70 according to the mapping to form a balanced shaft assembly 10 .
It will be appreciated that the method of the present disclosure has application to propshaft assemblies having more than one tube, such as the propshaft assembly 10 a of FIG. 7 . In this example, the propshaft assembly 10 a additionally includes a second tube 12 a and a third universal joint 100 , and both the second universal joint 16 a and the set of correction weights 18 a are modified somewhat from the configuration that was discussed above.
The second universal joint 16 a can be configured with a third end cap 102 instead of the yoke flange. The third end cap 102 can be fixedly coupled to the second tube 12 a so that the second universal joint 16 a directly couples the tube 12 to the second tube 12 a . The set of correction weights 18 a can be generally similar to the set of correction weights 18 ( FIG. 1 ) discussed above, except that it can include additional correction weights 70 that are configured for use with the second tube 12 a.
With reference to FIGS. 7 and 8 , the second tube 12 a can be a relatively thin-walled tube that can be formed of a suitable material, such as aluminum or steel. A third set of balancing holes 110 can be formed in the tube 12 a . The third set of balancing holes 110 can comprise a predetermined third quantity of balancing holes 24 , such as three or four holes, that can be spaced circumferentially about the tube 12 at a third predetermined circumferential spacing (e.g., a third spacing angle) and located at a third radial offset 112 from the predetermined radial datum 32 and a third longitudinal offset 114 from the predetermined longitudinal datum 36 . The third quantity of balancing holes 24 can be equal to or different from the first quantity of balancing holes 24 and/or the second quantity of balancing holes 24 . The third predetermined circumferential spacing can be equal to or different from the first predetermined circumferential spacing (e.g., the first spacing angle A 1 ( FIG. 3 ) can be equal to or different from the third spacing angle A 3 ) and/or the third predetermined circumferential spacing can be equal to or different from the second predetermined circumferential spacing (e.g., the second spacing angle A 2 ( FIG. 4 ) can be equal to or different from the third spacing angle A 3 ). The third radial offset 112 can be equal to the first radial offset 30 ( FIG. 3 ) and the second radial offset 38 ( FIG. 4 ) so that the balancing holes 24 of the first, second and third sets of balancing holes 20 , 22 and 110 can be disposed in lines that are parallel to a longitudinal axis 42 of the tube 12 in situations where the quantity of balancing holes 24 of the first, second and third sets of balancing holes 20 , 22 and 110 are equal and the first, second and third spacing angles A 1 ( FIG. 3 ), A 2 ( FIG. 4 ) and A 3 ) are equal. The third longitudinal offset 114 can be configured to place the balancing holes 24 of the third set of balancing holes 110 at an end of the second tube 12 a that is proximate the third universal joint 100 . The balancing holes 24 of the third set of balancing holes 110 can be deburred on one or both circumferential sides of the second tube 12 a.
The third universal joint 100 can be any type of universal joint, such as a Cardan joint. In the particular example provided, the third universal joint 100 is configured in a manner that is similar to that of the second universal joint 16 ( FIG. 1 ). Accordingly, other than merely noting that its (second) end cap 60 is fixedly coupled to the tube 12 a on an end opposite the end to which the second universal joint 16 a is coupled, a detailed discussion of the configuration of the third universal joint 100 need not be provided herein.
Accordingly, a method for balancing the unbalanced, multi-tube propshaft assembly can comprise: providing a first quantity (n) of thin-walled tubes; forming a second quantity (n+1) of sets of balancing holes in the first quantity (n) of thin-walled tubes, wherein the second quantity (n+1) is one (1) more than the first quantity (n), each set of balancing holes comprising balancing holes that are spaced circumferentially apart from one another in a predetermined manner; coupling universal joints to opposite ends of each of the thin-walled tubes after the sets of balancing holes have been formed radially through the thin-walled tubes to form a shaft assembly, the universal joints coupling each of the thin-walled tubes to one another; circumferentially relating at least one rotational imbalance of the shaft assembly to at least one set of the balancing holes; determining an imbalance correction to correct for the at least one rotational imbalance, the imbalance correction comprising a set of correction weights and a mapping of the correction weights to the balancing holes of the at least one set of balancing holes, the mapping of the correction weights matching a specific one of the balance weights to a specific one of the balance holes of the second quantity (n+1) of sets of balancing holes, wherein each specific one of the correction weights has a mass that is tailored to the specific one of the balance holes; and installing the specific ones of the correction weights according to the mapping to form a balanced shaft assembly.
While the above-referenced discussion has focused on the addition of (correction) weights to the tube(s) of a propshaft assembly to create an imbalance correction that reduces or eliminates at least one rotational imbalance, it will be appreciated that the invention, in its broadest aspects, could be configured somewhat differently. With reference to FIGS. 9 and 10 for example, the unbalanced propshaft assembly could be configured with a plurality of added mass sections 200 (i.e., sections or portions of a tube or universal joint having mass that is included for use in rotationally balancing the propshaft assembly 10 b ). In the particular example provided, the added mass sections 200 are formed on the first and second universal joints 14 b and 16 b and the tube 12 b and the imbalance correction is defined by a plurality of mass reductions 202 that are mapped to the added mass sections 200 . Each of the mass reductions 202 involves a removal of mass from a corresponding one of the added mass sections 200 to create the imbalance correction. Removal of mass may be achieved via machining, such as drilling or milling.
Accordingly, a method for balancing the unbalanced, propshaft assembly can comprise: providing a thin-walled tube 12 ; coupling first and second universal joints 14 b and 16 b to opposite ends of the thin-walled tube 12 , the first universal joint 14 b having a first yoke portion that is welded to a first end of the thin-walled tube 12 b , the second universal joint 16 b having a second yoke portion that is welded to a second end of the thin-walled tube 12 b , each of the first and second yoke portions having a plurality of discrete, circumferentially spaced apart added mass sections 200 ; circumferentially relating at least one rotational imbalance to the added mass sections 200 of the first and second yoke portions; determining an imbalance correction to correct for the at least one rotational imbalance, the imbalance correction comprising a set of mass reductions 202 and a mapping of the mass reductions 202 to the added mass sections 200 , the mapping of the mass reductions 202 matching a specific one of the mass reductions 202 to a specific one of the added mass sections 200 such that a mass of each specific one of the mass reductions 202 is tailored to the specific one of the added mass sections 200 ; and machining the specific ones of the added mass sections 200 to remove material corresponding to the mapping of the mass reductions 202 to the added mass sections 202 to thereby form a balanced shaft assembly 10 b.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
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Methods for correcting a rotational imbalance of a shaft are disclosed. The methods include determining a rotational imbalance of an unbalanced shaft, determining an imbalance correction and mapping the imbalance correction to predetermined points on the shaft. The imbalance correction can be implemented through the addition of mass to or the subtraction of mass from the shaft.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to light bulb assemblies for vehicles, and in particular, concerns taillight assembly for an automobile wherein a light emitting diode assembly is mounted within a durable water-resistant structure that is used in conjunction with existing light bulb mounts present in the automobile.
2. Description of the Related Art
Light generating sources for automobiles typically comprise an assembly wherein an incandescent light bulb is mounted within a mounting apparatus further comprising a base, which may be reflective, and a light-transmissive cover, which may be tinted to produce a particular illuminated color. Prior art light assemblies are often large and bulky in nature, especially in the case where a reflector is used to direct and intensify the light source.
Another limitation of existing incandescent light sources employing evacuated glass bulbs with tungsten filaments or higher intensity halogen-based light sources is that they typically only produce one hue of white light. As a result, in order to obtain variations in color of the light, the glass of the bulb must be tinted or a light-transmissive cover having a tint must be used. However, the appearance of the tinted covers of tail light assemblies may not be a desired appearance by all vehicle owners, particularly if the tail light assembly requires significant amounts of red material.
Further, most rear tail light assemblies on vehicles require both red warning lights and white back up lights. As the incandescent light sources provide only a single hue of white light, the tail light assembly must have both red and white tinted light transmissive covers over the light sources. This increases the overall size and cost of the tail light assembly as it requires multiple shades of light transmissive covers.
A further difficulty that occurs with existing tail light assemblies is that the assemblies can become dirty which inhibits the light transmissive properties of the cover. With the particular example of a brake light, if the light transmissive cover becomes too dirty, the cover transmit less light which makes the brake lights harder to see by oncoming vehicles. This problem is particularly exacerbated with red brake light assemblies as the red plastic comprising the cover is already dark in color and is more easily occluded.
To address this problem, most incandescent light used in brake light assemblies are high intensity lights such that the brake lights will adequately illuminate the cover even when the cover is dirty. These high intensity lights, however, have comparatively low lifespans as they are operating at such a high intensity. When the light sources burn out, the risk to the driver of the vehicle is increased as the brake light is no longer visible to oncoming traffic.
One possible solution to this problem is to use LED light sources, which illuminate in a red color and have longer lifespans. One example of an LED light source is illustrated in U.S. Pat. No. 5,947,588 to Huang. In this patent, an LED light source is positioned within a cover and is connected to an existing incandescent-style mounting location. While the LED light source in the '588 patent can illuminate the cover with red light, it is not readily adapted for use as an aftermarket replacement to existing incandescent lights in vehicle applications.
Specifically, the '588 patent discloses the LED light source being positioned within a cover such that the printed circuit board is positioned exposed within the cover space. This results in the circuitry that operates the LEDs being exposed to water and dirt that enters the space beneath the cover. One problem that occurs in the covered space in which the light bulbs are positioned is that water vapor can condense within the covered space. In the device disclosed in the '588 patent, water can thus condense on the electronic circuitry of the LED light source thereby damaging the circuitry and potentially causing the failure of the light.
Hence, there is a need for an improved light source that has longer life and produces light in a desired hue that is less affected by occlusion of the colored covers covering the light. To this end, there is a need for an LED light source that is better protected from the elements and thus able to provide light in a red hue for a longer period of time.
SUMMARY OF THE INVENTION
The aforementioned needs are satisfied by the LED assembly of the present invention which, in one aspect, comprises a replacement light assembly for a vehicle that has a circuit board having a first and a second side with a plurality of LEDs mounted on a first side of the circuit board and at least one electrical components coupled to the plurality of LEDs wherein the at least one electrical components are connected to the second side of the circuit board. The assembly further includes a housing that defines a recess wherein the circuit board is mounted within the housing such that the circuit board and the housing define an enclosed space so that the second side of the circuit board is positioned within the enclosed space separate from the LEDs themselves and is thereby more protected from the elements. In this aspect, the light assembly includes a plug member that is connected to the housing which is adapted to fit in a receptacle in the vehicle, wherein the at least one wire extends through the plug member so as to be coupled with electrical connectors positioned within the receptacle of the vehicle.
Since the electrical components of the circuit board are positioned within an enclosed space, the electrical components arc thereby more protected from exposure to the elements and, thus, the life of the light assembly is enhanced. Moreover, since the light source is an LED, a high intensity red light source is thereby provided which can provide red illumination suitable for, among other things, brake lights, without requiring the same power as ordinary incandescent lights which results in a longer lasting, brighter light. Moreover, the use of red LED lights can also permit the use of clear tinted replacement taillight assemblies instead of red tinted assemblies.
In another aspect of the present invention, the LED assembly includes a two piece housing that is coupled together via clips to retain the circuit board within an enclosed space defined by the two piece housing. The housing also advantageously connects to the plug member such that when the housing members are interconnected, the plug member is securely attached to the housing. The use of such a two-piece housing results in an inexpensive, easy to assembly housing that still affords protection to the circuitry of the LED from dust, dirt and water, but allows for quick and easy manufacturing of the assembly. These and other objects and advantages of the present invention will become more fully apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the components of the light assembly comprising an LED assembly to be joined with a plug member using two side housing members;
FIG. 2 is an exploded perspective view of the partially assembled light assembly of FIG. 1 wherein the LED assembly and plug member have been joined to one side housing member;
FIG. 3 is an exploded perspective view of the fully assembled light assembly of FIG. 1 wherein the LED assembly and plug member have been secured used two housing members;
FIG. 4 is perspective view of the light assembly of FIG. 3 housed within a mounting assembly present in a vehicle comprising a light reflective member and a light transmissive lens.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made to the drawings wherein like numerals refer to like parts throughout. FIG. 1 illustrates an exploded view of the LED assembly 100 with left 104 and right 102 housing members and a male plug member 106 . The assembled light fixture 90 (shown in FIG. 3) is adapted to be mounted by removable attachment to a female plug member (not shown) such as might be found in taillight or turn indicator assembly in a vehicle. The male plug member 106 may be adapted to join with any of a number of female plug member configurations so as to be compatible with various makes and models of vehicles. The light assembly of the present invention as such, can therefore be used to replace stock incandescent light bulbs in these vehicles by quickly and easily removing the light assembly without modifying the existing components of the female plug member or light assembly housing of the vehicle.
While a particular plug and LED configuration is shown in the illustrated embodiment it should be appreciated by those of skill in the art that many possible plug and LED combinations are possible which represent other embodiments and applications of the present invention. Thus other configurations, color combinations, or quantities of LEDs can be utilized without detracting from the spirit of the present invention. Similarly, the shape and configuration of the circuit board and housing members can be configured to other shapes and LED arrangements, for example; a rectangle, a triangle, an ellipse, a star, or other similar rounded or polygonal shape.
Referring again to FIG. 1, the LED assembly 100 in the illustrated embodiment comprises a plurality of LEDs I 10 arranged in a circular pattern. Each LED 110 is attached to a first (top) side 120 of a circuit board 122 . The circuit board 122 is further configured to be circular in shape and is sized to contain the base of each LED 110 in the desired pattern. The power contacts or wires 132 for each LED 110 are attached to the circuit board 122 by crimping, soldering or suitable means, mounting the LED 110 in an upright manner substantially perpendicular to the first side 120 of the circuit board 122 with the base of each LED 110 resting flushly against the first side 120 of the circuit board 122 .
The power contacts or wires 132 for each LED 110 are further passed through the circuit board 122 where they are joined to one or more electronic components 140 necessary to power and illuminate the LEDs 110 in the sequence and patterns desired. The electronics 140 which may include for example; resistors, capacitors, and wiring are located in the area directly below the bottom side 154 of the circuit board 122 and are further disposed in the recesses of the housing members 102 , 104 of the completed light assembly 100 as will be discussed in greater detail hereinbelow.
A plurality of wires 170 comprising power lines to the LED assembly 100 extend from the electronic components 140 and enter a plug member 106 through an opening 174 defining a slit which extends through the body 169 , top side 171 and bottom side 173 of the plug member 106 . The number and arrangement of power lines 170 is based, in part, on the desired control patterns to be used with the LEDs 110 as well as any existing power contacts in the female plug member present in the automobile. In the illustrated embodiment, a series of four power lines 170 arc shown. Each power line 170 extends through the male plug member 106 and is coupled to a slit opening 176 on the bottom edge of the plug member 106 . The power line 170 is positioned within the slit opening 176 and secured in position by bending, gluing, soldering or other suitable methods to provide discrete and accessible contacts points that are mated with power contacts in the female connector of the vehicle.
As previously described, the male plug member 106 is further configured to fit within a female plug member in the vehicle. In the illustrated embodiment, the plug member 106 comprises a piece of plastic, metal or other durable material, generally rectangular in shape and having front and back side 200 , 202 , two side walls 204 , 206 , and a top 171 and bottom 173 side. The width of the male plug member 106 allows it to be inserted securely into a complimentary female plug member and secured, in part, by friction generated when the male plug member sides 200 , 202 , 204 , 206 and wiring 170 extending from the slits 176 when inserted into a compatible female plug member.
Areas along each side wall 204 , 206 of the plug member 106 further define two recesses 210 , 212 of similar size and depth. The recessed areas 210 , 212 are configured accept latching flanges 300 , 302 present on the left 102 and right 104 housing members that are passed through the recessed areas 210 , 212 creating a substantially uniform edge along each side wall 204 , 206 of the plug member 106 when the components comprising the right and left housing members 102 , 104 and the plug member 106 are joined together as will be discussed in greater detail in subsequent figures.
The plug member 106 also has a throughgoing opening 230 that transverses the front and back sides 200 , 202 , adjacent to the top side 171 , and equidistant from the two side walls 204 , 206 of the male plug member 106 . The diameter of the opening 230 is further configured to be substantially the same as the diameters of the two cylindrical pin members 310 present on the inner surfaces of each housing member 102 , 104 . As will be described in greater detail below, the cylindrical pin members 310 are sized so as to extend through the opening 230 so as to retain the plug member 106 within the housing defined by the two housing members 102 , 104 when the housing members 102 , 104 are secured together.
As is also illustrated in FIG. 1, a thin, substantially rectangular plate 240 is flushly mounted along the top side 171 of the plug member 106 wherein the plate 240 is configured to extend parallel to the top 171 and bottom 173 sides and perpendicular to the front/back sides 200 , 202 and side wall 204 , 206 members. The plate 240 extends slightly beyond the area defining the top side 171 of the male plug member 106 so as to create an overhang 242 along the top edge of the plug member 106 . The slits 246 are positioned along the overhang 242 and aligned in parallel with the slit openings 176 in the bottom side 178 of the plug member 106 relative to the side walls 204 , 206 . The slits 246 each receive one power line 170 that has been passed through the male plug member 106 and bent about a slit 176 in the bottom side 178 in a manner that will be described in greater detail below.
The left 104 and right 102 housing members are comprised of plastic, metal or other durable material and joined to each other using couplers which in the illustrated embodiment comprise top 320 , 322 and bottom 300 , 302 latching flanges. The couplers comprising latching flanges 320 , 322 , 300 , 302 extend from the housing member 102 , 104 in a perpendicular direction to the plane created between the interface 301 between the joined housing members 102 , 104 (see FIG. 3 ). The latching flanges 320 , 322 , 300 , 302 are mated with flange receiving openings 321 , 323 , 325 , 327 formed on the opposing housing member 102 , 104 in the region where the latching flange 320 , 322 , 300 , 302 of one housing member joins with the opposing housing member. An outwardly extending catch 299 formed on the ends of the latching flanges 320 , 322 , 300 , 302 is positioned within the openings 321 , 323 , 325 and 327 and thereby secures the housing member sides 102 , 104 together through snapwise assembly. Preferably, the flanges 320 , 322 , 300 and 302 are biased outward such that the extending catch 299 is biased into the openings 321 , 323 , 235 and 327 to thereby retain the interconnection between the flanges 320 , 322 , 300 and 302 and the respective openings. As will be described below, the flanges and the openings are positioned so as to engage with each other at either ends of the housing member 102 , 104 so as to retain interconnection therebetween.
In the illustrated embodiment shown in the FIG. 1, the housing members 102 , 104 possess a top semicircular region 340 with the sides 342 of the housing members 102 , 104 further shaped to enclose a semicylindrical recess 341 of sufficient size so as to contain all of the electronic components 140 present below the bottom side 154 of the circuit board 122 when the two housing members 102 , 104 are joined. The bottom 360 of the semicylindrical sides 342 further taper to join with a rectangular region 362 of the housing members 102 , 104 . The rectangular region 362 additionally comprises a recessed area 367 with a coupler that joins the plug member 106 to the housing member 102 , 104 . In the illustrated embodiment the coupler comprises a centrally disposed cylindrical protrusion comprising a plug positioning pin 310 extending into the space of the recessed area 361 .
When the two housing members 102 , 104 are joined the cylindrical cuplike recess 341 is formed which is contains the electronic components 140 attached to the lower side 154 of the circuit board 122 . The circuit board 122 is further secured in a first position between a plurality of board positioning tabs 372 , 374 , 376 present along the inside perimeter of the semicylindrical sides 342 of both housing members 102 , 104 , As shown in the illustrated embodiment, three board positioning tabs 372 , 374 , 376 comprising two outer board positioning tabs 374 , 376 and one central board positioning tab 372 are spaced substantially equidistant from each other along the inside wall 380 of the housing member 102 , 104 . The central board positioning tab 372 is situated along the top edge 378 of the housing member 102 , 104 and equidistant from both ends 382 , 384 of the housing member 102 , 104 . The two additional outer board positioning tabs 374 , 376 are each positioned equidistant from the ends 383 , 384 of the housing member 102 , 104 and disposed below the central board positioning tab 372 at a distance substantially equivalent to the thickness of the material comprising the circuit board 122 .
The plug positioning pin 310 is further disposed in the center of the rectangular region 362 of the housing member 102 , 104 at a position substantially equidistant from the lower edge of the rectangular region 362 and the tapered region 360 of the housing member 102 , 104 . The plug positioning pin 310 is configured with similar diameter as the opening 230 in the plug member 106 with a height measuring approximately half of the width of the plug member 106 .
FIG. 2 illustrates a partially assembled light fixture 89 wherein the LED assembly 100 and circuit board have been positioned within the semicylindrical recess 341 of the housing member 104 between the board positioning tabs 372 , 374 , 376 (not visible). The housing member 104 is slidably attached to the circuit board 122 by positioning the housing member 104 with the central board positioning tab 372 above the top side 120 of the circuit board 122 and the outer board positioning tabs 374 , 376 below the lower side 154 of the circuit board 122 . When so positioned, the circuit board 122 may be slidably inserted into the semicylindrical recess 160 whereby the sides 342 of the housing members 102 , 104 flushly fit against the contour of the edge of the circuit board 122 . The board positioning tabs 372 , 374 , 376 further secure the circuit board 122 along a plane substantially parallel with and defined by the outer semicircular perimeter of the housing member 104 . When so positioned, the LED assembly 100 extends from the housing member 104 with the circuit board 122 forming a top side enclosing the upper semicircular plane of the housing member 104 .
Prior to mounting of the plug member 106 to the housing member 104 , power lines 170 extending below the circuit board 122 are passed through the central slit opening 174 of the plug member 106 with each power line 170 exiting from the bottom side 173 . Each power line 170 is further bent about a second slit opening 176 directing the power lines 170 towards the LED assembly 100 along the outer face of the front or back side 200 , 202 of the plug member 106 . The free end of each power line 170 is subsequently captured by a third slit openings 246 present on the plate 240 on the top side of the plug member 106 to secure the power line 170 in position and provide a conductive surface along the power line 170 extending from the second 176 to third slit 246 areas that will be met by contacts within the female plug member (not shown).
The plug member 106 is further attached to the housing member 102 in the rectangular recess 362 below the LED assembly 100 , circuit board 122 , and electronics and wiring 140 by positioning the opening 230 about the plug positioning pin 310 of the housing member 104 . The recessed areas 210 of the plug member 106 are additionally captured by the latching flange 302 resulting in alignment of the plug member 106 and securing it in a flush position against the rectangular portion 362 of the housing member 104 . The plug member 106 thereby partially extends from the bottom portion of the housing member 104 and is secured by the plug positioning pin 310 and latching flange 302 so as to prevent the plug member 106 from sliding in or out of the housing member 104 . Additionally, sufficient room is present in the recess between the plug member 106 , circuit board 122 , and housing member side 342 to contain the electronic components and wiring 140 protecting them and securing them in a confined area reducing their susceptibility to water and vibrational damage.
The second housing member 102 is joined to the LED assembly 100 , circuit board 122 and plug member 106 in a like manner as described above using the complimentary surfaces of these elements. When the two housing members 102 , 104 have been positioned about the LED assembly I 00 , circuit board 122 and plug member 106 , the locking flanges 320 , 322 , 300 , 302 of the housing members 102 , 104 are positioned adjacent to the flange receiving areas 321 , 323 , 325 , 327 and the resulting structure can be snapped into a completed light assembly 90 as shown in FIG. 3 . The construction of the light assembly 90 can be performed easily by hand and does not require any additional tools to complete.
FIG. 3 illustrates the assembled light fixture 90 comprising the LED assembly 100 disposed above the plug member 106 and disposed between the two housing members 102 , 104 . Top latching flanges 320 , 322 and lower latching flanges 300 , 302 further join the two housing members 102 , 104 together, capturing the LED assembly 100 and plug member 106 therebetween. A portion of the male plug member 106 extends below the housing members 102 , 104 and conforms to the appropriate shape and size required to be mated with a female accepting plug member present in the vehicle (not shown). The power lines 170 individually positioned within the lower slit openings 176 and bent to extend into the top slit areas 246 (not visible in this illustration) of the male plug member 106 , provide suitable contacts that are conductively mated with components present in the female plug member to power the LED assembly 100 .
The LED assembly 100 shown in FIG. 3 extends from the housing members 102 , 104 in an opposite direction from the plug member 106 with the electronic components and wiring 140 housed within the cuplike recess of the assembled light fixture 90 . This assembly 90 forms a rigid and water-resistant barrier that secures the LED assembly 100 and plug member 106 in a non-moveable manner and further protects the components and wiring 140 from corrosion or vibrational damage.
Additional elements such as protrusions 324 , recesses 326 , and contours 328 may optionally be present along the outer surface of the light assembly 90 to conform to the structure and design of the female plug member into which the light assembly 90 is inserted. Such structures may serve as additional mounting means whereby the male plug member 106 is secured in the female plug member of the light housing of the vehicle.
An illustrated embodiment of a mounting assembly 404 housing the assembled light fixture 90 is shown in FIG. 4 . The mounting assembly 404 comprises a substantially cylindrical component 406 with a proximal end enclosed by a substantially concave light reflective cover 410 . The reflective cover 410 contains an area 412 defining an opening through which the male plug member 106 of the assembled light fixture 90 is inserted. The mounting assembly 404 is further configured to rest over a female plug member (not shown) wherein the male plug member 106 is joined by insertion of the assembled light fixture 90 through the area 412 of the opening in the reflective cover 410 . When the plug members are joined the assembled light fixture 90 is positioned within the reflective cover 410 with the portion of the LED assembly 100 extending from the surface of the reflective cover 410 . A portion of the housing members 102 , 104 further extend from the reflective cover 410 so as to allow grasping of the assembled light fixture 90 about the housing members 102 , 104 facilitating insertion and removal of the assembled light fixture 90 . A light transmissive lens cover 402 may be additionally affixed to the mounting assembly 404 by attachment to the cylindrical component 406 in such a manner as to contain the LED assembly 100 under the lens cover 402 to provide additional protection of the components contained therein.
The mounting assembly and lens cover illustrated in FIG. 4 represents one of many possible configurations and, as such, other shapes and configurations of mounting assemblies may exist with or without a lens covers which perform similar functions and thus represent other applications of the present invention. Although the foregoing, description of the invention has shown, described and pointed out novel features of the invention, it will be understood that various omissions, substitutions, and changes in the form of the detail of the apparatus as illustrated as well as the uses thereof, may be made by those skilled in the art without departing from the spirit of the present invention. Consequently the scope of the invention should not be limited to the foregoing, discussion but should be defined by the appended claims.
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A light emitting diode (LED) assembly designed to be used in a light bulb mounting assembly in a vehicle, such as taillight or turn indicator assembly. The LED assembly having a plurality of LEDs mounted upon a single circuit board that may be arranged in numerous colors, patterns and shapes to give a distinctive look to the light generating assembly. The LED assembly is contained within a durable water and shock resistant structure with a compatible plug member to be used in conjunction with existing light bulb mounts present in the vehicle. The LED assembly can be used to easily replace existing incandescent light bulbs present in the vehicle and provide additional color and lighting patterns eliminating the need for tinted glass bulbs or light transmissive covers to generate variations in colored light.
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FIELD OF THE INVENTION
[0001] The present invention regards a system of components for the diffusion of sound, which is particularly suitable for permanent or semi-permanent installations in venues dedicated to the production or reproduction of music, speech, sounds or vibrations, outdoors, in cinemas, auditoriums and in all indoor rooms in general.
BACKGROUND OF THE INVENTIONS
[0002] New digital technology in the sound recording field has made it possible to record part of the sound spectrum with absolute fidelity, such as the low and especially infra-low frequencies, those below the levels which are audible by the human ear and are perceptible by the body as vibrations.
[0003] This technology is also characterized by the absence of distortion of the original wave shape at a much higher sound level than was and is possible with analog systems. Particularly, in analog systems adding to the pickup problems insurmountable mechanical and electromagnetic limits which are found during the storage or recording phase of the program on magnetic tape or vinyl records, it is absolutely impossible to exceed a certain level of dynamics, especially in the frequency bands in question, and to contain the distortion and therefore the degradation of the original signal within negligible limits.
[0004] In short, present digital systems enable the recording and the reproduction of a much wider dynamic range than is usually audible or necessary for the sensitivity of the human ear, maintaining great fidelity with features of low distortion and useful passband.
[0005] However, although this possibility is now widely accepted during recording and future development is looking to record further infinitesimal qualitative details, the possibility of reproducing the dynamic range by means of a modern amplification system is not as widely achieved.
[0006] In fact, in spite of the extensive technical/scientific literature on the subject, I'm not aware of any product capable of reproducing such a dynamic range, at least as far as the low or infra-low frequencies are concerned, which are the most difficult to reproduce in terms of power. This hoped for result is often unachievable due to environmental acoustics, which too often are not up to the reproduction system's standard, or at any rate don't allow the original sound quality to be fully respected.
[0007] It must not be forgotten that for the sensitivity curve of the human ear, the difference between the loudness level at the center of the audible band (e.g. taking a value of 90 dBSPL and 1,000 Hz) and the level necessary for the same loudness at the bottom end of the audible band, 20 Hz is no less than 30 dB SPL.
[0008] Now since 30 dB (logarithmic measurement unit) are equivalent to 1,000 times in power, this means that when 1 Watt of power is applied to its terminals, a given loudspeaker is capable of reaching (for example) a level of 90 dBSPL at 1,000 Hz; to obtain the same loudness at 20 Hz, it's necessary to use another loudspeaker with the same efficiency at the latter frequency as that of the former loudspeaker at 1,000 Hz, as well as a power capacity and mechanical construction able to support no less than 1,000 Watts applied to its terminals.
[0009] Although material and adhesive technology has now enabled the construction of loudspeakers with voice coils capable of supporting 1,000 electric Watts even for long periods without burning out, thanks also to ingenious cooling systems, this in fact occurs at relatively high frequencies, up to the transducers maximum efficiency zone, usually at frequencies of between 100 and 200 Hz; however, this same technology definitely does not make this practice possible at gradually lower frequencies, even from 100 Hz: the entire loudspeaker is mechanically destroyed in a very short, regardless of the capacity of the voice coil to hold power without burning out.
[0010] This occurs because a loudspeaker's diaphragm movement, necessary for the reproduction of low and infra-low frequencies at a high sound pressure levels, is almost always incompatible with its own intrinsic geometry or mechanical construction.
[0011] Moreover, even overlooking the fact that any loudspeaker which is capable of holding a sound signal applied to its input terminals with a power of 1,000 Watts would reproduce this signal with such a high distortion that no ear could bear it for a significant time, a larger quantity of loudspeakers, in a ratio of at least 1 to 10 or higher, according to the radiation conditions under which these units would have to operate, would have to be used to compensate for this enormous difference in efficiency, which is typical of woofers when reproducing low frequencies rather that those in the central band.
[0012] The premise is so generalized that it is possible to see with increasing regularity sound reinforcement systems using a section for the reproduction of low and infra-low frequencies composed of a large number (even ten) single high-power units linked together.
[0013] This is because of the need to obtain high sound levels which are distortion-free or almost when reproducing music, nowadays routine practice in all the types of related events; clubs, live concerts or even classical music reproduced live in stadiums for thousands of listeners, with the digital amplification of a large symphonic orchestra, or even modern films' soundtracks which, thanks to digital recording, are able to recreate the sound's level and quality in a captivatingly realistic manner.
[0014] All this obviously leads to a significant rise in costs and consumption due to the use of a large amount of electricity for powering numerous units together, as well as a rise in maintenance costs because of the greater possibility of repair work.
[0015] However, realistic high-level sound reproduction even for low and infra-low frequencies isn't the only problem that prevents the intrinsic quality of modern sound production and/or recording techniques from being achieved.
[0016] In fact, rooms delegated mainly to the reproduction of music and speech (e.g. movie theaters, projection rooms, etc.) very often have architectural characteristics which considerably change the original sound played back inside them, even more so if levels must be kept high for the degree of realism required.
[0017] Walls that are parallel and often reflective, lack of homogeneous, well-distributed absorption for achieving optimal reverberation times for the venue and the type of program being reproduced lead to the concentration of greater energy on some frequency bands rather than others in certain positions in the room, according to the studies and statistics that have stood the test of time for decades.
[0018] In relatively small rooms, it's even possible that so-called well-known stationary waves occur at low frequencies, greatly altering reproduction quality, masking medium and high frequency bands, whose intelligibility is indispensable to enable speech to be understood when there is an often extremely complex music program.
[0019] Generally speaking, rooms built in the past, but also nowadays, for the reproduction of the film soundtracks (e.g. movie theaters), often for budget reasons, have classical parallelepiped layouts with parallel walls, regardless of the fact that there are also the so-called “balconies”, even if these are less frequently built for cost reasons.
[0020] Moreover, apart from the necessary insulation towards the outside, internal acoustic treatment which should be very accurate to obtain the required reverberation curve according to the hall's frequency and dimensions, is generally limited to the ceiling and (for reasons intrinsic to the function) to the area of the floor on which the audience's fabric-covered seating is installed.
[0021] Walls are rarely suitably well treated. “Flutter” echoes, “slap” echoes, unwanted reflections and stationary low-frequency waves often considerably worsen reproduction of soundtracks and speech in theaters screening films.
SUMMARY AND AIMS OF THE INVENTION
[0022] A first aim of the present invention is to overcome and solve the aforementioned problems regarding reproduction of low and infra-low frequencies, using an enclosure purposely designed and constructed for installation in rooms in which it's often or always necessary to have a section available for the reproduction of low and infra-low frequencies able to give a sound level suited to the dimensions of the room in question and the events taking place in it.
[0023] A second aim of the invention is to solve the above-mentioned problems of the diffusion of sound in walled environments in a simple economic manner, particularly in the case of new or renovated buildings, based on the assumption that a particular design regarding a specific room is not necessary, but it's sufficient to use modular architectural elements which are practical from an acoustic point of view and can be adapted from a structural point of view to any room, regardless of its specific pre-existent or new architecture.
[0024] These aims are achieved, according to the invention, using a sound diffusion system including, in combination or separately, at least one large cost-effective horn made of brickwork using traditional methods or prefabricated cement elements, assembled on-site in the foreseen position, and an architectural structure with a continuous or intermittent “multi-hemicylindrical” surface covering the room's walls, for the diffusion/reflection of the sound in wide spectrum of frequencies and at the same time for adjustable absorption of low and infra-low frequencies.
[0025] This large horn should preferably be located at the point in which the stage is installed in certain rooms, so that the upper covering of horn can be used as the stage surface, or at least the surface on which the stage is built.
[0026] The horn will be designed and built with parallel upper and lower walls, which will thus be load-bearing, able to support any weight on the top. The side walls will be curved (which can also be built using numerous straight sections) due to the need to comply with the necessary expansion of the horn area, provided for at the design stage and carefully calculated for the correct operation of this type of unit (i.e. the horn) as an acoustic load for a “woofer” loudspeaker, particularly if dedicated to accurate reproduction of low and infra-low frequencies.
[0027] The horn's dimensions will be calculated, according to usable space, preferably (but not exclusively) to obtain, at the highest sound level possible from the loudspeakers or drivers, reproduction of low and ultra-low frequencies, starting at 200 Hz and going down to below or even under 20 Hz. This is the case when the sound being played back requires the reproduction of actual vibrations, perceptible to the body rather than the ear and necessary, for example, with the highly realistic recording of soundtracks involving natural phenomena, such as earthquakes, tidal waves, volcanoes or other explosions, often indispensable “effects” in recently produced films.
[0028] Even if the horn has the apparent drawback of not being able to be removed, due to the structural features described, in reality it offers absolutely the best solution to requirements connected with the reproduction of the low and infra-low frequencies, from the point of view of cost, performance and consumption.
[0029] Another structural detail not to be overlooked is the design of the system that drives the horn(s), in a section, which is separate from the horn and can be easily and securely fitted to it when required.
[0030] In other words, the loudspeaker or loudspeakers, which constitute the “powerhouse” of the system, will be housed in a dedicated “container” with the volume required to produce the necessary rear load that these loudspeakers require for driving the horn correctly: this compact “container” will be easily transported, thanks to its base's built-in wheels.
[0031] As well as facilitating maintenance work, this solution solves any problem of system elements susceptible to damage being exposed to bad weather, vandalism or simply damage, in fact reducing, especially in the case of outdoor use, the decline in performance of the active elements (the loudspeakers), which will thus only be subject to wear due to their actual operation.
[0032] Another considerable advantage is due to the fact that travelling or touring shows, on which use is made of large amplification systems and therefore the appropriate number of cumbersome subwoofers, can use permanent local systems, with great savings from the point of view of transport (including that of the amplifiers) and energy consumed, while maintaining the reproduction quality of the low and infra-low frequency parts of the program.
[0033] Moreover, the horn system is directive in terms of width even at low frequencies, very advantageous for reducing undesired pollutant sound spill, unequalled by more expensive traditional systems, as they are necessarily constructed with dimensions suited to transport and therefore each individual unit is compact.
[0034] Moreover, from the point of view of performance, combining multiple units is only useful in the case of dimensions that are certainly much smaller than those in which the horn described can be constructed without any problem of interference.
[0035] In fact, whereas so many enclosures placed side by side to form a dimension greater than that of the wavelength of the frequency reproduced cause considerable harmful modifications in the polar response, due to interference and vibrations, although having large dimensions compared to the wavelengths of the band of frequencies reproduced, the horn according to the present invention behaves like one large source free from any interference or vibration capable of seriously deteriorating the program reproduced. The architectural structure consists of a series of modules or panels having a hemicylindrical surface, which are equal or different in terms of chord and radius of curvature, constituting a “multi-hemicylindrical” surface for covering the walls of a room, characterized by a lack of flat or concave surfaces. This may be run through by openings or holes with a width that can be modified or varied as required during construction.
[0036] This enables to obtain the desired diffusion of the entire spectrum of frequencies required in a foreseeable manner, because it is closely related to the dimension of the “hemicylindrical” elements and the distance between them and between them and the wall, according to procedures that are well known in acoustics, and at the same time to obtain low frequency acoustic absorption which is adjustable, thanks to the possibility of closing the holes or openings in the said “hemicylindrical” elements successively and empirically, after their installation in the room.
[0037] The results of using these architectural elements lies in the advantageous contribution of the room to the reproduction of wide-band sound with even spatial distribution throughout the entire “audience” which has (without appreciable differences in level or quality between zones) greater presence and thus maximum sound spectacularity, without the typical limitations of traditional rooms.
[0038] The attached drawings illustrate in a non-limiting manner some possible embodiments of the present invention of a horn-type diffuser designed for a rapid connection of the active driver part to its throat and having an architectural structure for the covering of walls.
[0039] The various innovative features that characterise the invention are pointed out in detail in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific aims attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] In the drawings:
[0041] [0041]FIG. 1 is a perspective view showing a configuration of the horn without the top wall;
[0042] [0042]FIG. 2 is an enlarged perspective view of a part of the horn close to the driver unit;
[0043] [0043]FIG. 3 is a perspective view of an example of a finished horn with the driver unit removed;
[0044] [0044]FIG. 4 is a perspective view of the horn-type enclosure in another configuration example with two separate ducts forming two adjacent horns;
[0045] [0045]FIG. 4 a is a schematic view of an arrangement with a screen with a horn-type enclosure at the base and screen loudspeaker systems for the 3 or 5 main channels;
[0046] [0046]FIG. 4 b is a front view showing the horn, whose upper wall forms the surface of a stage floor (e.g. for concerts) and which functions as a subwoofer in the sound reinforcement system which is installed at either side;
[0047] [0047]FIG. 5 is a schematic axonometric view of the interior of a room complete with a structure for the diffusion/reflection/absorption of sound;
[0048] [0048]FIG. 6 is a perspective view showing an exemplary embodiment of the architectural structure without rear absorbent material;
[0049] [0049]FIG. 7 is a perspective view showing the exemplary embodiment of the architectural structure of FIG. 6 with rear absorbent material;
[0050] [0050]FIG. 8 is a perspective view showing another exemplary embodiment of the architectural structure also without absorbent material; and
[0051] [0051]FIG. 9 is a perspective view showing the exemplary embodiment of the architectural structure of FIG. 8 with absorbent material.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] Referring to the drawings in particular, FIGS. 1 - 4 show a speaker enclosure in the form of a large horn 10 defined by a lower wall 11 and an upper wall 12 which are horizontal and parallel, and curved side walls 13 , which are dimensioned and follow a line dependent on the expansion of the areas required for the correct operation of the horn itself.
[0053] All the parts may be produced on site in brickwork or with the use of prefabricated elements. The upper wall 12 of the horn may itself constitute a surface that can be walked on. As an alternative, this upper wall may be overhung by a support cover 14 , represented by or forming the floor of a stage.
[0054] The curved walls 13 of the horn extend outwards away from a space 15 of suitable volume, in which a driver unit 16 is housed. This unit comprises one or more loudspeakers 17 , which are arranged in a cabinet 18 fitted with wheels 19 . The driver unit 16 can thus be moved in the manner of a trolley to be easily inserted into the dedicated space 15 and be easily removed and transferred as required.
[0055] The horn 10 may be built for example at the base of a screen in a room used for the reproduction of music and speech, as is schematically shown in FIGS. 4 and 5, or of a concert stage (FIG. 4 b ) in combination with complete, low, medium, high and screen loudspeaker systems, respectively. The walls 20 of such a room may be covered, according to the present invention, with a diffusing/reflecting/absorbing structure 21 , which consists of basic modules or panels 22 , in a large variety of shapes and materials. The structure 21 may therefore be made of bricks, may consist in prefabricated modules or even wood panels or wood modules and may be applied to walls made of brickwork or reinforced concrete.
[0056] [0056]FIGS. 6 and 7 show a structure wherein the component modules 22 are spaced at a distance from one another, leaving an opening 23 between adjacent modules or groups of modules.
[0057] The structure 21 may be installed close to the walls 20 , forming cavities between themselves and the walls that may or may not be filled with absorbent material 24 such as mineral wool or the like.
[0058] [0058]FIGS. 8 and 9 show a structure 21 , made up of modules which are provided with longitudinal 25 and/or transverse 26 holes which can have different diameters, as required. Even in this case, cavities, which may or may not be filled with acoustic absorbent material 27 , may be formed between the elements of the structure 21 and the walls 20 against which they are installed.
[0059] Since it is not always possible to know the acoustic features of rooms to be restructured before the actual work is done, or of those still to be constructed, the architectural structure proposed here is designed to act on a broad acoustic spectrum as a highly effective diffuser which is capable of reflecting the incident sound energy and restoring it, not as powerful harmful reflections (typical of flat or concave surfaces) but splitting the energy into countless other low intensity and low energy reflections, positively decisive for better sound diffusion, regardless of the reverberation time or even of the echo that the room might have.
[0060] Moreover, this structure may be constructed of dimensions appropriate for diffusing sound, beginning at the frequencies for which such diffusion becomes highly useful, from 200 Hz upwards for example. The structure may has the peculiarity, obtained without any increase in cost or construction time, of incorporating a large number of Helmholtz resonators, which can be selectively tuned in frequency with a simple effective method. Such resonators may easily be converted into broadband Helmholtz resonators with a suitable use of economic materials, such as mineral wool.
[0061] Because of its original structural features, once these multiple resonators have been obtained and selectively tuned to the multiple different low frequencies or to a broadband absorption efficacy, the structure can easily be varied. A great freedom of action in relation to the same low frequencies is provided for which this is considered to be necessary, by means of the simple closure of the tuning openings 23 , 26 of the resonators proper, e.g. by injecting normal expanded polystyrene or any material used for sealing in construction work.
[0062] The device, system and method of the invention makes it possible to obtain from the same architectural element a suitable combination of two opposed acoustic effects, such as absorption and diffusion, which is a necessary condition for obtaining a low reverberation time, as is best for speech, and at the same time also excellent diffusion of music, as usually occurs with a higher reverberation time.
[0063] Another peculiar feature of the proposed structure lies in the superior insulation towards the outside, when combined with a traditional insulating wall on the side of the cavities, which are or are not filled with mineral wool.
[0064] It should also be noted that the construction of the structure described can be carried out with a large variety of basic elements both in terms of shape and highly different materials, provided they have the necessary density, enabling room designers to obtain original aesthetic features which are different from room to room and architecturally valid. It's therefore possible to use the most economic bricks, mass-produced prefabricated parts or even wood.
[0065] Therefore, according to the present invention, each structure in which the functions of broad bandwidth diffuser and of low-frequency selective absorber are found, is a complete, economic, effective and easily adaptable solution, even after installation, to all the acoustic problems that afflict many rooms in which it's necessary to obtain intelligible speech and good music reproduction simultaneously.
[0066] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A system for sound diffusion, particularly at low and infra-low frequencies in rooms used for the reproduction of music and speech including at least one large horn enclosure and an architectural structure with a continuous or intermittent “multi-hemicylindrical” surface. The surface covers the walls of the room, for the diffusion/reflection of the sound in a broad spectrum of frequencies and with absorption that is adjustable at least at the low frequencies.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/240,380, filed Oct. 12, 2015, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to aircraft panels with attachment points molded therein.
BACKGROUND OF THE INVENTION
[0003] Conventional panels used in aircraft are typically uniform in cross-sectional strength, and are not optimized for part installations. As a result, to provide structural improvement to panels, the only option is to bond a doubler or wet-lay-up support on the back of the panel. The prior art in manufacturing thermoplastic sheet stock has focused on a light weight scrim added to the bottom of the paper layers to create a support for material during the forming process. The scrim is often not considered structural and is in many ways a sacrificial layer, as it cannot stretch during the forming process and tears as needed in molding.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0004] In accordance with a first aspect of the present invention there is provided a method of making a panel assembly that includes forming a thermoplastic panel, placing a thermoset portion into a pocket in a mold, placing an attachment member into the pocket in the mold, positioning the thermoplastic panel in the mold, cooling the thermoplastic panel while heating the thermoset portion to flow at least a portion of the thermoset portion into openings defined in the thermoplastic panel, and cooling the panel assembly so that the thermoset portion hardens, thereby securing the attachment member to the thermoplastic panel. In a preferred embodiment, the panel assembly includes a plurality of thermoset portions and respective attachment members. Preferably, the panel assembly is an aircraft side panel or ceiling panel. The attachment member can be comprised of metal and can be any one or more of a bracket, a flange, a threaded fastener, a boss, a ring, an insert for receiving a threaded fastener, a slide-in strips, a holding mechanism for a slide-in strip, an anchor points for a window reveal or a receiver.
[0005] In accordance with another aspect of the present invention there is provided a panel assembly that includes a thermoplastic panel having at least one attachment member secured thereto. The attachment member is secured to the thermoplastic panel by a thermoset material. In a preferred embodiment, the thermoplastic panel comprises a plurality of openings therein and the thermoset material at least partially fills the openings.
[0006] The present invention relates to integrally molded attachment schemes for thermoformable plastic reinforced panels for aircraft liners (e.g., ceiling panels, sidewalls, etc.). The invention provides high strength anchor points and molded in features for attachment of a sidewall or other interior lining system into an aircraft fuselage.
[0007] In a preferred embodiment, the liner thermoformable panel is made of short and/or medium length fibers and a matrix comprised of a thermoplastic resin, such as polyetherimide (PEI), polyphenylsulphone (PPSU), polyphenylene sulfide (PPS), polyoxymethylene/acetal (POM), acrylic (PMMA), fluoropolymers (PTFE, FEP, PVF), ketone-based systems (PEK, PEEK, PEKK), polyimide, polycarbonate (PC), polyethylene (PE), polyphenyleneether (PPE), polyphthalamide (PPA), polypropylene (PP), styrenic systems (ABS, PS, etc.), other sulfone based systems (PES, PSU), urethane and polyurethane (PUR, TPU, etc.), vinyl based systems (PVC, CPVC, etc.) and polyarylamide (PAA) and possibly a binder resin. The molded in attachment features are accomplished on the thermoform part using a thermoplastic resin and chopped fiber Sheet Molding Compound (SMC), or Bulk Molding Compound (BMC). As the thermoform sheet is brought to a plastic state (often temperatures exceeding 500° F.) it is shuttled in a forming machine over to a mold—typically maintained at 250°-350° F. The matched metal die mold in effect cools the material while forming the part. The SMC Material (e.g., a matrix resin of epoxy, vinyl ester, or phenolic resin) and chopped glass or carbon strands is inserted (manually or by a machine—robotically) into the forming mold die. As the tool is closed and the thermoplastic sheet formed and shaped, the molding compound becomes mobile and flows through the substrate, co-mingling with the thermoplastic matrix, permanently molding in the attachment feature.
[0008] Features such as the anchor points for window reveals can be molded into the panel. Conventional fixturing of sidewalls employing slide-in strips—the holding mechanisms for the slide-in strips can be co-molded or post molded directly onto the part. It will be appreciated that most in the industry bond attachment schemes to the exterior of the panel rather than mold the features into the part. The present invention molds a thermoset SMC or BMC into a thermoplastic panel. The present invention also contemplates a product or panel assembly created by the method or process described herein.
[0009] See U.S. Patent Publication Nos. 2009/0072086 and 2011/0108667, and U.S. Pat. No. 9,358,703, the entireties of which are incorporated by reference herein, for a discussion of thermoplastic panels.
[0010] The invention, together with additional features and advantages thereof, may be best understood by reference to the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an exploded perspective view of a panel assembly in accordance with a preferred embodiment of the present invention; and
[0012] FIG. 2 is a perspective view of the panel assembly of FIG. 1 .
[0013] Like numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in certain instances, well-known or conventional details are not described in order to avoid obscuring the description. References to one or an embodiment in the present disclosure can be, but not necessarily are references to the same embodiment; and, such references mean at least one of the embodiments.
[0015] Reference in this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the-disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.
[0016] The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Certain terms that are used to describe the disclosure are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the disclosure. For convenience, certain terms may be highlighted, for example using italics and/or quotation marks: The use of highlighting has no influence on the scope and meaning of a term; the scope and meaning of a term is the same, in the same context, whether or not it is highlighted. It will be appreciated that the same thing can be said in more than one way.
[0017] Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein. Nor is any special significance to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and is not intended to further limit the scope and meaning of the disclosure or of any exemplified term. Likewise, the disclosure is not limited to various embodiments given in this specification.
[0018] Without intent to further limit the scope of the disclosure, examples of instruments, apparatus, methods and their related results according to the embodiments of the present disclosure are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions, will control.
[0019] It will be appreciated that terms such as “front,” “back,” “upper,” “lower,” “side,” “short,” “long,” “up,” “down,” and “below” used herein are merely for ease of description and refer to the orientation of the components as shown in the figures. It should be understood that any orientation of the components described herein is within the scope of the present invention.
[0020] Referring now to the drawings, which are for purposes of illustrating the present invention and not for purposes of limiting the same, FIGS. 1-2 show a panel assembly 10 that includes a panel 12 having attachment members 14 integrally molded thereto. As described herein, the panel assembly is intended to be used in an aircraft (e.g., side panel, ceiling panel, etc.). However, this is not a limitation on the present invention and the panel assembly can be used elsewhere.
[0021] As will be appreciated by those of ordinary skill in the art, the panel 12 comprises a plurality of layers of thermoplastic. Each layer is typically made of short and/or medium length fibers (e.g,. fiberglass, carbon fiber, basalt fiber, quartz or partially oxidized polyactrynitrile (PAN)) and a matrix comprised of a thermoplastic resin. The attachment members 14 can be any component that is typically secured to aircraft panels for attaching the panel to the aircraft frame and the like. For example, the attachment members 14 can be brackets, flanges that attach to brackets on the frame, threaded fasteners, bosses, rings, inserts for receiving a threaded fastener, slide-in strips or the holding mechanisms for the slide-in strips, anchor points for window reveals, a receiver or any other component for attaching the panel to the frame. The attachment members 14 are often made of metal or hard plastic. However, the type of material is not a limitation on the present invention. In a preferred embodiment, a thermoset sheet molding compound or bulk molding compound (referred to herein as SMC, BMC or a thermoset portion 16 ) is used to secure the attachment member 14 to the panel 12 during the molding of the thermoplastic panel 12 . The thermoplastic panel 12 generally comprises a number of layers that are pressed together in a thermal form press. During this procedure, the thermoplastic material heats up and becomes plastic, above the glass transition temperature, (e.g., above 700°). In a preferred embodiment, the temperature range for creating the thermoplastic panel 12 in a thermoform press or shuttle is between about 450° F. and about 800° F. and in a more preferred embodiment the temperature range is between about 600° F. and about 750° F. The thermoplastic panel 12 is then placed in a mold that is typically maintained at about 250° to about 350° F. The thermoset portions 16 are placed in the mold (e.g., in a trough or depression in the mold) prior to raising the temperature. At the raised temperature, the thermoset portion 16 , which has a much lower molding temperature or glass transition temperature and melting temperature than the thermoplastic panel, becomes fluid and welds or integrates into the thermoplastic panel 12 . Therefore, in the mold, the thermoplastic panel 12 is cooling, while the thermoset portion 16 is rising in temperature and being melted. This allows the thermoplastic and thermoset to mold together or be welded together. It should be understood that the thermoplastic panel 12 has pores, pockets or voids in it that the fluid thermoset portion 16 enters or fills. The matched metal die mold cools the material while forming the panel assembly 10 . The thermoset portion 16 (e.g., a matrix resin of epoxy, vinyl ester, or phenolic resin) and chopped glass or carbon strands is inserted (manually or by a machine—robotically) into the forming mold die. As the tool is closed and the panel assembly 10 is formed and shaped, the molding compound thermoset portion 16 ) becomes mobile and flows through the substrate, co-mingling with the thermoplastic matrix, permanently molding in the attachment member 14 . It will be appreciated that different attachment members can be incorporated into the same thermoplastic panel 12 . In another embodiment, all of the attachment members 14 within a panel assembly 10 are the same.
[0022] Generally, the steps for creating the panel assembly 10 include heating layers in a shuttle above their glass transition temperature to form a thermoplastic panel 12 , placing the thermoset portions 16 into locations (e.g., pockets) in the tool, placing the attachment members 14 into locations in the tool, moving the thermoplastic panel 12 to the matched metal die, mold or tool, cooling the thermoplastic panel 12 while heating the thermoset portions 16 , flowing at least a portion of the thermoset portion 16 into pores in the thermoplastic panel 12 and cooling the panel assembly 10 .
[0023] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” As used herein, the terms “connected,” “coupled,” or any variant thereof, means any connection or coupling, either direct or indirect, between two or more elements; the coupling of connection between the elements can be physical, logical, or a combination thereof. Additionally, the words “herein,” “above,” “below,” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. Where the context permits, words in the above Detailed Description of the Preferred Embodiments using the singular or plural number may also include the plural or singular number respectively. The word “or” in reference to a list of two or more items, covers all of the following interpretations of the word: any of the items in the list, all of the items in the list, and any combination of the items in the list.
[0024] The above-detailed description of embodiments of the disclosure is not intended to be exhaustive or to limit the teachings to the precise form disclosed above. While specific embodiments of and examples for the disclosure are described above for illustrative purposes, various equivalent modifications are possible within the scope of the disclosure, as those skilled in the relevant art will recognize. Further any specific numbers noted herein are only examples: alternative implementations may employ differing values or ranges.
[0025] Any patents and applications and other references noted above, including any that may be listed in accompanying filing papers, are incorporated herein by reference in their entirety. Aspects of the disclosure can be modified, if necessary, to employ the systems, functions, and concepts of the various references described above to provide yet further embodiments of the disclosure.
[0026] Accordingly, although exemplary embodiments of the invention have been shown and described, it is to be understood that all the terms used herein are descriptive rather than limiting, and that many changes, modifications, and substitutions may be made by one having ordinary skill in the art without departing from the spirit and scope of the invention.
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A method of making a panel assembly that includes forming a thermoplastic panel, placing a thermoset portion into a pocket in a mold, placing an attachment member into the pocket in the mold, positioning the thermoplastic panel in the mold, cooling the thermoplastic panel while heating the thermoset portion to flow at least a portion of the thermoset portion into openings defined in the thermoplastic panel, and cooling the panel assembly so that the thermoset portion hardens, thereby securing the attachment member to the thermoplastic panel.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a twin wire former for the production of a fiber web, specifically a paper, cardboard or tissue web, from a fiber suspension. This type of twin wire former is generally referred to as “Roll-Blade-Former” in the industry.
[0003] 2. Description of the Related Art
[0004] A twin wire former of this type for the production of a paper web, specifically a fine paper web, is already known from the PCT-disclosure document WO 97/47803. The disclosed twin wire former includes an upstream headbox with several separation elements in its headbox nozzle, and a forming roll, preferably a suction type forming roll, having a roll diameter of ≧1.4 m and an angle of wrap of <25°. In a curved twin wire zone located downstream from the forming roll, there are also methods for the introduction of pulsating pressure effects into the paper web that is being formed.
[0005] Further, a twin wire former as mentioned above, for the production of a paper web, specifically SC paper, is also known from the European patent application EP 0 627 523 A1. Here, initial dewatering of a fiber suspension occurs on a first forming roll in a forming zone. The fiber suspension is then brought onto a curved forming shoe, having a radius of 2 m to 8 m and is further dewatered. Subsequently, at least one dewatering unit including dewatering methods is located in the line. At the end zone of the twin wire zone there is a second forming roll including at least one suction zone, where the top wire of the twin wire former is separated from the forming paper web and is led away by way of a guide roll.
[0006] The two aforementioned twin wire formers have in common that the dewatering accomplished on the forming roll or in the area of the forming zone is greater than 70%. Since considerable portions of the paper web are formed without the presence of pressure pulsations, a forming quality that is only average is unavoidable when running fiber stock suspensions that are difficult to form. It is also a disadvantage that both twin wire formers have a very long open jet distance (distance: headbox nozzle to jet impact point), for example longer than 400 mm. This has a negative effect on the web quality, in machine direction (MD) as well as in machine cross direction (CD).
[0007] In order to achieve optimum sheet quality, a certain level of forming strip dewatering is particularly important. This requires very precise dimensioning of the forming angle, since large volumes are dewatered per angle degree. The optimum forming roll wrap must generally be determined during pilot trials, which are expensive and time intensive. Since the angle of wrap must always be matched to paper type, web weight and machine speed, even a small change in any one parameter causes extensive effects, which then will have to be neutralized at great expense.
[0008] If the sheet formation system is required to accommodate a larger weight range (specific production volume P), which is always the case with production lines, then the operating point abandons the optimum operating range on product changes. In the instance of the aforementioned twin wire formers, the fiber stock suspension throughput through the headbox must then be increased detrimentally in order to regain the optimum operating window.
[0009] The present invention provides an improved twin wire former to such an extent that the aforementioned disadvantages of the state of the art are avoided. A second objective is that fiber stock suspensions having a high long fiber content which makes them particularly difficult to form, for example papers, may find optimum use.
SUMMARY OF THE INVENTION
[0010] Characteristics of the present invention include:
[0011] the rotating forming roll has an open volume (storage volume) and is a non-suction type,
[0012] the rotating forming roll has a roll diameter of less than 1,400 mm,
[0013] the rotating forming roll has an angle of wrap of less than 7°,
[0014] a forming suction box is located immediately downstream from the rotating forming roll as viewed in the direction of wire travel, and
[0015] in the area of the wedge-shaped inlet nip, the fiber suspension has a stock consistency of between 0.4% and 2.0%, preferably between 0.6% and 1.5%.
[0016] By combining these characteristics in a twin wire former, the initial dewatering (dwell time) on the forming roll, or the dewatering volume is reduced to a minimum, whereby the minimum is smaller than 30% relative to the headbox throughput of a fiber stock suspension having a stock density of between 0.4% and 2.0%, preferably between 0.6% and 1.5% in the area of the wedge-shaped inlet nip. This is achieved by the maximum forming roll diameter of 1,400 mm and by the maximum forming roll angle of wrap of 7°. The maximum forming roll diameter of 1,400 mm and the maximum forming angle of wrap of 70 cause a greatly reduced dwell time on the forming roll.
[0017] Moreover, the minimum initial dewatering on the forming roll ensures a non-critical positioning of the headbox jet.
[0018] The headbox in whose nozzle—at least one machine-wide separation element, specifically a plate—is located produces a high quality headbox jet. In accordance with the present invention, this allows and even favors utilization in the twin wire former, of fiber stock suspensions having a high long fiber content (for example paper) which are particularly difficult to form.
[0019] The surface of the forming roll having the “open volume” is grooved and/or drilled and/or deflected, or is constructed in a honeycomb design. These configurations are cost effective to produce and do not influence the rigidity or the operational safety of the forming roll negatively, which, depending upon the application may be up to 10 m wide.
[0020] In order to considerably increase the dewatering capacity of the twin wire former of the present invention, at least one additional forming suction box must be located following the forming suction box as viewed in direction of wire travel.
[0021] In order to achieve as symmetrical a web quality as possible, the forming suction boxes are located opposite each other, whereby the forming suction boxes, as viewed in the direction of wire travel, may have some distance between them.
[0022] Under technological and qualitative aspects it is advantageous if the at least one forming suction box has a curved suction surface having a radius of curvature of 1,500 mm to 10,000 mm, preferably of 2,000 mm to 5,000 mm.
[0023] At least one forming suction box includes at least one suction chamber, whose vacuum is adjustable/controllable by way of a controllable vacuum source. This permits, and even enhances considerably the adjustment of optimum operating conditions in the area of the forming suction box.
[0024] In order to once more increase the dewatering capacity of the twin wire former in accordance with the present invention, while maintaining good web qualities, a multitude of forming strips are located opposite at least one forming suction box. In accordance with the present invention at least one of the forming strips is mounted flexibly and/or at least one of the forming strips is mounted stationary, whereby their base position is adjustable relative to their wire, for example by way of sliding or pivoting.
[0025] Additionally, at least one wet suction box is located downstream from at least one forming suction box as viewed in the direction of wire travel. Preferably, the wet suction box is supplied with vacuum, whereby the vacuum is adjustable/controllable by way of a controllable vacuum source. This permits, and even considerably enhances, the adjustment of optimum operating conditions in the area of the wet suction box.
[0026] In order to keep the spatial dimensions of the twin wire former according to the present invention as small as possible, a turning roller is located prior to the separation element as viewed in the direction of wire travel, thereby reducing the actual horizontal and/or vertical length of the twin wire zone to a certain degree.
[0027] In order to permit further processing of the fiber web that is supported on the wire after the separation from the top and bottom wires, at least one flat suction box and a suction couch roll are located after the separating element as viewed in the direction of travel of the wire. This allows the degree of dewatering of the fiber web to be increased further.
[0028] When using wood-free fiber suspensions it is also advantageous if at least one machine-wide separating element, specifically a plate, is located in the nozzle of the headbox.
[0029] In a first embodiment, the twin wire zone of the twin wire former according to the present invention can essentially rise vertically from the bottom to the top, preferably with a vertical excursion of −15° to +15°, preferably from −5° to +5°; and in a second configuration can rise from the bottom to the top with an incline from the horizontal plane of approximately 5° to 45°. In another embodiment, the twin wire zone can slope from the top to the bottom with sloping gradient in the end zone. These embodiments represent the known possibilities in accordance with the state of the art, and have proven themselves frequently in the field.
[0030] It is understood that the aforementioned characteristics of the invention, which will be explained in further detail below, may be utilized not only in the cited combinations but also in other combinations, or freestanding, without abandoning the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0032] [0032]FIG. 1 is a schematic side view representation of a first embodiment of the twin wire former of the present invention;
[0033] [0033]FIG. 2 is a schematic side view representation of a second embodiment of the twin wire former of the present invention;
[0034] [0034]FIG. 3 is a schematic side view of a third embodiment of the twin wire former of the present invention;
[0035] [0035]FIG. 4 is a schematic side view of a fourth embodiment of the twin wire former of the present invention;
[0036] [0036]FIG. 5 is a diagram of the operation performance for fiber suspension in a conventional Roll-Blade-Former concept; and
[0037] [0037]FIG. 6 is an enlarged version of the optimum operating window of the operating performance for fiber suspension in a conventional Roll-Blade-Former concept.
[0038] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate one preferred embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0039] Referring now to the drawings, and more particularly to FIG. 1, there is shown a first embodiment of the twin wire former 1 in accordance with the present invention. Two continuous wires (bottom wire 2 and top wire 3 ) together form a twin wire zone 5 . In an initial area of the twin wire zone 5 in which the two wires 2 , 3 run over a dewatering element which is in the embodiment of a rotating forming roll 6 , the two wires 2 , 3 together form a wedge-shaped inlet nip 7 (“Gap-Former”) at the forming roll 6 . The nip directly accepts the fiber suspension 9 from a headbox 8 which is located at an angle toward the left and top and which is illustrated only in part. In a central area of the twin wire zone 5 the two wires 2 , 3 together with the fiber web 4 which is forming between them, run over a multitude of additional dewatering and forming elements 10 . In an end area of the twin wire zone 5 , viewed in direction of wire travel S (arrow), the two wires 2 , 3 run over a separating element 11 which is in the embodiment of a suction couch roll 12 , which separates the top wire 3 from the formed fiber web 4 and from the bottom wire 2 .
[0040] According to the present invention rotating forming roll 6 has an open volume (storage volume) and has no suction. The rotating forming roll 6 according to the present invention also has a diameter DF smaller than 1,400 mm and a forming angle of wrap a smaller than 7°. Moreover, provisions are made in accordance with the present invention that a forming suction box 15 . 1 is located immediately following the rotating forming roll 6 , viewed in the direction of wire travel S, preferably on the same side as the forming roll. In the area of the inlet nip 7 the fiber suspension 9 has a stock consistency according to the present invention of between 0.4% and 2.0%, preferably between 0.6% and 1.5%.
[0041] The open volume of the forming roll 6 is such that its surface is grooved and/or drilled and/or deflected or is constructed in a honeycomb design. An additional forming suction box 15 . 2 is also located downstream from the first forming suction box 15 . 1 , as viewed in the direction of wire travel S, whereby the forming suction boxes 15 . 1 and 15 . 2 are located opposite each other and at a distance from each other. The forming suction boxes 15 . 1 , 15 . 2 have a curved suction surface 16 having a radius of curvature R K (arrow) of 1,500 mm to 10,000 mm, specifically of 2,000 mm to 5,000 mm.
[0042] The first forming suction box 15 . 1 includes at least one suction chamber 17 . 1 , the second forming suction box 15 . 2 includes two suction chambers 17 . 21 , 17 . 22 whose vacuums are adjustable/controllable by means of controllable vacuum sources 18 . 1 , 18 . 2 .
[0043] In accordance with the present invention a multitude of forming strips 19 are located opposite the first suction chamber 17 . 21 of the second forming suction box 15 . 2 . At least one of the forming strips 19 is mounted flexibly, or at least one of the forming strips 19 is mounted stationary, whereby their base positions are adjustable relative to the top wire 3 , for example by means of sliding or pivoting.
[0044] Additionally, the headbox 8 includes a headbox nozzle 13 in which at least one machine-wide separating element 14 , specifically a plate, is located. Two separating elements 14 are depicted in FIG. 1. This separating element 14 may be divided into sections across the machine width and its effective length may be designed to be movable within the headbox nozzle 13 by way of a mechanism including a control unit. Utilization of at least one separating element 14 is recommended, particularly when using wood-free fiber suspensions.
[0045] The twin wire zone 5 of the twin wire former 1 covered by the present invention, as viewed in the direction of wire travel S, essentially rises vertically from the bottom to the top, whereby the vertical excursion Av from the vertical plane V assumes a value of −15° to +15°, preferably from −5° to +5°.
[0046] A schematic side view of a second embodiment, which is similar to the first embodiment of the twin wire former 1 , according to the present invention, is shown in FIG. 2. We hereby refer to FIG. 1 for reference.
[0047] The present invention provides that a wet suction box 20 which is effective on the top wire 3 is located downstream from the first forming suction box 15 . 1 which is effective on the bottom wire 2 as viewed in the direction of wire travel S. The forming suction box 15 . 1 includes three suction chambers 15 . 11 , 15 . 12 15 . 13 , whereby the vacuum is controlled by way of an adjustable vacuum source 18 . 3 . In contrast, the wet suction box 20 includes only one suction chamber 20 . 1 which is supplied with vacuum, whereby the vacuum is controlled by way of an adjustable vacuum source 18 . 4 . A multitude of forming strips 19 are located opposite the forming suction box's 15 . 1 three suction chambers 15 . 11 , 15 . 12 , and 15 . 13 . The headbox 8 , which is illustrated only partially in FIG. 2, does not contain a machine wide separation element, specifically a plate.
[0048] [0048]FIGS. 3 and 4 illustrate schematic side views of a third and fourth embodiment of the twin wire former 1 according to the present invention. Since the configurations are again similar in principal to the embodiment in FIG. 1, we refer you to FIG. 1 for reference.
[0049] Both FIG. 3 and FIG. 4 provide, according to the present invention, that the twin wire zone 5 , as viewed in the direction of wire travel S, rises from the bottom to the top with an incline N from the horizontal plane H of approximately 5° to 45°. In FIG. 3 the headbox 8 which is illustrated only partially, is located at an angle toward the right bottom and in FIG. 4 at an angle toward the right top. The twin wire formers 1 in both FIG. 3 and FIG. 4 show two forming suction boxes 15 . 1 , 15 . 2 which are located immediately downstream from the rotating forming roll 6 , as viewed in the direction of wire travel S. FIG. 3 illustrates a forming suction box 15 . 1 located on the bottom wire 2 , followed by a forming suction box 15 . 2 located on the top wire 3 , with forming strips 19 located opposite it. In contrast, FIG. 4 shows an arrangement whereby a suction forming box 15 . 1 is first located on the top wire 3 , with forming strips 19 located opposite it, followed by a forming suction box 15 . 2 located on the bottom wire.
[0050] In FIG. 3 a turning roller 21 is located downstream from the second forming suction box 15 . 2 , as viewed in the direction of wire travel S, which allows the twin wire zone 5 to slope from top to bottom in the end zone. A separating element 11 in the embodiment of a transfer suction box 22 which separates the top wire 3 from the formed fiber web 4 , and from the bottom wire 2 is located following the turning roller 21 . A flat suction box 23 and a suction couch roll 12 are located following the transfer suction box 22 . At a downstream pick-up roll 25 the fiber web 4 is taken from the bottom wire 2 by a felt 24 and is transferred to the subsequent manufacturing process.
[0051] In FIG. 4 a separating element 11 in the embodiment of a suction couch roll 12 is located downstream from the second forming suction box 15 . 2 as viewed in the direction of wire travel S. This separates the top wire 3 from the formed fiber web 4 and from the bottom wire 2 .
[0052] [0052]FIG. 5 is a diagram of the operating performance for fiber suspensions in a conventional Roll-Blade-Former concept. The abscissa indicates the throughput D S of fiber suspension through the headbox in [1/(min·m)], the ordinate indicates the forming shoe dewatering E F in [1/(min·m)]. The throughput D S assumes a value range of 8,500 [1/(min·m)] (left terminating straight line) to 18,380 [1/(min·m)] (right terminating straight line), while the forming shoe dewatering E F assumes a value range of 600 [1/(min·m)] (bottom terminating straight line) to 2000 [1/(min·m)] (top terminating straight line). The terminating straight lines provide an operating window in which the Roll-Blade-Former can be operated along a curve K (bold print) with good results within a wider weight range (specific product volume P). Very good results are achieved with the Roll-Blade-Former, for example with a view to sheet formation, within an optimum operating window Af opt. which is defined by the following terminating straight lines:
[0053] throughput D S with the terminating straight lines at 15,000 [1/(min·m)] and 18,380 [1/(min·m)], and forming shoe dewatering E F at 1,300 [1/(min·m)] and 1,800 [1/(min·m)].
[0054] [0054]FIG. 6 illustrates an enlarged version of the optimum operating window Af opt. , whereby the operating point AP is in the optimum operating window Af opt. . On product changes the operating point AP leaves the optimum operating window Af opt . (vertical down arrow) and is placed on the curve K′ (broken line) outside the operating window A F , providing poorer results. With the known and aforementioned twin wire formers the fiber suspension throughput D S through the headbox must then be increased in a negative way (upward arrow, angled toward right) in order to return to the optimum operating window.
[0055] In summary it can be said that the present invention of a twin wire former provides, that the aforementioned disadvantages of the state of the art are completely avoided and that fiber suspensions containing long fibers which are particularly difficult to form, for example papers, can be put to optimum use.
[0056] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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The invention relates to a twin wire former for the production of a fiber web specifically a paper, cardboard or tissue web, from a fiber suspension. The invention is characterized in that
the rotating forming roll has an open volume and is a non-suction type;
the rotating forming roll has a forming roll diameter of less than 1,400 mm;
the rotating forming roll has a forming roll angle of wrap of less than 70°;
a forming suction box is located immediately downstream from the rotating forming roll as viewed in direction of wire travel; and
in the area of the wedge-shaped inlet nip, the fiber stock suspension has a stock density of between 0.4% and 2.0%, preferably between 0.6% and 1.5%.
These characteristics result in an improved forming quality and web quality.
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This application is a divisional part of application Ser. No. 09/957,184, filed on Sep. 21, 2001, now U.S. Pat. No. 6,576,085 B2, which is a divisional of application Ser. No. 09/224,804 filed on Dec. 31, 1998, now U.S. Pat. No. 6,346,169 B1, for which priority is claimed under 35 U.S.C. § 120. This application also claims priority of Application No. 10-4877 filed in Japan on Jan. 13, 1998 under 35 U.S.C. § 119. The entire contents of each of these applications is hereby incorporated by reference.
BACKGROUND OF THE PRIOR ART
1. Technical Field
This invention relates to a paper bulking promoter with which the sheets of paper obtained from a pulp feedstock can be bulky without impairing paper strength.
2. Description of the Prior Art
Recently, there is a desire for high-quality paper, e.g., paper excellent in printability and voluminousness. Since the printability and voluminousness of paper are closely related to the bulkiness thereof, various attempts have been made to improve bulkiness. Examples of such attempts include a method in which a crosslinked pulp is used (JP-A 4-185792, etc.) and a method in which a mixture of pulp with synthetic fibers is used as a feedstock for papermaking (JP-A 3-269199, etc.). Examples thereof further include a method in which spaces among pulp fibers are filled with a filler such as an inorganic (JP-A 3-124895, etc.) and a method in which spaces are formed (JP-A 5-230798, etc.). On the other hand, with respect to mechanical improvements, there is a report on an improvement in calendering, which comprises conducting calendering under milder conditions (JP-A 4-370298).
However, the use of a crosslinked pulp, synthetic fibers, etc. makes pulp recycling impossible, while the technique of merely filling pulp fiber spaces with a filler and the technique of forming spaces result in a considerable decrease in paper strength. Furthermore, the improvement in mechanical treatment produces only a limited effect and no satisfactory product has been obtained so far.
Also known is a method in which a bulking promoter is added during papermaking to impart bulkiness to the paper. Although fatty acid polyamide polyamines for use as such bulking promoters are on the market, use of these compounds results in a decrease in paper strength and no satisfactory performance has been obtained therewith.
SUMMARY OF THE INVENTION
The inventors have made intensive investigations in view of the problems described above. As a result, they have found that by incorporating at least one compound selected among specific cationic compounds, amine compounds, acid salts of amine compounds, amphoteric compounds, amide compounds, quaternary ammonium salts, and imidazoline derivatives optionally together with at least one specific nonionic surfactant into a pulp feedstock, e.g., a pulp slurry, in the papermaking step, the sheet made from the feedstock can have improved bulkiness without detriment to paper strength. This invention has thus been achieved.
Namely, this invention provides a process for producing a bulky paper, comprising the step of making paper from pulp in the presence of a bulking promoter comprising at least one compound selected from the group consisting of a cationic compound, an amine compound, an acid salt of an amine compound, an amphoteric compound, an amide compound, a quaternary ammonium salt, and an imidazoline derivative.
The term “paper bulking promoter” used herein means an agent with which a sheet of paper obtained from a pulp feedstock can have a larger thickness (can be bulkier) than that having the same basis weight obtained from the same amount of a pulp feedstock.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Examples of the cationic compounds for use in this invention include compounds represented by the following formulae (a 1 ) and (b 1 ):
wherein R 11 and R 12 are the same as or different from each other, and an alkyl, alkenyl or β-hydroxyalkyl group having 8 to 24 carbon atoms; R 13 , R 14 and R 15 are the same as or different from each other, and an alkyl or hydroxyalkyl group having 1 to 8 carbon atoms, benzyl or -(AO)n 11 -Z 11 , wherein AO is an oxyalkylene unit having 2 or 3 carbon atoms, Z 11 is a hydrogen atom or an acyl group and n 11 is an integer of 1 to 50; R 16 is an alkyl, alkenyl or β-hydroxyalkyl group having 8 to 36 carbon atoms; and X − is an anionic ion.
In the formula (a 1 ), R 11 and R 12 , which are the same or different, each preferably is an alkyl or alkenyl group having 10 to 22 carbon atoms. R 13 and R 14 , which are the same or different, each preferably is a hydrogen atom or an alkyl group having 1 to 3 carbon atoms. Examples of X − , which is an anionic ion, include hydroxy, halide, and monoalkyl(C1-C3)sulfate ions and anions derived from inorganic or organic acids. X − is preferably a halide ion, especially Cl − .
In the formula (b 1 ), R 13 , R 14 , and R 15 , which are the same or different, each is preferably an alkyl group having 1 to 3 carbon atoms or a benzyl group. R 16 is preferably an alkyl group having 10 to 22 carbon atoms. Examples of the anionic ion X − are the same as those in the formula (a 1 ). X − is preferably a halide ion, especially Cl − .
In the present invention, the cationic compounds may include quaternary ammonium salts.
Hereinafter X − may be an anionic ion as an anionic ion.
Examples of the amine compounds and the acid salts of amine compounds for use in this invention include compounds represented by the following formulae (a 2 ) to (f 2 ):
wherein R 21 is an alkyl, alkenyl or β-hydroxyalkyl group having 8 to 36 carbon atoms; R 22 and R 23 are the same as or different from each other, and a hydrogen atom, an alkyl group having 1 to 24 carbon atoms or an alkenyl group having 2 to 24 carbon atoms; R 24 and R 25 are the same as or different from each other, and a hydrogen atom or an alkyl group having 1 to 3 carbon atoms; HB represents an inorganic acid or an organic acid; AO is an oxyalkylene unit having 2 or 3 carbon atoms; l 21 and m 21 are 0 or a positive integer, and the sum in total of l 21 , and m 21 is in an integer ranging from 1 to 300; and n 21 is a number of 1 to 4.
In the formulae (a 2 ) to (f 2 ), R 21 is preferably an alkyl group having 10 to 22 carbon atoms. R 22 and R 23 , which are the same or different, each preferably is a hydrogen atom or an alkyl group having 1 to 22 carbon atoms. In HB in the acid salts of amine compounds, B is preferably a halogen or a carboxylate having 2 to 5 carbon atoms, especially preferably a carboxylate having 2 or 3 carbon atoms. Preferred amine compounds and preferred acid salts of amine compounds are the compounds represented by the formulae (a 2 ) and (b 2 ), respectively.
The acid salt represented by the formula (b 2 ) may be signified by the following formula (b 21 ):
wherein R 21 , R 22 and R 23 are same as above-mentioned; H is hydrogen atom; and B − represents a base.
That is, the acid salt may be an ionized compound.
Examples of the amphoteric compounds for use in this invention include compounds represented by the following formulae (a 3 ) to (j 3 ):
wherein R 31 , R 32 and R 33 are the same as or different from each other, and an alkyl group having 1 to 24 carbon atoms or an alkenyl group having 2 to 24 carbon atoms; R 34 is an alkyl, alkenyl or β-hydroxyalkyl group having 8 to 36 carbon atoms; M is a hydrogen atom, an alkali metal atom, a half a mole of an alkaline earth metal atom or an ammonium group; Y 31 is R 35 NHCH 2 CH 2 —, wherein R 35 is an alkyl group having 1 to 36 carbon atoms, or an alkenyl or a hydroxy alkyl group having 2 to 36 carbon atoms; Y 32 is a hydrogen atom or R 35 NHCH 2 CH 2 —, R 35 being defined above; Z 31 is —CH 2 COOM, M being defined above; and Z 32 is a hydrogen atom or —CH 2 COOM, M being defined above.
In the formulae (a 3 ) to (j 3 ), R 31 , R 32 , and R 33 , which are the same or different, each preferably is an alkyl group having 1 to 22 carbon atoms. Especially preferably, R 31 is an alkyl group having 10 to 20 carbon atoms, and R 32 and R 33 each is an alkyl group having 1 to 3 carbon atoms. R 34 is preferably an alkyl group having 10 to 22 carbon atoms. Preferred amphoteric compounds are those represented by the formulae (a 3 ) and (b 3 ).
Examples of the other amine compounds and the other acid salts of an amine compound for use in this invention include compounds represented by the following formulae (a 4 ) to (d 4 ):
wherein R 41 is an alkyl, alkenyl or β-hydroxyalkyl having 8 to 35 carbon atoms; R 43 and R 44 are same as or different from each other, an alkyl, alkenyl or β-hydroxyalkyl group having 7 to 35 carbons atoms; R 46 is a hydrogen atom or an alkyl group having 1 to 3 carbon atoms; R 45 is an alkyl group having 1 to 3 carbon atoms; R 42 is a hydrogen atom or R 47 , wherein R 47 is an alkyl, alkenyl or β-hydroxyalkyl group having 7 to 35 carbons atoms; Y 41 is a hydrogen or —COR 44 ; and Z 41 is —CH 2 CH 2 O(AO)n 41 —OCOR 47 , wherein A is a liner or branched alkylene unit having 2 to 3 carbon atoms, or —CH 2 CH(OH)—CH 2 OCOR 47 and n 41 is an average added-number ranging 1 to 20.
Examples of the amide compounds for use in this invention include compounds represented by the following formulae (a 5 ) and (b 5 ):
wherein R 51 and R 54 are same as or different from each other, an alkyl, alkenyl or β-hydroxyalkyl group having 7 to 35 carbon atoms; R 52 and R 53 are same as or different from each other, a hydrogen atom or an alkyl group having 1 to 3 carbon atoms; and Y 51 and Y 52 are same as or different from each other, and a hydrogen atom, R 52 CO—, R 54 CO—, —(AO)n 51 —COR 55 , wherein A is a liner or branched alkylene unit having 2 to 3 carbon atoms n 51 is an average added-number ranging 1 to 20, and R 55 is an alkyl, alkenyl or β-hydroxyalkyl group having 7 to 35 carbon atoms, or —(AO)n 51 —H, wherein A and n 51 are defined above.
Examples of the cationic compounds for use in this invention include quaternary ammonium salts represented by the following formulae (a 6 ) and (b 6 ):
wherein R 61 and R 63 are same as or different from each other, an alkyl, alkenyl or β-hydroxyalkyl group having 7 to 35 carbons atoms; R 65 is a hydrogen atom or an alkyl group having 1 to 3 carbon atoms; R 62 and R 64 are same as or different from each other, an alkyl group having 1 to 3 carbon atoms; and X − is an anionic ion.
Examples of the imidazoline derivative for use in this invention include compounds represented by the following formulae (a 7 ):
wherein R 71 is an alkyl, alkenyl or β-hydroxyalkyl group having 7 to 35 carbons atoms.
The paper bulking promoter of this invention preferably further contains at least one specific nonionic surfactant. By the use of at least one of compounds represented by the above formulae (a 1 ) and (b 1 ), (a 2 ) to (e 2 ), (a 3 ) to (h 3 ), (a 4 ) to (d 4 ), (a 5 ) and (b 5 ), (a 6 ) and (b 6 ), and (a 7 ); and at least one specific nonionic surfactant in combination, the effect of this invention can be improved. Examples of the nonionic surfactant for use in this invention include the following (A) to (C).
(A): a compound represented by the following formula (A)
R 81 O (EO) m 81 (PO) n 81 H (A)
wherein R 81 is a C6 to C22 straight or branched alkyl or alkenyl group or an alkylaryl group having a C4 to C20 alkyl group; E is an ethylene unit; P is a propylene unit; m 81 and n 81 are an average number of added moles, m 81 is a number in the range of 0 to 20 and n 81 is a number in the range of 0 to 50; and the addition form of EO and PO may be any of block and random and the addition order of EO and PO may be not limited.
The compounds represented by the formula (A) are ones each obtained by causing a higher alcohol, an alkylphenol, or the like in which the alkyl has 6 to 22 carbon atoms to add an alkylene oxide such as ethylene oxide (EO) or propylene oxide (PO). In this invention is used the compound in which the average number of moles of ethylene oxide added is in the range of 0≦m 81 ≦20. The range of the average number of moles added, m 81 , is preferably 0≦m 81 ≦10, more preferably 0≦m 81 ≦5. If m 81 exceeds 20, the effect of imparting bulkiness to paper is lessened. Further, the compound used is one in which the average number of moles of propylene oxide (PO) added, n 81 , is in the range of 0≦n 81 ≦50, preferably 0≦n 81 ≦20. When n 81 exceeds 50, such a compound is economically disadvantageous although the decrease in performance is little.
R 81 in the formula (A) is preferably a linear or branched, alkyl or alkenyl group having 8 to 18 carbon atoms. If R 81 in the formula (A) is an alkyl or alkenyl group in which the number of carbon atoms is outside the range of from 6 to 22 or if R 81 is an alkylaryl group in which the number of carbon atoms of the alkyl group is outside the range of from 4 to 20, then the compound is less effective in imparting bulkiness to paper.
Examples of E and P in the formula (A), which each represents a linear or branched alkylene group having 2 or 3 carbon atoms, include ethylene and propylene. When the group (EO) m 81 (PO) n 81 in the formula (A) is composed of a combination of polyoxyethylene and polyoxypropylene, the C 2 H 4 O and C 3 H 6 O units may have any of random and block arrangements (or the addition form of EO and PO may be any of block and random). In this case, the polyoxypropylene (C 3 H 6 O) group(s) account for preferably at least 50 mol %, especially preferably at least 70 mol %, of all groups added on the average. The alkylene oxide group bonded to R may begin with any of EO and PO (or the addition order of EO and PO may be not limited).
(B): Compounds represented by the following formula (B)
R 81 COO (EO) m 81 (PO) n 81 R b (B)
wherein R 81 , E, P, m 81 and n 81 are the same as those of the formula (A); and R b is H, an alkyl, an alkenyl or an alkylaryl group.
Preferred examples of R 81 , E, P, m 81 , and n 81 in the formula (B) are the same as those in the formula (A). Examples of the alkyl and alkenyl groups represented by R b in the formula (B) include those having 1 to 4 carbon atoms, while examples of the alkylaryl group represented by R b include alkylphenyl groups in each of which the alkyl has 1 to 4 carbon atoms.
(C): a nonionic surfactant selected from the followings (1) to (3):
(1) an oil-fat type nonionic surfactant (i.e. a ninionic surfactant based on fat),
(2) a sugar-alcohol type nonionic surfactant (i.e. a nonionic surfactant based on sugar alcohol) and
(3) a sugar-type nonionic surfactant (i.e. a nonionic surfactant based on sugar).
(1) Nonionic Surfactants Based on Fat
Examples of the nonionic surfactants based on a fat (1) include ones obtained by mixing an alcohol having 1 to 14 hydroxy groups with a fat such as those given in, e.g., JP-A 4-352891 or with a product of the reaction of the fat with glycerol and causing the mixture to add an alkylene oxide (AO) Preferred is one obtained by causing a mixture of a fat and a polyhydric alcohol to add an AO. The AO is ethylene oxide (EO) and/or propylene oxide (PO). In the case of using both EO and PO, the EO/PO polymer may have any of random and block arrangements. The average number of moles of EO added is preferably 0 to 200, more preferably 10 to 100, while that of PO added is preferably 0 to 150, more preferably 2 to 100.
Examples of the fat usable for this type of nonionic surfactant include land animal fats, marine animal fats, hardened or semihardened oils obtained therefrom, and recovery oils obtained during the purification of these fats. Preferred examples thereof include coconut oil, beef tallow, fish oils, linseed oil, rapeseed oil, and castor oil. In the case where any of these fats is reacted beforehand with glycerol, the fat/glycerol ratio is preferably from 1/0.05 to 1/1.
Examples of monohydric alcohols among the alcohols having 1 to 14 hydroxy groups usable for this type of nonionic surfactant include linear or branched, saturated or unsaturated alcohols having 1 to 24 carbon atoms and cyclic alcohols. Preferred are linear or branched, saturated alcohols having 4 to 12 carbon atoms. Examples of dihydric alcohols include α,ω-glycols having 2 to 32 carbon atoms, 1,2-diols, symmetric α-glycols, and cyclic 1,2-diols. Preferred are α,ω-glycols having 2 to 6 carbon atoms. Examples of trihydric and higher alcohols include those having 3 to 24 carbon atoms, such as glycerol, diglycerol, sorbitol, and stachyose. Especially preferred alcohols are di- to hexahydric alcohols having 2 to 6 carbon atoms.
(2) Nonionic Surfactants Based on Sugar Alcohol
Examples of the nonionic surfactants based on a sugar alcohol (2) include sugar alcohol/AO adducts, fatty acid esters of sugar alcohol/AO addicts, and fatty acid esters of sugar alcohols. The sugar alcohol as a component of a nonionic surfactant based on a polyhydric alcohol is an alcohol obtained from a monosaccharide having 3 to 6 carbon atoms through reduction of the aldehyde or ketone group. Examples thereof include glycerol, erythritol, arabitol, sorbitol, and mannitol. Especially preferred are those having 6 carbon atoms. The fatty acid as a component of the fatty acid ester in a sugar alcohol/AO adduct may be any of saturated and unsaturated fatty acids each having 1 to 24, preferably 12 to 18, carbon atoms. Preferred is oleic acid. With respect to the degree of esterification of the sugar alcohol, the number of OH groups which have undergone esterification may be any of from zero to all of the OH groups. However, the degree of esterification is preferably 1 to 3. The kinds of AO and the average number of moles of AO added are the same as in (1).
(3) Nonionic Surfactants Based on Sugar
Examples of the nonionic surfactants based on a sugar (3) include sugar/AO adducts, fatty acid esters of sugar/AO adducts, and sugar/fatty acid esters. The sugar may be a polysaccharide such as sucrose, besides any of the monosaccharides mentioned above with regard to the sugar alcohol. Preferred are glucose and sucrose. The kinds of AO and the average number of moles of AO added are the same as in (1). Especially preferred of the nonionic surfactants based on a sugar (3) are sugar/AO adducts, in particular, glucose/PO adducts in which the average number of moles of PO added is 1 to 10.
When at least one compound (i) selected among cationic compounds, amine compounds, acid salts of amine compounds, amphoteric compounds, amide compounds, quaternary ammonium salts, and imidazoline derivatives is used in combination with at least one nonionic surfactant (ii) such as the compounds (A) to (C) described above, the proportion of the compound (i) to the nonionic surfactant (ii) is from 100/0 to 1/99, preferably from 100/0 to 10/90 by weight.
The compounds (i) and (ii) maybe added either as a mixture of both or separately.
The bulking promoter of this invention is applicable to a variety of ordinary pulp feedstocks ranging from virgin pulps such as mechanical pulps and chemical pulps to pulps prepared (deinked) from various waste papers. The point where the bulking promoter of this invention is added is not particularly limited as long as it is within the papermaking process steps. In a factory, for example, the bulking promoter is desirably added at a point where it can be evenly blended with a pulp feedstock, such as, the refiner, machine chest, or headbox. After the bulking promoter of this invention is added to a pulp feedstock, the resultant mixture is subjected as it is to sheet forming. The bulking promoter remains in the paper. The paper bulking promoter of this invention is added in an amount of 0.01 to 10 wt. %, preferably 0.1 to 5 wt. %, based on the pulp.
The pulp sheet obtained by using the paper bulking promoter of this invention has a bulk density (the measurement method is shown in the Examples given later) lower by desirably at least 5%, preferably at least 7% than the product not containing the paper bulking promoter and has a tearing strength as measured according to JIS P 8116 of desirably at least 90%, preferably at least 95% of that of the product.
EXAMPLES
This invention will be explained below in more detail by reference to Examples, but the invention should not be construed as being limited thereto. In the Examples, all parts and percents are based on weight unless otherwise indicated.
When the unit number of an (AO) group is, defined by an integer, the compound is one of a mixture of reaction products. When it is defined by an average value, the compound is a mixture of reaction products.
Examples 1 to 42 and Comparative Example 1
[Pulp Feedstocks]
The deinked pulp and virgin pulp shown below were used as pulp feedstocks.
<Deinked Pulp>
A deinked pulp was obtained in the following manner. To feedstock waste papers collected in the city (newspaper/leaflet=70/30%) were added warm water, 1% (based on the feedstock) of sodium hydroxide, 3% (based on the feedstock) of sodium silicate, 3% (based on the feedstock) of a 30% aqueous hydrogen peroxide solution, and 0.3% (based on the feedstock) of EO/PO block adduct of beef tallow/glycerol (1:1), as a deinking agent, in which the amounts of EO and PO were respectively 70 and 10 (average number of moles added). The feedstock was disintegrated and then subjected to flotation. The resultant slurry was washed with water and regulated to a concentration of 1% to prepare a deinked pulp (DIP) slurry. This DIP had a freeness of 220 ml.
<Virgin Pulp>
A virgin pulp was prepared by disintegrating and beating an LBKP (bleached hardwood pulp) with a beater at room temperature to give a 1% LBKP slurry. This LBKP had a freeness of 420 ml.
[Bulking Promoters]
The cationic compounds, amine compounds, acids salts of amine compounds, and amphoteric compounds shown in Tables 1 to 5 were used optionally together with the nonionic surfactants shown in Table 6 in the combinations shown in Tables 7 and 8, which will be given later.
TABLE 1
Compound
Structure in the formula (a1)
No.
R 11
R 12
R 13
R 14
X −
Cationic
Compound
A-1
C18
C18
C1
C1
Cl −
A-2
C12
C14
C1
C1
Cl −
a-1
C2
C2
C1
C1
Cl −
a-2
C4
C4
C1
C1
Br −
TABLE 2
Compound
Structure in the formula (b1)
No.
R 13
R 14
R 15
R 16
X −
Cationic
Compound
B-1
C1
C1
C1
C12
Cl −
B-2
C1
C1
C1
C16
Br −
B-3
C1
C1
C1
C18
Cl −
B-4
benzyl
C1
C1
C12
Cl −
b-1
C1
C1
C1
C2
Cl −
b-2
C1
C1
C1
C4
Br −
TABLE 3
Compound
Structure in the formula (a2) or (b 2 )
No.
R 21
R 22
R 23
HB
Amine compound
and acid salt of
amine compound
C-1
C12
H
H
—
C-2
C18
H
H
—
C-3
C16/C18 =
C16/C18 =
H
—
3/7
3/7
C-4
C18
C1
C1
—
c-1
C4
H
H
—
c-2
C6
H
H
—
c-3
C2
C2
H
—
c-4
C4
C1
C1
—
C-5
C16/C18 =
H
H
CH 3 COOH
3/7
c-5
C4
H
H
CH 3 COOH
TABLE 4
Structure in the
Compound
formula (a 3 )
No.
R 31
R 32
R 33
Amphoteric
compound
D-1
C12
C1
C1
d-1
C4
C1
C1
TABLE 5
Structure in the formula
Compound
(b 3 )
No.
R 31
R 32
R 33
Amphoteric
compound
D-2
C12
C1
C1
D-3
C18
C1
C1
d-2
C6
C1
C1
TABLE 6 (1)/(2)/(3) Nonionic surfactant Weight No. (1) (2) (3) ratio 1 C12 alcohol 100/0/0 2 C12/C14 alcohol = 5/5 100/0/0 PO = 5 3 Beef tallow/fatty acid, 100/0/0 PO = 5 4 Methyl laurate, 100/0/0 EO2/PO3 block 5 Coconut 100/0/0 oil/glycerol = 1/1, EO2/PO10 block 6 Sorbitan monooleate, 100/0/0 EO20 7 Dobanol23 EO2/PO4 Sorbitan 75/25/0 random monooleate, EO10 8 C12 alcohol Sorbitan Hardened 80/15/5 monooleate, EO15 castor oil, EO25 9 C18 alcohol, PO = 10 100/0/0 10 Castor oil/fatty acid, 100/0/0 EO5/PO15 random 11 C12/C14/C18 C12 alcohol EO = 5 Fish oil/ 75/15/10 alcohol = 6/2/2, PO = 10 sorbitol = 1/1, PO = 15 12 Beef tallow/glycerol = 100/0/0 1/0.3 EO10/PO10 block 13 Sorbitan monolaurate, 100/0/0 EO15 14 C12/C14/C18 lauric acid EO5, 90/10/0 alcohol = 60/30/10, PO25 PO20 15 C12/C14 alcohol = 70/30 100/0/0 16 Lauric acid/stearic 100/0/0 acid = 50/50, PO = 18 17 Dobanol23, PO = 2 lauric acid/myristic Sorbitan 70/15/15 acid/palmitic acid = trioleate EO6 70/20/10. EO10, PO20 (Note) In the table, Cn means an alkyl group having n carbon atoms. In Table 6, each fat/polyhydric alcohol ratio is by mole, and the other ratios are by weight. EO and PO mean ethylene oxide and propylene oxide, respectively, and the numbers following these are the average numbers of moles added. “Dobanol 23” is an alcohol manufactured by Mitsubishi Chemical.
[Papermaking Method]
Each of the above 1% pulp slurries was weighed out in such an amount as to result in a sheet of paper having a basis weight of 60 g/m 2 . The pH thereof was adjusted to 4.5 with aluminum sulfate. Subsequently, various bulking promoters shown in Tables 7 and 8 were added in an amount of 3% based on the pulp. Each resultant mixture was formed into a sheet with a rectangular TAPPI paper machine using an 80-mesh wire. The sheet obtained was pressed with a press at 3.5 kg/cm 2 for 2 minutes and dried with a drum dryer at 105° C. for 1 minute. After each dried sheet was held under the conditions of 20° C. and a humidity of 65% for 1 day to regulate its moisture content, it was evaluated for bulk density as a measure of paper bulkiness and for tearing strength as a measure of paper strength performance. The results obtained are shown in Tables 7 and 8. Ten found values were averaged.
<Evaluation Item and Method>
Bulkiness (Bulk Density)
The basis weight (g/m 2 ) and thickness (mm) of each sheet having a regulated moisture content were measured, and its bulk density (g/cm 3 ) was determined as a calculated value.
Equation for calculation:
Bulkiness (Bulk Density)=(basis weight)/(thickness)×0.001
The smaller the absolute value of bulk density, the higher the bulkiness. A difference of 0.02 in bulk density is sufficiently recognized as a significant difference.
Paper Strength (Tearing Strength)
Each sheet having a regulated moisture content was examined according to JIS P 8116 (Testing Method for Tearing Strength of Paper and Paperboard).
Equation for calculation:
Tearing strength= A/S ×16
Tearing strength: (gf) A: Reading S: Number of torn sheets
The larger the absolute value of tearing strength, the higher the paper strength. A difference of 20 gf in tearing strength is sufficiently recognized as a significant difference.
TABLE 7
Cationic
compound, amine
compound, acid
Nonionic
Deinked
salt of amine
surfactant
pulp
LBKP
compound, of
used in
Bulk
Tearing
Bulk
Tearing
amphoteric
combination
(i)/(ii)
density
strength
density
strength
Example
compound (i)
(ii)
weight ratio
(g/cm 3 )
(gf)
(g/cm 3 )
(gf)
1
B-1
none
—
0.330
420
0.377
480
2
B-2
↑
—
0.328
420
0.376
480
3
B-3
↑
—
0.325
415
0.374
475
4
B-4
↑
—
0.330
415
0.378
480
5
A-1
↑
—
0.325
420
0.375
475
6
A-2
↑
—
0.330
420
0.377
480
7
C-1
↑
—
0.342
430
0.385
485
8
C-2
↑
—
0.340
430
0.383
485
9
C-3
↑
—
0.338
425
0.383
480
10
C-4
↑
—
0.335
420
0.379
480
11
C-5
↑
—
0.332
420
0.377
480
12
D-1
↑
—
0.331
415
0.377
475
13
D-2
↑
—
0.331
415
0.377
475
14
D-3
↑
—
0.328
420
0.375
475
15
B-1
1
20/80
0.313
410
0.349
470
16
B-3
2
30/70
0.308
400
0.342
460
17
B-3
3
50/50
0.309
405
0.344
455
18
B-3
4
85/15
0.312
410
0.346
460
19
B-3
5
90/10
0.314
410
0.349
465
20
A-1
6
85/15
0.309
400
0.345
460
21
B-4
7
30/70
0.310
405
0.345
455
22
B-3
8
20/80
0.308
400
0.341
460
23
C-2
9
65/35
0.324
410
0.360
470
24
C-3
10
80/20
0.323
415
0.358
470
25
C-4
11
10/90
0.317
415
0.355
465
26
C-5
12
70/30
0.321
410
0.357
465
27
C-5
13
55/45
0.322
415
0.357
470
28
C-5
14
20/80
0.319
415
0.356
465
29
D-1
15
15/85
0.314
410
0.348
460
30
D-3
16
80/20
0.312
405
0.345
460
31
D-3
17
35/65
0.308
400
0.342
455
TABLE 8
Cationic compound,
amine compound,
acid salt of amine
compound, or
Nonionic
Deinked pulp
LBKP
amphoteric
surfactant used in
Bulk density
Tearing strength
Bulk density
Tearing strength
Example
compound (i)
combination (ii)
(g/cm 3 )
(gf)
(g/cm 3 )
(gf)
32
b-1
none
0.366
440
0.405
495
33
b-2
↑
0.365
440
0.402
485
34
a-1
↑
0.365
435
0.404
490
35
a-2
↑
0.366
430
0.405
490
36
c-1
↑
0.367
435
0.404
495
37
c-2
↑
0.368
430
0.407
490
38
c-3
↑
0.365
425
0.404
490
39
c-4
↑
0.365
435
0.403
485
40
c-5
↑
0.366
430
0.405
490
41
d-1
↑
0.364
440
0404
495
42
d-2
↑
0.363
430
0.406
490
Control (no bulking
0.375
430
0.414
490
promoter)
Comparative example 1
0.330
280
0.379
345
Note
In Comparative Example 1 was used commercial bulking promoter “Bayvolume P Liquid” (fatty acid polyamide polyamine type; manufactured by Bayer AG)
|
This invention is to provide a paper bulking promoter with which a highly bulky sheet can be obtained without impairing paper strength. Namely, this invention provides a process for producing a bulky paper, comprising the step of making paper from pulp in the presence of a bulking promoter comprising a cationic compound.
| 3
|
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates an improved method of detecting microbiological growth and, more particularly, to a method of filtering background noise of chemical redox reactions to prevent or minimize false positives in analyzing a sample using the technique of measuring the redox reactions in a sealed container which is a result of microbial growth.
BACKGROUND OF THE INVENTION
[0002] Current methods are manual for detection of microorganisms. In such manual systems, a sample of material to be tested is incubated, usually in a suitable growth medium. Various manipulations such as agitation are required during the incubation and monitoring period. The detection of growth is achieved by visual inspection. For example, technicians observe and assess the growth of bacteria on a Petri dish, or evaluate the clarity of a broth (turbidity). The visual observations and assessments are subjective and, therefore, subject to error. In addition, these manual methods are labor intensive, require significant manipulation, and entail observation of all samples by laboratory personnel.
[0003] A number of methods have been suggested to detect the presence or absence of microorganisms by less subjective means. U.S. Pat. No. 3,743,581 (1973), Cady et al., discloses a method for monitoring microbiological growth by measuring the change in the conductivity of selected nutrient media inoculated with a sample.
[0004] U.S. Pat. No. 3,907,646 (1975), Wilkins et al, describes measurement of gas production of microorganisms. A pressure transducer is applied to a test tube and connected to a power source and strip recorders. Measurements are recorded on the strip recorders producing a plot of an electrical signal, which is generated over time, indicative of the presence and quantity of microorganisms. The instrument is very large and cumbersome, making it impractical to monitor multiple samples.
[0005] U.S. Pat. No. 4,152,213 describes a system by which the growth of microorganisms in a sealed container is detected by measuring reduction in headspace pressure as the microorganism consumes oxygen and comparing the reduction in pressure to a reference standard of the initial pressure. A vacuum sensor senses a reduction in pressure in the headspace of a container and provides an electrical signal to remote electronics. A major problem with such a system is that it is limited to those organisms that consume oxygen. Many microorganisms do not consume oxygen. Thus, the presence of a vacuum is not a universal indicator of microbial growth. Another problem with such a system is that in many instances the maximum decrease in the headspace pressure is small in comparison to the natural variations of the atmospheric pressure. In addition, this method requires precise pressure sensors since it functions on the basis of absolute value of initial and threshold pressures.
[0006] U.S. Pat. No. 5,232,839 describes a system by which the presence of microbiological growth in a sealed sample container is detected by measuring the rate of change of headspace pressure in the container as the microorganism consumes oxygen and comparing the change in pressure to a reference standard of the initial pressure. A vacuum sensor senses a reduction in pressure in the headspace of a container and provides an electrical signal to remote electronics. A major problem exists for weak consumers, or slower growing organisms, where background redox reactions can occur because the reagents added to the culture broth cause an unpredictable change in the pressure differential in the headspace due to reduction oxidation. A major problem with such a system is that it suffers from false positives due to background redox reactions.
[0007] It is well known that pH buffers are utilized for end point growth determinations using pH dyes, such as phenol red. The pH buffers are known to stabilize background pH drift due to chemical reactions within the test system. It is with this concept that one uses Redox buffer/dye systems to stabilize background chemical redox reactions, which can be applied generally to a detection system for microbial growth.
[0008] Use of poising agents to stabilize redox dyes for determination of end point growth reactions, such as antibiotic susceptibility has been described in U.S. Pat. No. 5,501,959 by Lancaster et al.
[0009] U.S. Pat. No. 6,395,506 discloses a device for monitoring cells for detection and evaluation of metabolic activity of eukaryotic and/or prokaryotic cells based upon their ability to consume dissolved oxygen. The methods utilize a luminescence detection system which makes use of the sensitivity of the luminescent emission of certain compounds to the presence of oxygen, which quenches (diminishes) the compound's luminescent emission in a concentration dependent manner.
SUMMARY OF THE INVENTION
[0010] According to the present invention, there is disclosed a method of stabilizing the output signal of a system that detects microbiological growth in a sealed sample container that contains a sample which may contain an unknown microorganism. The method comprises: (a) providing a sealed sample container which contains a fluid mixture of a culture broth, at least one reagent mixture, the fluid sample, and at least one poising agent for stabilizing the base line pressure within a headspace above the fluid mixture in the sample container; (b) monitoring pressure changes within the headspace of the sealed sample container; and (c) indicating a presence of microbiological growth within the sealed sample container as a function of the change of the pressure in the headspace.
[0011] Also according to the invention, the method includes providing a pair of coupled poising agents. The pair of coupled poising agents are selected from the group consisting essentially of ferricyanide/ferrocyanide and ferrous/ferric.
[0012] Further according to the invention, the method includes providing a second poising agent which is a reversible oxidation-reduction indicator. The second poising agent selected from the group consisting essentially of methylene blue, toluidine blue, azure I, and gallocyaninc.
[0013] Still further according to the present, the method includes providing at least two reagent mixtures. One reagent mixture is a growth supplement and a second reagent mixture of an antibiotic supplement.
[0014] According to another embodiment of the invention, there is also disclosed a method of stabilizing the output signal of a system that is monitoring a liquid mixture in a sealed container with a sensor that detects redox outputs related to microbial growth. The method comprises the step of mixing into the liquid mixture at least one poising agent for stabilizing the “output” of the test within the sample container.
[0015] Also according to another embodiment of the invention, the step of mixing at least one poising agent comprises the step of mixing a pair of coupled poising agents. The pair of coupled poising agents are selected from the group consisting of ferricyanide/ferrocyanide and ferrous/ferric.
[0016] Further according to another embodiment of the invention, a second poising agent which is a reversible oxidation-reduction indicator can be mixed into the liquid mixture. The second poising agent is selected from the group consisting essentially of methylene blue, toluidine blue, azure I, and gallocyanide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Reference will be made in detail to preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. The drawings are intended to be illustrative, not limiting. Although the invention will be described in the context of these preferred embodiments, it should be understood that it is not intended to limit the spirit and scope of the invention to these particular embodiments.
[0018] Certain elements in selected ones of the drawings may be illustrated not-to-scale, for illustrative clarity.
[0019] The structure, operation, and advantages of the present preferred embodiment of the invention will become further apparent upon consideration of the following description taken in conjunction with the accompanying drawings, wherein:
[0020] FIG. 1 is an elevational view of a prior art culture container and pressure sensing device connected to the bottle headspace by a disposable connector adapted to be used in performing the method of the present invention;
[0021] FIG. 2 is a graph showing the curve of voltage versus time in a pressure analysis of a typical mixture of a culture broth and reagents;
[0022] FIG. 3 is a graph showing the curve of voltage versus time in a pressure analysis of the identical mixture of culture broth and reagents as shown in the curve of FIG. 2 plus a pair of poising agents added to the mixture in accordance with the present invention;
[0023] FIG. 4 is a graph showing the curve of voltage versus time in a typical pressure analysis of a mixture of culture broth and reagents as shown in the curve of FIG. 2 plus a pair of poising agents added to the mixture in accordance with the present invention, plus a test sample containing a microorganism for a positive growth response;
[0024] FIG. 5 is a graph showing percentage of false positivity using the prior art mixture of culture broth and reagents as compared to the mixture of culture broth and reagents and poising agents according to the present invention; and
[0025] FIG. 6 is a graph showing the percentage of true positives with the prior art mixture of culture broth and reagents as compared to the mixture of culture broth and reagents and poising agents according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring to FIG. 1 , a vial or container 10 of well-known construction such as a glass bottle having a cap 12 with a resilient elastomeric stopper 14 that is exposed at its upper end in the performance of the method. The container 10 is filled with a culture broth of either an aerobic or anaerobic culture medium depending upon the microorganism, which is to be detected prior to sealing the container with cap 12 . The container 10 includes a neck 16 and a shoulder 18 .
[0027] Besides the culture broth, one or two types of a growth supplement, such as OADC (oleic acid, albumin, dextrose and catalase), egg yolk, or any supplement required to enhance growth, can be added to the culture broth in the bottle. The growth supplement is typically added to the culture broth before the bottle is sealed. In addition, an antibiotic supplement, to inhibit microorganisms, other than the target, present within the sample can be added to the culture broth. For example, the culture medium or broth can include naladixic acid, amphoteracin B, vancomycin. Here again, the antibiotic supplement is typically added to the culture broth and possibly the growth supplement before the bottle is sealed. At this stage, in the prior art, it is customary to add the sample to be tested to the bottle. In a typical system, the sample is 0.5% to 5% of the liquid mixture which includes the sample, the culture broth, the growth supplement (if included) and/or the antibiotic supplement (if included). The growth supplement is 1% to 10% of the liquid mixture and the antibiotics (if included) are 0.001% to 0.1% (w/v) of the liquid mixture.
[0028] However, in the prior art systems, there was often a problem of false positives due to chemical redox reactions (reduction/oxidation). The reagents themselves, such as the growth supplement and/or the antibiotic supplement can react with oxygen in the headspace or the sensor, even without a sample being added to the mixture in the container 10 . Thus, there can be a change in the concentration of oxygen within the system and therefore, the pressure in the headspace 20 above mixture 21 irrespective of the sample. Utilization or consumption of oxygen within the system due to reagent-driven chemical reactions (baseline drift) that will, in turn, cause increased numbers of false positives. This baseline drift, also referred to as background noise, cannot be predicted because the reagents are not chemically defined and are comprised of variable amounts of reactive components.
[0029] According to the present invention, a poising agent (a oxidation-reduction [redox] stabilizer) is added to the mixture of the culture broth and the reagents, such as the growth supplement and/or the antibiotic supplement. Surprisingly, it has been found that that one or two poising agents act to stabilize the effects of the reagents, i.e. the growth supplement and/or the antibiotic supplement, and thereby significantly reduce the baseline drift.
[0030] Preferably, a pair of coupled poising agents will be added to the growth medium to stabilize the oxidation-reduction potential within the range where the culture broth and reagent mixture is oxidized. Suitable poising pairs include ferricyanide/ferrocyanide, ferrous/ferric, and the like.
[0031] Using the ferricyanide/ferrocyanide as the coupled poising agents is preferred. The concentration and ratios of the ferricyanide and ferrocyanide in the culture broth will affect the stability of the reagents and will be selected to control the autoreduction effect.
[0032] The ferricyanide/ferrocyanide ratio affects the actual redox potential value and controls the beginning potential. If the initial beginning potential is too high, it creates a large oxidation state that has to be to overcome. This large oxidation state delays or inhibits desired metabolic reduction. If the initial beginning potential is too low, it increases the probability for baseline drift thereby increasing false positives.
[0033] The preferred concentration is 0.0001M, with the range of 0.00005M to 0.001M total concentration of both components being useful. The preferred ferricyanide/ferrocyanide ratio is 1:1 with ratios of 1:4 to 4:1 of ferricyanide/ferrocyanide being acceptable.
[0034] In addition to the coupled poising agents, the poising agent of the present invention will preferably further include a second poising agent, which is itself a reversible oxidation-reduction indicator. It has been found that methylene blue acts to stabilize the oxidation-reduction potential of the growth medium. Other suitable second poising agents include toluidine blue, azure I, and gallocyaninde.
[0035] In operation, the growth supplement and or/ the antibiotic supplement and/or the one or two poising agents are added to the culture broth prior to sealing the bottle 10 with the stopper 14 . The resulting mixture is mixed by any conventional means. Then, the sample is added to the mixture of the growth supplement and the other reagents and poising agents and the entire mixture is mixed.
[0036] The sample can be added through means such as a hypodermic needle (not shown) inserted through the stopper 14 . A disposable plastic fitment 22 comprising a sleeve 23 is telescoped over the neck 16 of the container 10 so that the lower end of the sleeve 23 engages the shoulder 18 , see FIG. 1 . The sleeve 23 includes a lower tubular portion 24 and an integral upper tubular portion 26 that extends upwardly from lower tubular portion 24 and is formed with an opening 28 communicating with the opening 30 of an integral inner tubular projection 32 into which a hypodermic needle 33 is frictionally and sealingly supported, as shown in FIG. 1 . A top section 27 of upper tubular projection 26 secures a hydrophobic vent filter or membrane 34 in the opening 28 . The vent filter membrane 34 functions to prevent liquid from passing upwardly. The vent filter membrane 34 functions with the sleeve 23 and the needle 33 to: a) Provide bi-directional gas flow from the vial headspace 20 to a pressure sensor 36 located in an electronic unit 38 during measurement or to the ambient during the initial or the final venting stages; and b) To prevent any liquid flow from the vial 10 to the pressure sensor 36 or to ambient in order to protect the operator from bacterial or viral contamination.
[0037] The fitment 22 , including needle 33 , forms an integral disposal unit that can be placed on the upper end of a container 10 . The fitment 22 is adapted to receive a tubular projection 40 of the removable electronic sensor unit 38 so that the projection is sealingly engaged, such as by a seal ring 41 , with top section 27 of the integral tubular portion 26 .
[0038] The electronic unit 38 includes pressure sensor 36 and is preferably connected to remote electronics (not shown), as described in U.S. Pat. No. 5,232,839 which is incorporated in its entirety into the present invention. In addition, the electronic unit 38 includes a bottle in place sensor 42 and a positivity light 44 .
[0039] The presence of organisms in a specimen can be detected by a microprocessor (not shown), incorporated in the remote electronics, which employs a number of pre-set criteria based upon the dynamic characteristics of the absolute value of the rates of change of pressure. These rates generally depend upon the following parameters: a) Type of organism (aerobic or anaerobic); b) Media/Temperature combination (intrinsic properties); c) Total volume of medium; d) Volume of the bottle's headspace; and e) Pneumatic and electrical variations among components.
[0040] These parameters affect the general trend of the rates of change. The microprocessor incorporates a plurality of algorithms that function to recognize the relatively wide range of absolute value of the rates and detect microorganisms by their rates of growth. The algorithms, however, do not consider the pressure values and do not make a comparison of these values to a known sample.
[0041] After the sample is placed in the container 10 through a hypodermic needle (not shown), the disposable fitment 22 is placed on top of the container 10 . The fitment 22 is pressed downwardly so that the hypodermic needle 33 penetrates the stopper 14 and the lower end of the sleeve 24 engages the shoulder 18 . In this position, the free end of needle 33 is in the headspace 20 above the level of the liquid medium 21 . The electronic unit 38 is then inserted into the disposable fitment 22 .
[0042] After a predetermined amount of time, a pressure magnitude is read by the pressure sensor 36 , processed by the signal processor and stored in the memory of the microprocessor as a first value or data point. The initial activation time allows the container 10 , which is placed in an incubator (not shown) to reach its incubation temperature.
[0043] The procedure repeats itself at the predetermined time intervals. The algorithms embedded in the microprocessor determines whether significant pressure rate change has occurred due to presence of organisms. If a positive decision is made, the microprocessor (not shown) activates the visual indicator, such as a positivity light 44 . Indicator light 44 will stay on, regardless of any pressure variations, until the reset switch is pressed again to start a new test.
[0044] FIG. 2 illustrates a typical voltage-time curve generated by a pressure sensor measuring the developed pressure at the vial's headspace. In this example, the typical pressure analysis of a mixture of a culture broth and reagents leads to a significant drift where after about 50 days, the baseline drift is +30 millivolts to −15 millivolts (a change of 45 millivolts).
[0045] By comparison, in FIG. 3 , the graph shows the curve of voltage versus time in a typical pressure analysis of the identical mixture of culture broth and reagents as shown in the curve of FIG. 2 but with the addition of a pair of poising agents added to the mixture in accordance with the present invention. In this example of a typical pressure analysis of a mixture of a culture broth and reagents, the addition of a pair of poising agents leads to a less significant drift. The baseline drift after 50 days is +30 to +15 millivolts (a change of 15 millivolts).
[0046] Referring to FIG. 4 , there is a graph showing the curve of voltage versus time in a typical pressure analysis of the identical mixture of culture broth and reagents plus a sample to be tested to determine the presence of an organism. In this example of a typical pressure analysis of a mixture of a culture broth and reagents and a pair of poising agents, one of the algorithms is satisfied because of the significant decrease in headspace pressure, which is the result of oxygen consumption by the organism.
[0047] Referring to FIG. 5 , there are two sets of examples from two different herds, each of 100 animals. Using the prior art, typical pressure analysis of a mixture of a culture broth and reagents and a sample from each animal, the percentage of false positives for the first herd was 27.14% and for the second herd was 6.33%, where there was actually no organism. The samples that were mixed with the culture broth and reagents and placed into the bottle were processed fecal samples that may contain “ mycobacterium paratuberculosis .” Using the pressure analysis of a mixture of a culture broth and reagents and two poising agents, in accordance with the present invention, and a sample from each animal, the percentage of false positives for the first herd was reduced to 5.71%, and for the second herd was reduced to 0.00%, where there actually was no organism.
[0048] Referring to FIG. 6 , there is shown the recovery of true positives from the two sets of examples from the first herd of animals. In the first herd indicated on the left, using the prior art, typical pressure analysis of a mixture of a culture broth and reagents and a sample from each animal, the percentage of true positives is 21.43%. The percentage of true positives for these animals same animals indicated on the right side of the chart, using the pressure analysis of a mixture of a culture broth and reagents and two poising agents, in accordance with the present invention, and a sample from each animal, the percentage of true positives is higher or 38.57%.
[0049] While only one sample container 10 is shown, the system typically monitors a plurality of sample containers 10 . Typically, a plurality of sample bottles are placed in an incubator. The location of each bottle can be recognized by the bottle in place sensor 42 . The bottles 10 can be incubated for a long period of time, including but not limited to 3 or 4 months. The bottles are automatically monitored, as discussed before. An operator can visually determine when a positive has been sensed in a bottle when the light 44 turns on.
[0050] While one embodiment of the invention has been described above, it is within the terms of the present invention to add the poising agents of the present invention to any liquid mixture which is being monitored using a redox sensor so as to reduce the background noise due to undefined chemical reactions within the system and thereby significantly reduce false positives.
[0051] In another embodiment, the poising agents of the present can be added to any liquid mixture which is being monitored using a redox sensor, such as a colorimetric or fluorimetric redox sensor, so as to reduce the background noise due to undefined chemical reactions within the calorimetric dye or fluorimetric dye, respectively, and thereby significantly reduce false positives. Using these sensors, oxygen attaches to the calorimetric dye or fluorimetric dye. In these embodiments, as with the embodiment described before, there can be a problem of false positives due to chemical redox reactions (reduction/oxidation). Examples of fluorimetric dyes are tris-4,7-diphenyl-1,10-phenanthroline ruthenium (II) salt; tris-2,2′-bipyridyl ruthenium (II) salt; and 9,10-diphenyl anthracene. Examples of calorimetric dyes are resazurin and tetrazolium dyes, for example MTT (3-4,5-dimethylthiazol-2,5-diphenyltetrazolium bromide). Examples of a luminescent dyes include luminescent sensor compounds selected from the group comprising platinum (II); palladium (II) octaethyl complexes immobilized in PMMA (polymethyl methacrylate); CAB (Cellulose acetate brityrate); platinum (II) and palladium (II) octaethyl porphrin keytone complexes immobilized in PVC and polystyrene. The calorimetric dye or fluorimetric dye can react with oxygen from the reagents themselves, such as the growth supplement and/or the antibiotic supplement, even without a sample being added to the culture mixture in a container. The result is that the color of the colorimetric dye changes or the fluorimetric dye doesn't fluoresce. In other words, there is a signal generated by the utilization or consumption of oxygen within the system due to reagent-driven chemical reactions (baseline drift) that will, in turn, cause increased numbers of false positives. This baseline drift, also referred to as background noise, cannot be predicted because the reagents are not chemically defined and are comprised of variable amounts of reactive components. Thus, it is within the terms of the present invention to add the poising agents of the present invention to any liquid mixture which is being monitored using a colorimetric or fluorimetric redox sensor so as to reduce the background noise due to undefined chemical reactions within the system and thereby significantly reduce false positives.
[0052] In this connection, it will be appreciated that the test procedure of the present invention is qualitative—i.e., presence of a microorganism is determined but no effort is made to establish concentration. In the same way, no effort is made to establish either the family or type of microorganism. These determinations can be made in other procedures, if desired. The present invention seeks merely to determine presence of a microorganism, regardless of type or concentrations. Thereby, the present invention may be applied to kinetic or threshold end point determinations.
[0053] While the invention has been described in combination with embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing teachings. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.
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According to the present invention, there is disclosed a method of stabilizing the output signal of a system that detects microbiological growth in a sealed sample container that contains a sample which may contain an unknown microorganism. One embodiment relates to a method of providing a sealed sample container which contains a fluid mixture of a culture broth, the sample, and at least one poising agent for stabilizing the base line pressure within a headspace above the fluid mixture in the sample container. By monitoring pressure changes within the headspace of the sealed sample container, the presence of microbiological growth within the sealed sample container as a function of the change of the pressure in the headspace is indicated.
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RELATED U.S. APPLICATION DATA
[0001] This patent application claims priority to U.S. Provisional Patent Application No. 60/451,897 (Attorney Docket No. 15958ROUS01P) filed Mar. 4, 2003; the contents of which are hereby incorporated by reference.
[0002] This patent application is related to the following Provisional patent applications filed in the U.S. Patent and Trademark Office, the disclosures of which are expressly incorporated herein by reference:
[0003] U.S. patent application Ser. No. 60/446,617 filed on Feb. 11, 2003 and entitled “System for Coordination of Multi Beam Transit Radio Links for a Distributed Wireless Access System” [Attorney Docket No. 15741]
[0004] U.S. patent application Ser. No. 60/446,618 filed on Feb. 11, 2003 and entitled “Rendezvous Coordination of Beamed Transit Radio Links for a Distributed Multi-Hop Wireless Access System” [Attorney Docket No. 15743]
[0005] U.S. patent application Ser. No. 60/446,619 filed on Feb. 12, 2003 and entitled “Distributed Multi-Beam Wireless System Capable of Node Discovery, Rediscovery and Interference Mitigation” [Attorney Docket No. 15742]
[0006] U.S. patent application Ser. No. 60/447,527 filed on Feb. 14, 2003 and entitled “Cylindrical Multibeam Planar Antenna Structure and Method of Fabrication” [Attorney Docket No. 15907]
[0007] U.S. patent application Ser. No. 60/447,643 filed on Feb. 14, 2003 and entitled “An Omni-Directional Antenna” [Attorney Docket No. 15908]
[0008] U.S. patent application Ser. No. 60/447,644 filed on Feb. 14, 2003 and entitled “Antenna Diversity” [Attorney Docket No. 15913]
[0009] U.S. patent application Ser. No. 60/447,645 filed on Feb. 14, 2003 and entitled “Wireless Antennas, Networks, Methods, Software, and Services” [Attorney Docket No. 15912]
[0010] U.S. patent application Ser. No. 60/447,646 filed on Feb. 14, 2003 and entitled “Wireless Communication” [Attorney Docket No. 15897]
[0011] U.S. patent application Ser. No. 60/453,011 filed on Mar. 7, 2003 and entitled “Method to Enhance Link Range in a Distributed Multi-hop Wireless Network using Self-Configurable Antenna” [Attorney Docket No. 15946]
[0012] U.S. patent application Ser. No. 60/453,840 filed on Mar. 11, 2003 and entitled “Operation and Control of a High Gain Phased Array Antenna in a Distributed Wireless Network” [Attorney Docket No. 15950]
[0013] U.S. patent application Ser. No. 60/454,715 filed on Mar. 15, 2003 and entitled “Directive Antenna System in a Distributed Wireless Network” [Attorney Docket No. 15952]
[0014] U.S. patent application Ser. No. 60/461,344 filed on Apr. 9, 2003 and entitled “Method of Assessing Indoor-Outdoor Location of Wireless Access Node” [Attorney Docket No. 15953]
[0015] U.S. patent application Ser. No. 60/461,579 filed on Apr. 9, 2003 and entitled “Minimisation of Radio Resource Usage in Multi-Hop Networks with Multiple Routings” [Attorney Docket No. 15930]
[0016] U.S. patent application Ser. No. 60/464,844 filed on Apr. 23, 2003 and entitled “Improving IP QoS though Host-Based Constrained Routing in Mobile Environments” [Attorney Docket No. 15807]
[0017] U.S. patent application Ser. No. 60/467,432 filed on May 2, 2003 and entitled “A Method for Path Discovery and Selection in Ad Hoc Wireless Networks” [Attorney Docket No. 15951]
[0018] U.S. patent application Ser. No. 60/468,456 filed on May 7, 2003 and entitled “A Method for the Self-Selection of Radio Frequency Channels to Reduce Co-Channel and Adjacent Channel Interference in a Wireless Distributed Network” [Attorney Docket No. 16101]
[0019] U.S. patent application Ser. No. 60/480,599 filed on Jun. 20, 2003 and entitled “Channel Selection” [Attorney Docket No. 16146]
FIELD OF THE INVENTION
[0020] The present invention relates to patch antenna arrays and is particularly concerned with minimizing the overall array dimensions of an omnidirectional multi-facetted array.
BACKGROUND OF THE INVENTION
[0021] Within a wireless communication system, it is strongly desirable for cellular antenna arrays to have minimal size for reasons of ease of installation, greater stability under wind loading conditions, and minimal visual obtrusiveness.
[0022] One variety of omnidirectional antenna used in cellular installations is a multi-facetted patch array. This type of antenna has a series of patch antenna on facets, and the facets are circumferentially disposed around an axis with each antenna facing outward. A minimum overall array size may be obtained when the facets abut one another, forming a faceted tube.
[0023] Existing patch antenna designs have a lower bound on facet sizes because of engineering limitations. These limitations are imposed due to space requirements for: patch antenna width for efficient operation at the required Gigahertz frequencies used in today's cellular systems; the patch antenna ground plane; the interconnection tracking; the printed circuit board (PCB) radio frequency (RF) switch; and the RF cabling used to interconnect to the RF amplifier modules. An antenna array of an unsightly size occurs when sufficient space is allotted for all these requirements on each facet. Further, wind loading characteristics of the resulting sized array imposes mounting stresses on the antenna array and tower.
[0024] In view of the foregoing, it would be desirable to provide a technique for providing a patch antenna on an omnidirectional multi-facetted array which overcomes the above-described inadequacies and shortcomings.
SUMMARY OF THE INVENTION
[0025] An object of the present invention is to provide an improved multi-faceted antenna array.
[0026] According to an aspect of the present invention there is provided an antenna array having a plurality of facets disposed around an axis, each of the facets having sides abutting the sides of an adjacent facet so as to form a faceted tube. There is at least one patch antenna disposed on each of the facets and at least one radio frequency interface module. A plurality of signal tracks disposed across the facets interconnects the patch antennas across the abutting sides to the radio frequency interface module. There is at least one ground plane separated from the at least one patch antenna and plurality of signal tracks by a dielectric having at thickness. Each facet has a substantially planar region under the patch antenna, and at least a first curved region under at least a portion of the signal tracks. The first curved region has a radius of curvature sufficient to avoid any discontinuities in RF propagation along the signal tracks.
[0027] Advantages of the present invention include a reduced array size over comparable arrays having strictly planar facets. The reduced array size provides for better wind loading and less visual obtrusiveness when installed.
[0028] Conveniently, each facet may have a second curved region under at least a portion of the plurality of signal tracks, from a side of the substantially planar region opposite to the side of said first curved region, to the abutting side of an adjacent facet of the plurality of facets, with the curved region having a radius of curvature designed so as to avoid any discontinuities in RF propagation along the signal tracks. Further, the substantially planar region of at least one of the plurality of facets may be disposed off-center of the midline of the facet. Conveniently, the radius of curvature the first or the second curved region may be in excess of ten times the dielectric thickness.
[0029] The offsetting of the substantially planar region over which the patch antenna on the facet is situated provides space on the facet for locating a radio frequency interface module, or at least a portion thereof.
[0030] Advantageously, the at least one radio frequency interface module is disposed across an inside corner formed at the connectively abutting sides of two adjacent facets of the plurality of facets. This placement of the radio frequency interface module has the advantage of further reducing the width requirements for the facet upon which the radio frequency module is at least partially sited.
[0031] In accordance with another aspect of the present invention there is provided a method for forming an antenna array including the steps of disposing a plurality of facets around an axis, each of the plurality of facets having sides connectively abutting the sides of an adjacent facet, the plurality of facets forming a faceted tube, and disposing at least one patch antenna on each of the plurality of facets. Further, the method comprises disposing at least one radio frequency interface module within the array, and disposing a plurality of signal tracks across the plurality of facets interconnecting the patch antennas across the connectively abutting sides to the radio frequency interface module. Additionally, the method comprises disposing a ground plane separated from the at least one patch antenna and plurality of signalling tracks by a dielectric having a thickness, and configuring each facet to have a substantially planar region under the at least one patch antenna, and each facet to have at least a first curved region under at least a portion of the plurality of signal tracks. The first curved region has a radius of curvature designed so as to avoid any discontinuities in RF propagation along the signal tracks.
[0032] Conveniently, the configuring step has each facet having a second curved region under at least a portion of the plurality of signal tracks, from a side of the substantially planar region opposite to the side of said first curved region, to the abutting side of an adjacent facet of the plurality of facets. Also conveniently, the configuring step further has at least one of the substantially planar region of at least one of the plurality of facets disposed off-center of the midline of the facet.
[0033] Conveniently, the radius of curvature the first or the second curved region may be in excess of ten times the dielectric thickness.
[0034] Advantageously, the step of disposing the at least one radio frequency interface module within the array further comprises disposing the least one radio frequency interface module across an inside corner formed at the abutting sides of two adjacent facets of the plurality of facets.
[0035] The present invention will now be described in more detail with reference to exemplary embodiments thereof as shown in the appended drawings. While the present invention is described below with reference to the preferred embodiments, it should be understood that the present invention is not limited thereto. Those of ordinary skill in the art having access to the teachings herein will recognize additional implementations, modifications, and embodiments which are within the scope of the present invention as disclosed and claimed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The invention will be further understood from the following detailed description of embodiments of the invention and accompanying drawings in which:
[0037] [0037]FIG. 1 is a perspective view of a multi-facetted antenna array.
[0038] [0038]FIG. 2 is an unfolded view of a multi-facetted antenna array.
[0039] [0039]FIG. 3 is a top view of a multi-facetted antenna array having symmetrical facets.
[0040] [0040]FIG. 4 is a top view of a multi-facetted antenna array having asymmetrical facets according to an embodiment of the invention.
[0041] [0041]FIG. 5 is a top view of multi-facetted antenna array according to a alternative embodiment of the invention.
[0042] [0042]FIG. 6 is an unfolded view of the multi-facetted antenna array depicted in FIG. 5.
DETAILED DESCRIPTION
[0043] In the discussion that follows, like reference numbers refer to like elements in similar figures. Referring to FIG. 1 there may be seen an example multi-section antenna array 101 in perspective view. The array is formed by a number of facets 103 , the total quantity being a function of the particular application but typically comprising six or eight in total. The facets are arranged with abutting sides 105 which form edges or corners of the resultant polygonal tube. The facets need not be separate units, but instead may be formed on a single or convenient number of sheets which are effectively creased or folded at the edges of the facets. Located upon the facets are the patch antenna elements 107 which radiate or receive the requisite radio frequency (RF) signal. As is generally known, the patch antenna elements 107 have an associated ground plane (not shown) located beneath the patch antenna element, and separated from the conductive surface of the patch antenna element by a dielectric material. The thickness of the dielectric material, as well as the associated dielectric constant of the material, are characteristics determinant of the patch antenna performance.
[0044] Referring to FIG. 2, there may be seen an unfolded version of an example multi-section antenna array 201 . An array facet 203 may be seen bounded by the facet side edges 205 . Also visible are the patch antenna 207 on the facets. Additionally, interconnecting tracks 209 may be seen. These are conductive elements, for example conductive tracks or microstrips, used to couple the signals to and from the patch antennas, and to link the patch antennas to generate appropriate phase and polarization relationships. These conductive elements, similar to the patch antenna elements, are also typically associated with one or more ground planes, being separated from the ground plane or multiple ground planes by a dielectric material having an associated dielectric constant and thickness.
[0045] The interconnecting tracks 209 terminate on a radio frequency interface module 211 which is mounted on the antenna array so as to receive the tracks. In this figure the radio frequency interface module 211 has been shown placed on a particular position for illustration purposes only, and may be placed in alternative arrangements as more particularly described in the following discussion. The RF interface module or board acts to connect and disconnect the various patch antennas on the facets according to the transmission and reception needs of the radio site being served by the antenna array. RF cabling from the RF interface module connects to RF modules, typically power amplifiers and receiving circuitry. The RF interface module may implement a switch function, so that the patch antenna on one particular facet may be routed to the RF modules. Alternatively, a beam forming or other phase aligned combination function may be implemented within the RF interface module. Depending upon what functionality is being implemented a particular antenna array may use a single RF interface module or multiple modules as illustrated in FIG. 2. As the RF interface module needs to connect to the facets to receive the interconnecting tracks 209 , the issue arises as to how to site the RF interface module, and the impacts of possible siting choices. In the following description of embodiments of the invention, the RF interface module is described as performing switching functions. However, it is to be understood that In genera, the RF Interface module may encompass arbitrary radio functions.
[0046] In FIG. 2 the facets 203 may be seen to be equivalent in size with the patch antennas 207 situated substantially along a center line c-c of each facet. The net result of this arrangement for the resulting array is a symmetrical unit exhibiting predictable wind loading characteristics. In general, each facet has a minimum width w determined by the sum of the actual patch antenna width, the additional extension width that the associated ground plane for the patch antenna must occupy, and the tracking space required to connect to each antenna patch.
[0047] Referring now to FIG. 3, there is depicted a top view of an antenna array 301 in which the width w of each facet 303 has been increased so as to provide room on one of the facets for the RF interface module 311 . Also visible are the patch antenna 307 (not to scale in terms of thickness) and facet abutting edges 305 . The overall size of the array has been increased symmetrically, and the resulting antenna array size exceeds the desirable nonobtrusiveness. For an antenna array with patch antenna widths appropriate to the 5.5 GHz region of the spectrum, the resultant size imposes undesirable mounting loads and is deemed unsightly.
[0048] Referring now to FIG. 4, there is shown a top view of an alternative antenna array 401 according to an embodiment of the invention in which the width of one of the facets 413 has been increased to allow for siting of the RF interface module 411 . In order to maintain symmetry, opposing facet 415 has also had a width increase. The width of the remaining facets is chosen to minimize the overall profile of the array. Opposed facets in arrays with an even number of facets are typically matched in length in order to achieve the desired equiangular omnidirectional coverage. The net result is an antenna array which is smaller than the equivalent array as described in relation to FIG. 3. However, this version of antenna array proved more disturbed by wind than a symmetrical array, exhibiting vibration when wind loaded.
[0049] Referring now to FIG. 5, there is depicted a top view of an alternative antenna array 501 according to a different embodiment of the Invention. Patch antenna 507 may be seen as in the previous figures, however modifications to the portion of the facets outside of the patch antenna portions have been made. In particular, referring to patch antennas 507 a and 507 b, it may be seen that the portions of the facets 523 and 525 between these patch antennas has been given a gentle curvature 517 . These sections of the facets contain the interconnecting tracks. Normally, bending losses associated with curving the tracks would lead one skilled in the art to avoid adding a curvature to a facet, however it was determined that bend radiuses in excess of ten times the dielectric thickness would have minimal transmission losses. Thus, it became possible to utilize curvature as an aspect of the facets. Note that an even distribution of curvature 517 tends to blur the abrupt edge between abutting sides of the facets, however, the sides of the facets are still to be considered as lying at some point along the curvature 517 .
[0050] In alternative embodiments of the invention, less radii of curvature are contemplated wherein signal propagation discontinuities due to the bending are traded off against the overall size of the antenna array and resulting size of the faceted tube shape. Similarly, localized adjustments to the width of the interconnecting tracks may be applied in order to compensate for the discontinuity effects of the bend curvature of tracks above the ground plane.
[0051] Additionally, there was also a concern that shifting a portion of the patch antennas partially around a corner bend would significantly degrade antenna performance as the ground planes beneath the patch antennas would be curved as well. Simulations showed that the required ground planes could be reduced to little more than the basic antenna patch width, thus allowing curvature exterior to the antenna patch.
[0052] The net result of the curvature was a reduction in overall array size as may be seen by the outline 519 of the normal polygonal (such as that shown in FIG. 3) relative to the resultant position 517 of the curved portion of the facets. The curvature can be disposed on one side of the patch antenna only, should such an arrangement be desired, but more normally the curvature would be on both sides of the patch antenna extending to the edge of the facet.
[0053] Yet a further aspect of the invention may be seen in FIG. 5 at the position of the RF interface module 511 . The RF interface module 511 is mounted across the inner corner 521 formed by the abutting sides 527 and 529 of two of the facets 526 and 528 . The positioning of the RF interface module with a side on each of the facets allows connection at the facet surface, yet reduces the area required for the RF interface module on the facet. This reduction in area further serves to reduce the overall size of the resultant antenna array.
[0054] In FIG. 6 there is a depiction of an antenna array 601 as described for FIG. 5, but in opened form showing the disposition of the facets 603 , the facet edges 605 , the patch antennas 607 , the interconnecting tracking 609 , and the RF interface module 611 . Visible in this figure is the non-central placement of the patch antennas relevant to the facets, i.e. the patch antenna elements 607 are placed on facets off of the center line of the facet when it is advantageous to do so for routing the interconnecting tracking 609 . Particularly pointed out are regions 623 where appropriate bending to form the curved orientation shown in FIG. 5 is allowed, and areas 625 where such bending is proscribed.
[0055] In an antenna of this type, the overall antenna may be formed of a single overall panel which is manipulated to yield the final array, or of smaller assemblages. For example, the symmetry of the panels may allow a two panel assembly, with the RF interface module placed at the corner of the abutting sides of the two panels. An alternative contemplated embodiment could be an assembly wherein the patch antennas are formed on a metallized film which is subsequently assembled via a flexible wrap around band.
[0056] While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the broad scope of the appended claims.
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A multi-facetted antenna array is disclosed for omnidirectional signalling. The multi-facetted antenna array includes a plurality of abutting facets having a planar region under the patch antenna structures, and curving regions between the planar regions and across the abutting edges of the facets. The planar regions under the patch antenna provide proper RF antenna performance, while the curved regions minimize the size of the assembled array. Further disclosed is a method of mounting the associated RF interface module across an inside corner formed by abutting facets. The disclosed multi-facetted antenna array is particularly useful for overcoming the unsightly size and wind loading problems of multi-facetted antenna arrays known in the art.
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FIELD OF THE INVENTION
[0001] The present invention relates to a phase locked loop (PLL) circuit, and more particularly to a wide-locking range phase locked loop circuit using the adaptive post division technique.
BACKGROUND OF THE INVENTION
[0002] Please refer to FIG. 1 , which illustrates the conventional phase locked loop (PLL) circuit. The PLL circuit 100 includes a phase frequency detector 10 , a charge pump 20 , a loop filter 30 , a voltage controlled oscillator (VCO) 40 and a divider 50 . An input clock signal (CK in ) with a reference frequency (f ref ) is generated by a reference oscillator (not illustrated). Both the input clock signal and a frequency divided signal are inputted into the phase frequency detector 10 . The phase frequency detector 10 detects the difference in phase and frequency between the input clock signal (CK in ) and the frequency divided signal and then outputs a phase difference signal to the charge pump 20 . According to the phase difference signal, the charge pump 20 then outputs the current proportional to the amplitude of the phase difference. The output current charges capacitors C 1 and C 2 of the loop filter 30 , thereby generates a control voltage (Vc) to the VCO 40 . The VCO 40 generates an output clock signal (CK out ) with a voltage controlled frequency (f vco ) in response to the control voltage (Vc). The divider 50 receives the output clock signal (CK out ) and generates a frequency divided signal after dividing the voltage controlled frequency (f vco ) by an integer M (i.e. multiply by 1/M) for being inputted to the phase frequency detector 10 . Therefore, the frequency relation between input clock signal (CK in ) and the output clock signal (CK out ) of the PLL circuit 100 is f voc =M*f ref .
[0003] As widely known, the frequency operation range of the VCO 40 is restricted in its resonant frequency; further, the control voltage (Vc) is proportional to the voltage controlled frequency (f vco ); hence, the control voltage (Vc) would be restricted within a voltage operation range. That is to say, the conventional frequency locked range of the PLL circuit 100 would be restricted to within the frequency operation range of the VCO 40 .
[0004] In order to achieve PLL circuit with wide-locking range, as illustrated in FIG. 2 , a PLL circuit with multi-modulus divider is proposed. The proposed multi-modulus divider 60 of the PLL circuit 150 includes a main divider 62 and a coefficient-selecting unit 64 . The main divider 62 provides a basic numeric M. The coefficient-selecting unit 64 switches using the controlling pins to choose one of the coefficients from many (1, 1/2, 1/4, . . . , 1/2 N ). For example, if user selects the coefficient 1/2 from the coefficient-selecting unit 64 , the output voltage controlled clock signal (CK vco ) with a voltage controlled frequency (f vco ) outputted from the VCO 40 is undergoing a first frequency division by the coefficient 1/2 to generate the output clock signal (CK out ) with an output frequency equal to f vco /2. The output clock signal (CK out ) further undergoes a second frequency division by the main divider 62 according to the basic numeric M, which divides the output frequency (f out ) of the output clock signal (CK out ) by the integer M (multiply by 1/M) to generate the frequency divided signal with frequency equal to f vco /2M.
[0005] The conventional multi-modulus divider 60 provides a coefficient-selecting unit 64 to the PLL circuit 150 . Through dynamically selecting one value of the coefficient-selecting unit 64 and applying to the PLL circuit 150 , the output frequency (f out ) of output clock signal (CK out ) can achieve the purpose of wide-locking range. However, when designing such kind of PLL circuit in an application specific integrated circuit (‘ASIC’), a set of control pins are needed to be provided additionally in order to control switches (SW 0 ˜SWN) and select one coefficient in the coefficient-selecting unit 64 by user. The additional control pins or terminals would however increase difficulty of operation and the cost and complexity of design and testing.
SUMMARY OF THE INVENTION
[0006] One of the objects of the present invention is to provide a wide-locking range phase locked loop circuit with built-in auto-adjust mechanism.
[0007] The present invention provides a phase locked loop circuit including: a phase frequency detector receiving a frequency divided signal and an input clock signal with a reference frequency and detecting the difference in phase and frequency between the input clock signal and the frequency divided signal and then outputting a phase difference signal; a charge pump outputting an output current in response to the phase difference signal; a loop filter generating a control voltage in response to the phase difference signal; a voltage controlled oscillator generating a voltage controlled clock signal with a voltage controlled frequency in response to the control voltage; a multi-modulus divider receiving the voltage controlled clock signal and then generating the frequency divided signal and an output clock signal with an output frequency, wherein a first divisor can be selected from a plurality of divisors provided by the multi-modulus divider to achieve a relation that the voltage controlled frequency divided by the first divisor equals the output frequency; and a decision unit receiving the phase difference signal and the control voltage and determining to select a second divisor form the plurality of divisors provided by the multi-modulus divider if the phase difference signal indicates an unlocked state and the control voltage is not within a standard voltage operation range.
[0008] The present invention further provides a method of controlling a phase locked loop circuit, wherein the phase locked loop circuit divides a voltage controlled clock signal by a divisor for generating a frequency divided signal and generates a control voltage in response to a difference between the frequency divided signal and an input clock signal, the method including steps of: setting the divisor to an initial value; and changing the divisor if the control voltage is not within a standard voltage operation range over a period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The above contents of the present invention will become more readily apparent to those ordinarily skilled in the art after reviewing the following detailed description and accompanying drawings, in which:
[0010] FIG. 1 illustrates the conventional phase locked loop (PLL) circuit.
[0011] FIG. 2 illustrates a PLL circuit with multi-modulus divider.
[0012] FIG. 3 illustrates the PLL circuit of the present invention.
[0013] FIG. 4 illustrates the frequency operation range of the PLL circuit of the present invention.
[0014] FIG. 5 illustrates the state diagram of the decision unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Please refer to FIG. 3 , which illustrates the PLL circuit of the present invention. The PLL circuit 200 comprises a phase frequency detector 210 , a charge pump 220 , a loop filter 230 , a VCO 240 , a multi-modulus divider 250 and a decision unit 260 . The multi-modulus divider 250 comprises a main divider 252 and a coefficient-selecting unit 254 . The main divider 252 provides a basic numeric value M, while the coefficient-selecting unit 254 controls switches (SW 0 ˜SWN) through the decision unit 260 , which is used to choose one coefficient from several coefficients (1, 1/2, 1/4, . . . , 1/2 N ). That is to say, after the decision unit 260 selects one coefficient from the coefficient-selecting unit 254 , the voltage controlled clock signal (CK vco ) with the voltage controlled frequency (f vco ) outputted by VCO 240 undergoes a first frequency division by the coefficient-selecting unit 254 and then becomes an output clock signal (CK out ) with an output frequency (f out ). Further, the output clock signal (CK out ) further undergoes a second frequency division by the main divider 252 according to the basic numeric M which divides the output frequency (f out ) of output clock signal (CK out ) by the integer M (multiplied by 1/M) to generate the frequency divided signal.
[0016] According to the embodiment of the present invention, the decision unit 260 and the PLL circuit 200 with multi-modulus divider are designed and integrated into an ASIC. In this way, the embodiment enables the PLL circuit 200 to have the characteristic of wide-locking range without using control pins to select one coefficient in the coefficient-selecting unit 254 by user.
[0017] The decision unit 260 comprises a lock detector 262 , a comparator 264 , an accumulator 266 and a switch controller 268 . The comparator 264 receives and monitors the control voltage (Vc). When the control voltage (Vc) is smaller or larger than the standard voltage operation range, the comparator 264 will output pulses from either a low Vc terminal or a high Vc terminal to the accumulator 266 . The accumulator 266 will count the number of pulses from low Vc terminal or the high Vc terminal. As the number accumulated by the accumulator 266 reach a predetermined value (X times), the accumulator 266 will generate an adjust-up signal (UP) or an adjust-down signal (DN) to the switch controller 268 . The switch controller 268 can select a coefficient in the coefficient-selecting unit 254 according to the adjust-up signal (UP) or the adjust-down signal (DN). Further, the lock detector 262 receives the phase difference signal from the phase frequency detector 210 and determines whether the PLL circuit 200 is in a locked state or an unlocked state. When the lock detector 262 determines that the PLL circuit 200 is in the locked state, the lock detector 262 outputs a clear signal to the accumulator 266 to clear the number counted in the accumulator 266 .
[0018] Please refer to FIG. 4 , which illustrates the frequency operation range of the PLL circuit of the present invention. The horizontal axis and vertical axis represent respectively the control voltage (Vc) and the output frequency (f out ) of output clock signal (CK out ). As illustrated, standard voltage operation range of the VCO 240 is in between Vx and Vy. When a divisor of the multi-modulus divider 250 is M, (multiply by 1/M), the frequency operation range of the PLL circuit 200 falls in between B MHz and A MHz; when the divisor of multi-modulus divider 250 is 2M, (multiply by 1/2M), the frequency operation range of the PLL circuit 200 falls in between B/2 MHz and λ/2 MHz; when the divisor of the multi-modulus divider 250 is 4M, (multiply by 1/4M), the frequency operation range of the PLL circuit 200 falls in between B/4 MHz and λ/4 MHz; the same applies for the divisor of 2 N M. Therefore, the PLL circuit 200 of the present invention can be operated between B/4 MHz and A MHz. Similarly, the more coefficients in the coefficient-selecting unit 254 for selection, the wider the frequency operation range of the PLL circuit 200 .
[0019] Please refer to FIG. 5 , which illustrates the state diagram of the decision unit. When the PLL circuit 200 begins to operate, the decision unit 260 is in state A, which is the initial state. As input clock signal (CK in ) with reference frequency (f ref ) is input into PLL circuit 200 , the control voltage (Vc) starts to change; and the decision unit 260 is in state B, which is the state of detecting control voltage (Vc). In state B, the comparator 264 of the decision unit 260 monitors whether the control voltage (Vc) is operated within the standard voltage operation range (Vx˜Vy). When the control voltage (Vc) is operated within the standard voltage operation range (Vx˜Vy) and the lock detector 262 confirms that the PLL circuit 200 has been locked, the decision unit 260 enters into state G, which is the locked state. In state G, when the lock detector 262 detects the PLL circuit 200 is unlocked, the decision unit 260 enters into state B.
[0020] Further, in state B, when the reference frequency (f ref ) of the input clock signal (CK in ) changes and makes the control voltage (Vc) smaller than Vx, the decision unit 260 enters into state C, which is a counting state in which Vb<Vc<Vx. In state C, the accumulator starts to count the number of pulses output from the low Vc terminal; from here, (1) when the control voltage (Vc) is larger than Vx and the number of pulses does not reach the predetermined value (X times), then the decision unit 260 enters into state B; (2) when the control voltage (Vc) is smaller than Vx and the number of pulses does not reach the predetermined value (X times) and the lock detector 262 confirms that PLL circuit 200 has been locked, then the decision unit 260 enters into state G; (3) when the control voltage (Vc) is even smaller than Vb and the number of pulses does not reach the predetermined value (X times), then the decision unit 260 enters into state D, which is a counting state in which Vc<Vb; and (4), when the control voltage (Vc) is smaller than Vx and the number of pulses reach the predetermined value (X times), then the decision unit 260 enters into state F, which is the state of increasing divisor and reset.
[0021] In State D, as control voltage (Vc) is already too low, the PLL circuit 200 is impossible to enter into state G (locked state). Therefore, unless reference frequency (f ref ) of input clock signal (CK in ) changes to enable the control voltage (Vc) larger than Vx again which causes the decision unit 260 to enter into state B, when the number of pulse reaches the predetermined value (X times), the decision unit 260 will enter into state F.
[0022] In state F, the switch controller 268 can select another coefficient from the coefficient-selecting unit 254 to increase the divisor of multi-modulus divider 252 ; for instance, increasing the divisor from M to 2M, or from divisor 2M to divisor 4M. After such, the decision unit 260 enters into state A and continues operation.
[0023] Further, in state B, when the reference frequency (f ref ) of the input clock signal (CK in ) changes and makes control voltage Vc larger than Vy, the decision unit 260 enters into state E, which is the counting state in which Vy<Vc<Vt. In state E, the accumulator starts to count number of pulses output from high Vc terminal. Following such, (1) when the control voltage (Vc) is smaller than Vy and the number of pulses is short of the predetermined value (X times), the decision unit 260 enters into state B; (2) when the control voltage (Vc) is larger than Vy, the number of pulses is short of the predetermined value (X times) and the lock detector 262 confirms that PLL circuit 200 has been locked, the decision unit 260 enters into state G; (3) when the control voltage (Vc) is further larger than Vt and the number of pulses does not reach the predetermined value (X times), the decision unit 260 enters into state I, which is the counting state in which Vc>Vt; and (4) when the control voltage (Vc) is larger than Vt and the number of pulses reach the predetermined value (X times), the decision unit 260 enters into state H, which is a state of decreasing divisor and reset.
[0024] In State I, as the control voltage (Vc) is already too high, the PLL circuit 200 is impossible to enter into state G (locked state). Thus, unless the reference frequency (f ref ) of input clock signal (CK in ) changes making the control voltage (Vc) smaller than Vy again to make the decision unit 260 enter into state B, when the number of pulses reaches the predetermined value (X times), the decision unit 260 enters into state H.
[0025] In state H, the switch controller 268 can select another coefficient from the coefficient-selecting unit 254 to decrease divisor of the multi-modulus divider 252 ; e.g. decreasing from divisor 2M to divisor M or from divisor 4M to divisor 2M. After such, the decision unit 260 then enters into state A and continues operation.
[0026] According to the embodiment of the present invention, the predetermined value (X times) is 24, and the frequency of pulses generated from low Vc terminal or high Vc terminal is f ref /256. That is to say, when the control voltage (Vc) is not operated in the standard voltage operation range (Vx˜Vy), the decision unit 260 can change the divisor of the multi-modulus divisor 250 after a period of 24*(256/f ref ).
[0027] For instance, when the reference frequency (f ref ) of the input clock signal (CK in ) is very low, the output current from the charge pump 220 suppresses the control voltage (Vc), making the decision unit 260 enter into state C or D. After a period in which the PLL circuit 200 remains unlocked, the decision unit 260 will control the multi-modulus divider 250 to increase the divisor; after resetting, the control voltage (Vc) is returned to within the standard voltage operation range (Vx˜Vy) and then the decision unit 260 enters into state G.
[0028] By the same logic, when the reference frequency (f ref ) of the input clock signal (CK in ) is very high, the output current from the charge pump 220 drive up the control voltage (Vc), and cause the decision unit 260 to enter into state E or I. After a period in which the PLL circuit 200 remains unlocked, the decision unit 260 will control the multi-modulus divider 250 to decrease divisor; the control voltage (Vc) is enabled to return to the standard voltage operation range (Vx˜Vy) and then the decision unit 260 enters into state G.
[0029] Therefore, the present invention provides a wide-locking range phase locked loop circuit, which enables application of PLL circuit to the ASIC without an additional control pin that increases user's loading. The present invention of the decision unit 260 is also achieved using only digital circuit; hence it has a higher immunity against the disturbance from manufacturing process.
[0030] While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.
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A wide-locking range phase locked loop circuit includes a decision unit and a closed loop connection comprising a phase frequency detector, a charge pump, a loop filter, a voltage controlled oscillator, and a multi-modulus divider. The decision unit receives a phase difference signal outputted from phase frequency detector and the control voltage outputted from the loop filter and determines to select a specific divisor form the plurality of divisors provided by the multi-modulus divider if the phase difference signal indicates an unlocked state and the control voltage is not within a standard voltage operation range.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent application Ser. No. 12/033,120, filed Feb. 19, 2008 now U.S. Pat. No. 7,812,122, which claims the benefit of U.S. provisional patent application 60/918,203 filed Mar. 15, 2007.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
The invention was made with government support under Grant No. DC006016 awarded by the National Institutes of Health. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
The present invention relates to sweet proteins. Specifically, this invention relates to Brazzein protein that has been modified to provide a candy-like taste with high potency.
The most widely used natural sweetener, sugar (sucrose), has significant problems associated with its use (especially causing weight gain by users). Many other sweeteners either have undesirable side effects or are deficient in certain respects. For example, aspartame loses its sweetness when exposed to elevated temperatures for long periods. This renders aspartame unsuitable for use in most baking applications.
Moreover, most existing artificial sweeteners have temporal sweetness profiles which do not adequately match that of sugar. For example, their sweetness may die out sooner or leave an undesirable after taste, and/or may be perceived sooner than sugar. It may therefore be desirable to mix an existing artificial sweetener with one or more other sweeteners having different temporal profiles (so as to create a mixed sweetener that more closely matches the overall temporal sweetness profile of sugar).
As described in WO 00/61759, and U.S. Pat. No. 6,274,707, attempts were made to improve certain sweetness characteristics of Brazzein through the substitution of Ala or Arg in replacement for an existing amino acid, and/or the addition of Ala or Arg, and/or the truncation of an existing terminal amino acid, of Brazzein. Some of these changes increased sweetness potency, while others decreased it.
Similarly, in H. Izawa et al. Pept. Sci.: Present Future, Proc. Int. Pept. Symp., 1st (1999) (Ed. Y. Shimonishi) there was a description of Ala substitutions for certain amino acids of Brazzein, with some results showing increased sweetness, while others showed decreased sweetness.
In U.S. Pat. No. 7,153,535 there was a discussion of the replacement of particular residues with Lys or Asn as positively affecting sweetness.
In Z. Jin et al., Monkey Electrophysiological and Human Psychophysical Responses to Mutants of the Sweet Protein Brazzein: Delineating Brazzein Sweetness, Chern. Senses 491-498 (2003); Z. Jin et al., Critical Regions For The Sweetness Of Brazzein, 544 FEBS Letters 33-37 (2003); and F. Assadi-Porter -e-t -a-l-., Sweetness Determinant Sites Of Brazzein, A Small, Heat-Stable, Sweet-Tasting Protein, 376 Archives of Biochemistry and Biophysics, 259-265 (2000) there was discussion regarding the N and C termini of Brazzein being important for sweetness (e.g. deletion of one C terminal residue eliminated sweetness).
While these developments are of significant interest, there is still a need for the development of protein sweeteners that provide a highly potent sweetness, particularly when providing a candy-like sweetness.
SUMMARY OF THE INVENTION
The present invention provides a sweet peptide comprising an amino acid sequence selected from the group consisting of SEQ ID NO: 2 (where Xaa is not Tyr) and SEQ ID NO: 3 (wherein at least one Xaa is isoleucine, glycine or proline). Preferred forms of SEQ ID NO: 2 are where the Xaa residue is Phe, Trp or His. Preferred forms of SEQ ID NO: 3 are where residues 1 and 2 are either both isoleucine, or are Gly Pro.
It has been surprisingly learned that the replacement of the tyrosine at position 53 of SEQ ID NO: 1 with another amino acid, or the insertion of two amino acid residues at the N terminus of wild type Brazzein (with at least one isoleucine, glycine or proline), desirably improve sweetness potency and nature. See SEQ ID NOS: 4-8.
Another form of the invention is to provide nucleotide sequences for expressing such peptides. Our most preferred embodiments are SEQ ID NOS: 9-13, when expressing in E. coli.
As is well known, a given amino acid can typically be expressed from different codons. Certain hosts (e.g. yeast) can have improved yields when the codons selected are optimized for use in that host. Thus, the nucleotide sequences of the present invention are not to be limited only to the specific examples.
The sweet proteins of the present invention should be useful to sweeten consumable foods and beverages. For example, a small amount of the peptide can be dissolved in iced tea.
Production of genes coding for these peptides (particularly when coding for a desirable fusion protein) and their insertion into production vectors, will allow large quantities of the sweeteners to be created at low cost. Further, it is expected that appropriately configured genes can be inserted directly into a plant genome (and even possibly an animal genome) so that the fruit, vegetables, and/or edible meats, milk or the like may be sweeter.
The advantages of the present invention include providing improved protein sweeteners, which can be detected by humans at concentrations lower than concentrations usually required for Brazzein to be detected, and genes coding for such protein sweeteners. Further, the nature of the sweetness mimics a candy-like sweetness, making the sweeteners particularly desirable.
These and still other advantages of the present invention will be apparent from the description, which follows. The following description is merely of the preferred embodiments. Thus, the claims should be looked to in order to understand the full scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph depicting the responses of humans regarding the sweetness of various compounds that were tested.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Natural Brazzein can be isolated from Pentaliplandra brazzeana as described in WO 94/19467. SEQ ID NO: 1 (natural Brazzein minus the beginning Glu), the Brazzein protein variants described in WO 94/19467, 95/31547 and 00/61759, and DNA coding therefore, can be obtained in accordance with the procedures described in those publications. For example, WO 00/61759 describes one expression vector pET3a/SNase into which DNA coding for mutant Brazzein can be inserted for expression in E. coli.
Restriction enzymes and T4 DNA ligase were purchased from Promega (Madison, Wis.). E. coli strains, HMS174 (DE3, recA) and BL21(DE3)/pLysS have been purchased from Novagen (Madison, Wis.). Protein expression vector pET-3a was purchased from Novagen (Madison, Wis.). Purchased plasmids were stored in a non-expression host strain HMS174 and expressed in BL21 (DE3)/pLysS.
NdeI and Bam HI sites were designed into the 5′ and 3′ ends, respectively, to permit cloning into the pET system plasmids (characterized by a T7 expression system with an optional fusion to a polyhistidine linker). In addition, a starting codon (Met) was introduced just before the first codon of the synthetic gene, since the amino acid sequence of natural Brazzein lacked an N terminal methionine.
The DNA for SEQ ID NO. 1 was synthesized by ligating eight oligonucleotides per strand. The Nde I/Bam HI fragment of the resulting DNA, which contained the entire sequence des-Glu-Brazzein, was isolated and cloned into a T7 expression vector. The sequence of the final, ligated expression vector was confirmed by automated DNA sequencing. Mismatches due to errors during synthesis of original oligos were corrected by site-directed mutagenesis using peR.
The synthetic Brazzein gene was cut with restriction enzymes and cloned into a T7 expression vector of the pET plasmid which contained Nde I and Bam HI sites. The fusion construct was made with a modification of the original nuclease-ovomucoid fusion gene. A. Hinck et al., 6 Prot. Engin. 221-227 (1993).
The four Met codons in the nuclease gene (Snase) were replaced with Ala codons by quick-change 5 site-directed mutagenesis (kit from Stratagene, La Jolla, Calif.). The DNA fragment coding for Brazzein (or the SNaseBrazzein fusion) was excised and cloned between Nde I and Bam HI sites at the C-terminus of the modified Snase gene in the pET-3a expression system. The resulting plasmid, 10 named pET-3a/SNase-SW (see FIG. 1 of WO 00/61759), was transformed into the E. coli strain BL21(DE3)/pLysS for protein expression. The use of pLysS in this strain enables expression of the nuclease-Brazzein fusion protein without the deleterious effect of nuclease.
A single colony of E. coli strain BL21(DE3)/pLysS, containing the plasmid pET-3a/SNase-SW was selected and grown overnight at 37° C. in 5 mL of Luria Broth medium with 100 ˜g ampicillin/mL and 34 ˜g of chloramphenicol/mL. The starting culture was used to inoculate 1 L of LB medium with chloramphenicol (34 ˜g/mL)/ampicillin (100 ˜g/mL) at 37° C. until an A600 nm of 0.8-1.0 was attained.
Cells were induced for 3 hours by the addition of isopropyl-˜-D-galactopyranoside (IPTG) to a final concentration of 0.2 mM. Cells were harvested and rapidly frozen in liquid nitrogen and stored at −70° C. After freeze/thawing once, 4-5 g of cells were resuspended in 50 mL lysis buffer (50 mM Tris-HCl, pH=8.0, containing 2 mM EDTA and 10 mM PMSF). The lysed cells were treated with 10 mM CaCl12 for a period of 15 minutes and subject to French pressing three times. The fully broken cells were centrifuged for 15 minutes at 12,000 g. The supernatant and the pellet were analyzed on 16% Tricine gels (Novex, San Diego, Calif.). More than 70% of the fusion protein was in insoluble form.
Where protein was present in inclusion bodies, the cell pellet after the French press steps was washed three times with lysis buffer. An extra wash step was carried out to ensure further purity of the inclusion body by adding nine volumes of lysis buffer containing 0.5% (v/v) Triton X-100 and 10 roM EDTA, waiting 5 minutes, and then centrifuging at 5,000×g for 10 minutes at 4° C.
The pellet was resuspended in 50 mL 8 M guanidinium chloride containing 10 roM EDTA and 100 roM DTT and stirred for 2-3 hours at room temperature. The clear resuspension was dialyzed overnight at 4° C. against 4 L deionized water (dH20) containing 3.5 mL acetic acid (pH-3.8-4.0) to ensure full protonation of the cysteine side chains. The precipitate was removed by centrifuging at 12,000×g.
The clear supernatant was dialyzed two more times against dH20 and acetic acid for a total period of 24 hours to completely remove the reducing agent. At this stage, more than 60-70% of the fusion protein was refolded, and the purity, as judged by gel electrophoresis, was greater than 80%. The typical yield of the fusion protein was 130-150 mg/L culture. The reduced sulfhydryl groups in the Brazzein domain were oxidized by rapidly diluting the dialysate with 4-5 volumes of 200 roM Tris-acetic acid, pH 8.0, to a final concentration of 0.5-0.7 mg/mL (based on the SNase extinction coefficient, ˜280, 1%=1.0), and this solution was stirred at room temperature for 24 hours. Following the oxidization step, the solution was concentrated with an Amicon Ultrafiltration apparatus to a final volume of 20-50 mL. When successfully folded and oxidized, the product was a clear solution. The concentrated fusion protein was dialyzed three times against 10 L of dH20 to remove residual salt and lyophilized as white powder.
Lyophilized fusion protein (130-150 mg) was dissolved in 65-75 mL water to a final concentration of 2 mg/mL. The pH of the sample was adjusted to 1.5 by adding 1 M HCl. Approximately 70-100 mg of CNBr was added to this solution, which was then stirred in the dark at room temperature for 12 hours. The cleaved product was lyophilized 4 times out of dH20 to ensure the complete removal of CNBr.
The white powder was dissolved in double distilled water to concentration of 3 mg/ml and was applied to a reverse phase HPLC C18 column (15 cm×1 cm). By raising the percentage of the buffer (70% CH3CN, 0.1% TFA) from 10 to 55, correctly folded and desalted Brazzein proteins were eluted and separated from the nuclease and uncleaved fusion protein. Brazzeincontaining fractions were combined and lyophilized.
An alternative approach is to insert six histidine amino acids at the C-terminus of Snase before linking to Brazzein. This fusion construct would then allow use of a nickel-NTA column chromatography to purify Brazzein from uncut Snase-Brazzein fusion material, and Snase proteins, prior to the final HPLC purification. To achieve this we used an elution buffer which was 20 mM Na2HP04, 0.3 M NaCl pH 8.0 to elute Brazzein.
Yet another approach would be to use an expression system referred to as the “SUMO” expression system, offered by Life Sensors. See generally R. Butt, SUMO Fusion Technology For Difficult-To-Express Protein, 43 Protein Expr. Purif. 1-9 (2005). We have successfully linked the Brazzein gene to the 3′ end of the SUMO gene and then used 0.5 roM IPTG to induce cells for 24 hours at 25 Q C. Cells were lysed by sonication. The soluble fraction was applied to nickel-NTA column chromatography and fusion protein was eluted at greater than 90% purity. The fusion protein was then cleaved by SUMO protease at high efficiency and purified using reverse phase HPLC. This SUMO alternative is expected to enhance expression of constructs, as well as facilitate production through improved solubility and folding. The SUMO-Brazzein system can then be expressed in either bacteria or yeast.
In any event, DNA sequences coding for the SEQ ID NOS. 4-8 Brazzein variants were prepared by site directed mutagenesis using the parental vector containing the DNA for SEQ ID NO.1. Basically, we followed the Quick Change™ PCR kit protocol from Stratagene, with the following variations:
To create SEQ ID NO.4 we used an oligo having the SEQ ID NO. 14 sequence.
To create SEQ ID NO. 5 we used an oligo having the SEQ ID NO. 15 sequence.
To create SEQ ID NO. 6 we used an oligo having the SEQ ID NO. 16 sequence.
These sequences were used to make mutations in the parental wild-type Brazzein using pET3a vector which contains the modified Snase fusion. Basically, 20 ng of template wild type Brazzein DNA was mixed with 125 ng of each of the complementary primers applicable to each PCR reaction. After 16-18 PCR cycles the reaction was treated with 10 units of DpnI at 37° C. for one hour to remove the original template DNA.
A somewhat similar approach was used for two amino acid insertions (after a Met at the junction between Snase and the Brazzein fusion protein). However, we prefer making one insertion at a time. Hence, to create the Ile Ile insertion we first inserted one amino acid residue using the SEQ ID NO. 17 oligo. After obtaining a sequence with one Ile insertion, we then used the SEQ ID NO. 18 sequence to insert the second Ile.
In an analogous fashion, the Gly/pro insertion 10 was inserted by first inserting only Gly using SEQ ID NO. 19, and then using SEQ ID NO. 20 to insert Pro.
To test the sweetness potency of our peptides we tested human perception of sweetness against known controls using varied concentrations of the protein (or other substance) being diluted in water. In the taste panel, humans were requested to score the sweetness sensations of the stimuli with a magnitude labeled scale in accordance with the techniques of B. Green et al., 21 Chemical Senses 323 (1996) (e.g. barely detectable; weak; moderate; strong; very strong; strongest imaginable).
We first gave those testers a sample of pure water with 2-10% sucrose as a calibration exercise two hours before protein testing. After the sucrose testing, they rinsed their mouth out thoroughly. The normal protocol included applying about 125 μI of the substance being tasted to the tongue, with the tested material kept in the mouth for about a minute.
As can be seen from FIG. 1 , the proteins of SEQ ID NOS. 5, 7 and 8 (Y53W, II12-ins and G1P2-ins) had significantly higher sweetness potency than either sucrose or wild type Brazzein, for the weight being tested. The protein of SEQ ID NO. 6 (Y53H) had significantly higher sweetness potency than sucrose for the weight being tested (while also having a desirable taste profile relative to wild type Brazzein).
As yet, we have not had a complete panel test SEQ ID NO.4. However, it was tested by an individual observer who reported results similar to those for SEQ ID NO.5.
Moreover, the reported nature of the taste for SEQ ID NOS. 4-8 was for each peptide purely sweet without detectable sourness, saltiness or bitterness, and was particularly thought to resemble candy sweetness of a pleasant nature (like sugar cane). These SEQ ID NOS. 4-8 variants therefore are excellent candidates for use alone, and/or in combination with other sweeteners, and/or in combination with each other. When used as the peptide (instead of as a DNA sequence expressing the peptide), e.g. as a food or beverage sweetener, a blend of a mutant with other known sweeteners may be desirable to most closely mimic sugar or some other desired taste.
These sweetness results are unexpected. In this regard, deletion of Tyr 53 (without replacement) greatly reduces sweetness to only slightly sweet in the powder form. Further, a variety of other substitutions of a single amino acid for another single amino acid decrease sweetness potency, or have less desirable sweetness properties. In this regard, we include in FIG. 1 examples of five substitutions which reduced sweetness potency relative to the wild type, and an example of an insertion that had a similar result.
As another example of the surprising nature of these results, we note that a variety of other changes at the N terminal adversely affect sweetness. For example, adding a Glu at the beginning of wild type Brazzein (to convert to its other natural alternative form) reduces the sweetness potency substantially. Nevertheless, adding two amino acids, where at least one is isoleucine, glycine or proline, increases potency.
Another benefit is that nearly one seventh of the amino acid composition of these peptides is lysine, an essential amino acid. Moreover, other Brazzein variants have shown desirable heat stability. Thus, these proteins may also be suitable for use in baking applications.
Given that these peptides are so sweet, only a very small amount of them should be needed to sweeten coffee, tea, or the like to the desired level of sweetness. For such uses, it is expected that they will be blended with a bulky filler (e.g. lactose) to give the user a feeling of perceived value and to ease consumer handling.
If one desires to produce these proteins in large quantity, one could synthesize the desired one of SEQ ID NOS: 9-13 using techniques analogous to those noted above, or by combining standard cloning and automated synthesizer techniques (e.g. 380 B ABI DNA synthesizer). Each gene could then be cloned into an expression vector such as those described above. Such vectors could then be inserted into suitable hosts such as BL21 (DE3/pLysS or BL21-CodonPlus (DE3) RIPL (Strategene), with expression in the usual manner.
The protein can then be harvested in the usual way (e.g. as part of a fusion protein). If desired, modifications can be made in conventional ways to reduce or eliminate undesired portions of the fusion proteins.
While production in bacteria, yeast or another cellular host is one technique, other means of producing the protein are also intended to be within the scope of the invention, such as direct synthesis using a peptide synthesizer, or synthesis in transgenic plants bearing the recombinant sequence. In this regard, as noted above, it should also be possible to insert the cDNA into pant or animal genomes using known means to cause the gene to be expressed (thereby creating sweeter fruit, vegetables or meats). Thus, when we use the term “synthetically produced peptide” we mean all of these techniques (even though a living host such as a plant, as distinguished from a laboratory vessel, might be involved).
Industrial Applicability
The invention provides sweet proteins that can, among other things, be added to or expressed in consumable items to impart a sweet flavor, and nucleotides useful to produce them.
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Disclosed herein are sweet proteins that are variants of Brazzein, and nucleotide sequences capable of expressing them. Through a replacement of a tyrosine residue at the C terminus in the naturally occurring Brazzein sequence, or the insertion of two residues (at least one being isoleucine, glycine or proline) before the N terminus of wild type Brazzein, sweetness potency, the taste profile and sweetness strength are improved.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This application relates to both radio frequency as well as free space optical data communication, particularly E-band millimeter wave Radio Frequency data communication.
[0003] 2. Description of the Related Arts
[0004] In 2003, the FCC-licensed for use 13 GHz of spectrum in the 70 GHz and 80 GHz bands, also known as the E-band millimeter wave Radio Frequency (RF) spectrum. Ten bands in this spectrum were made commercially available for a broad range of fixed wireless applications operating at gigabit data transfer rates. Applications include point-to-point local wireless networks and broadband internet access. Communication of data through E-band signals potentially serves as a cheap alternative to more costly fiber solutions, particularly in urban areas due to the cost of laying fiber. E-band RF data transfer is a particularly cost effective solution for filling the gap for short-haul wireless connectivity in the so-called “last mile” between network service providers and customers. E-band RF data transfer can also offer data rates that overlap with lower the end of rates available with fiber-based solutions.
[0005] Because of its location in the radio frequency spectrum (71-76 and 81-86 GHz), E-band data transmission is not very susceptible to interference due to fog, airborne particulates such as dust and atmospheric turbulence. E-band data transmission, however, is susceptible to degraded performance due to rain. Rain interferes with radio wave transmission in the E-band, such that during a rain storm, data transmission would necessitate repeated data retransmission at best or interrupted service at worst.
[0006] Radio waves in the E-band have a narrow, pencil beam-like characteristic, and as a result antennas producing E-band signals can be placed in close proximity to one another without concern for adjacent channel interference. However, due to the narrow pencil-like characteristic of the E-band RF beam, an E-band transmitter must be precisely pointed at its receiver in order to ensure data transmission. Twist and sway movements due to wind and other weather can more easily disrupt data transmission in the E-band versus data transmissions that occurs at lower frequencies.
SUMMARY OF THE INVENTION
[0007] To provide an integrated apparatus for free space data transmission, embodiments of the invention combine millimeter wave (mmW) Radio Frequency (RF) data transmission with Free Space Optical (FSO) data transmission on a common stabilized assembly. The apparatus may be used as part of a larger commercial communications network. The apparatus ensures high level of carrier availability, even under stressing environmental conditions. The apparatus further ensures that at least a mmW RF control link remains operational in the unlikely event that both rain and fog occur together.
[0008] Components of the apparatus include a mmW transceiver and a FSO transceiver. The transceivers are mounted on a stabilized mounting platform connected to a gimbal assembly inside a sheltered enclosure. The sheltered enclosure is mounted on a stationary platform, for example at a cell site or a network point of presence, and is positioned at a height above the ground in order to line up with an adjacent cell site that is located a distance away, but still within line-of-sight. In one embodiment, the sheltered enclosure also includes stationary equipment for supporting the stabilized mounting platform. The stationary equipment includes electronics for electrical power conditioning and distribution, as well as a drive controller for the gimbal assembly, and the bulk of the signal processing electronics. Electronics on the stabilized platform are minimized to reduce its power consumption and weight.
[0009] The gimbal assembly ensures that both the mmW RF antenna and the FSO transceivers are accurately pointed at an adjacent cell site containing the complement apparatus. Due to narrowness of both the mmW RF and FSO carrier beams, a high degree of stabilization is necessary for the moving platform. The gimbal assembly can correct for environmental effects that would otherwise disrupt communication by either of the transceivers (e.g., cell site vibration and sway). Coarse closed loop operation of the gimbal assembly is initially provided by the mmW RF transceiver, after which fine acquisition is performed by the FSO transceiver. The FSO transceiver includes fast steering mirror assembly that sends directional corrections to the gimbal assembly for pointing and stabilization of the transceivers.
[0010] In the unlikely event that both the RF and FSO carrier links are lost due to the simultaneous presence of both heavy rain and fog, the apparatus is capable of rapid reacquisition of a communications link. The apparatus uses a low data rate backchannel on the mmW RF carrier, which spreads a baseband carrier signal using a spread spectrum code, allowing for a much greater receiver sensitivity. This way, the mmW RF link is able to provide the gimbal assembly with at least the minimal amount of connectivity necessary to provide coarse control correction, even under inclement weather. This assists the FSO transceiver in reacquiring an optical link.
[0011] According to another embodiment, the FSO link may be configured to have a significantly higher data rate than the RF link. In this case, the apparatus is also capable of prioritizing the transmission of data. In one embodiment, when higher levels of throughput are available on the FSO link, higher priority data is transmitted by both transceivers, and lower priority data is transmitted only by the FSO transceiver. In another embodiment, if the RF and FSO links have similar data rates, then high priority data may be sent on both links, and low priority data may be split between the remaining RF and FSO data capacity.
[0012] In the event the transmission path is affected by rain, data transmission is minimally affected as the FSO transceiver is not significantly affected by rain. Conversely, if the transmission path is affected by fog or other particulate, data is also minimally affected as the mmW RF transceiver is not significantly affected by these weather conditions.
[0013] Other features and objectives of the present invention will be apparent from the following description and claims and are illustrated in the accompanying drawings, which by way of illustration, show preferred embodiments of the present invention and the principles thereof. Other embodiments of the invention embodying the same or equivalent principles may be used and structural changes may be made as desired by those skilled in the art without departing from the present invention or purview of the appended claims.
[0014] In one embodiment, the data transmitted by the transceivers incorporates data protection and loss mitigation techniques. In one embodiment, data to be transmitted may be preprocessed to incorporate forward error correction to improve robustness against packet loss. In one embodiment, packet retransmission can be used to recover data lost to momentary connection outages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The teachings of the embodiments of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings.
[0016] FIG. 1 is a system diagram of an integrated commercial communications network using two integrated communications apparatuses to communicate through free space.
[0017] FIG. 2 is a side view of an integrated communications apparatus including an E-band mmW RF and a FSO transceiver, both mounted onto a gimbal-controlled platform, according to one embodiment.
[0018] FIG. 3 is a diagram illustrating the components of the transceiver related to signal acquisition and reacquisition, according to one embodiment.
[0019] FIG. 4 is a flowchart illustrating the process for communications link acquisition and reacquisition by the integrated communications apparatus, according to one embodiment.
[0020] FIG. 5 is a block diagram of the electronics of the integrated communications apparatus, according to one embodiment.
DETAILED DESCRIPTION OF EMBODIMENTS
General Overview and Benefits
[0021] An integrated communication apparatus may be used as part of a commercial communications network to facilitate the exchange of fully duplexed data with another similar device. The apparatus is configured to maintain high carrier availability, or uptime, even in adverse weather conditions. The apparatus includes two transceivers, a millimeter wave (mmW) Radio Frequency (RF) transceiver, and a Free Space Optical (FSO) transceiver. In one embodiment, the mmW RF transceiver operates in the E-band RF range, or 13 GHz of spectrum in the 70 GHz and 80 GHz radio frequency bands. In one embodiment, the mmW RF transceiver is capable of operating outside the E-band RF range. The mmW RF transceiver may be used to transmit data and/or establish a link with an adjacent apparatus. In another embodiment, the E-band RF electronics support both a high data rate waveform, and an additional low data rate waveform with at least 20 dB of improved sensitivity. The low data rate waveform is intended primarily to provide a very robust command and control backchannel, and to assist in initial link acquisition or link re-acquisition.
[0022] Benefits of the disclosed apparatus include enhancement of existing systems for commercial communications by augmenting presently available mmW RF systems which are subject to interruption from weather effects. The combination of mmW RF and FSO transceivers is complimentary, whereby the FSO supports connectivity during rain, which interrupts mmW RF transmission, and conversely the mmW RF supports connectivity during conditions where fog, snow, airborne particulate matter, and atmospheric turbulence interrupt the FSO.
[0023] Integrating a mmW RF transceiver with a FSO transceiver provides an alternative solution to ground-based fiber optic communication systems. Fiber systems are expensive to deploy, as there is significant cost associated with the trenching and laying fiber in urban areas. The integrated communication apparatus provides a lower cost alternative to building a fiber optic network.
[0024] As the apparatus incorporates two different transceivers, the apparatus is able to transmit data over more than one connection. This allows data of different priorities to be transmitted in the most efficient manner possible based on the weather conditions affecting the transceivers. The apparatus also resistant to malicious attempts to defeat or interrupt data delivery through jamming, interception or hacking, as data is capable of being transmitted over both RF and FSO transmission mediums.
System Structure
[0025] FIG. 1 is a system diagram of an integrated commercial communications network using two integrated communications apparatuses to communicate through free space. An integrated communications apparatus 100 a located at a first cell site is configured to communicate with another integrated communications apparatus 100 b at a second cell site located remotely from the first cell site. The two apparatuses 100 do not have to be identical, so long as both devices are capable of transmitting and receiving both mmW RF 101 and FSO 102 transmissions at the relevant frequencies. The integrated communication apparatus 100 may be a stand-alone cell site, or attached to a cell site that performs other communications or network operations. The transceivers of the apparatus 100 a are directed at another similar device 100 b positioned a distance away within line of sight.
[0026] The distance between apparatuses may depend upon historical weather data for the area being serviced. For example, if the service area frequently experiences rain or fog, the distance between sites may be smaller than if these weather conditions are less frequent or severe. Often, an apparatus will be positioned at a prescribed height above ground to prevent interruption of line of sight due to building or landscape features. The apparatus may be land-based, maritime-based (i.e., mounted on a seaborne vessel), or airborne.
[0027] FIG. 2 is a side view of an integrated communications apparatus including an E-band mmW RF and a FSO transceiver, both mounted onto a gimbal-controlled platform, according to one embodiment. The apparatus 100 includes an environmental enclosure 203 . Inside the environmental enclosure 203 , a mmW RF transceiver 204 and a FSO transceiver 205 are coupled to a gimbal assembly 206 . In one embodiment, the gimbal assembly 206 is located external to the environmental enclosure 203 .
[0028] In one embodiment, environmental enclosure 203 includes one or more apertures for transmitting signals. Each aperture is transparent to the transmissions at least one of the transceivers. In one embodiment, each aperture is constructed using a different material transparent to the transmissions of its associated transceiver. In one embodiment, the environmental enclosure 203 has a single common aperture, made of a material having qualities that allow propagation of both E-band mmW RF 101 and FSO 102 transmissions. In the example embodiment shown in FIG. 2 , the apparatus 100 has only a single aperture 211 . In this embodiment, the housing of the environmental enclosure 203 is substantially transparent to mmW RF transmissions 101 . The aperture 211 for the FSO transceiver includes an optical window to FSO transmissions 102 .
[0029] The environmental enclosure 203 provides protection against environmental deterioration or destruction for all internal electrical and mechanical components of the apparatus. In one embodiment, the environmental enclosure 203 may also provide for internal environment control of properties such as temperature, humidly, condensation, and moisture. The environmental enclosure 203 may also employ a heater, wiper, or other mechanism 212 to preclude or limit precipitation or ice formation on the aperture 211 .
[0030] Both the mmW transceiver 204 and the FSO transceiver 205 are mounted on a moving platform 209 . In one embodiment, the FSO transceiver 205 is mounted to an optical bench, and the optical bench is mounted on the movable platform 209 . In one embodiment, the optical bench and moving platform 209 are identical. The moving platform 209 is connected to the environmental enclosure 203 through gimbal assembly 206 . Gimbal assembly 206 allows the transceivers to rotate within a range of motion on two axes dimensions, in order to assist the transceivers in forming communications links with other similar devices. Through their common mounting on the moving platform 209 , the motion of both is controlled by the gimbal assembly 206 . The transceivers share a near-common boresight.
[0031] The environmental enclosure 203 also contains a stationary platform circuit board 207 and a moving platform circuit board 208 which together transmit, receive, and process data. The stationary platform circuit board 207 is located off of the moving platform 209 , and thus does not move with gimbal 206 motion. The stationary platform circuit board 207 exchanges power and data with external electronics separate from the apparatus 100 through cables and/or fibers 213 that pass through a port 210 in the environmental enclosure 203 .
[0032] The moving platform circuit board 208 is located on the moving platform. The moving platform circuit board 208 includes those electronics that are only able to function in close proximity to the transceivers, or are best able to function in close proximity to the transceivers. Generally, it is preferable to minimize the mass and heat loading of the gimbal assembly 206 . Thus, electronics not required to be on the moving platform circuit board 208 are instead located on the stationary platform circuit board 207 . Removing unnecessary electronics from the moving platform circuit board 208 has the added benefit of minimizing the thermal loading of the moving platform 209 . In one embodiment, no electronics require close proximity to the transceivers, thus the moving platform circuit board 208 is omitted and all electronics for the apparatus are located on the stationary platform circuit board 207 .
[0033] Data received at the transceivers is communicated to the moving platform circuit board 208 , which may perform some data processing before sending the data to the stationary platform circuit board 207 for possible further processing. The stationary platform circuit board 207 sends the data to external electronics through cables 213 .
Transceiver Structure and Signal Acquisition/Reacquisition
[0034] The transceivers 204 and 205 of the apparatus 100 work in conjunction with the gimbal assembly 206 to establish communications links for data transmission. FIG. 3 is a diagram illustrating the components of the transceivers related to signal acquisition and reacquisition, according to one embodiment. The mmW RF transceiver 204 includes a mmW RF antenna 314 for transmitting and receiving mmW RF transmissions. In one embodiment, the mmW RF antenna 314 is 0.3 meters in diameter, and has a field angle of approximately 0.9 degrees. The mmW RF antenna 314 is also used in coarse steering correction for the gimbal assembly 206 .
[0035] The FSO transceiver 205 includes a FSO telescope 319 . The FSO telescope consists of an FSO boresight. The FSO telescope 319 consists of a laser 315 for transmitting FSO transmissions. In one embodiment, the laser 315 consists of a fully duplexed eye-safe 1550 nm central wavelength laser carrier. The FSO transceiver 205 additionally includes adaptive optics 316 . In one embodiment, the adaptive optics 316 include a wavefront sensor 317 . The adaptive optics 316 can consist of a low order system providing wavefront tip-tilt correction only, or a high order system providing higher order wavefront aberration correction (e.g., focus and higher).
[0036] The adaptive optics 316 provides improved wavefront phase coherency for FSO transmissions, despite the presence of atmospheric turbulence. The adaptive optics 316 does this by providing for correction of both an inbound and/or outbound optical wavefront to improve the wavefront's optical point spread function, thereby maximizing the FSO transceiver carrier throughput. The adaptive optics 316 also measure the arriving optical wavefront and use the resulting measurements as data to determine how to best orient the movable platform 209 towards the adjacent apparatus. The adaptive optics 316 include fast steering assembly 318 . The fast steering assembly 318 includes a fast steering mirror (FSM) 321 and a FSM control 320 . In one embodiment, the FSM control 320 consists of a motor drive coupled to the movable platform 209 .
[0037] The control system between the FSO transceiver 205 and the gimbal assembly 206 results in the transmission and reception of nearly collimated optical beams for establishing links and communicating data. As a result, the apparatus 100 is able to communicate FSO data over significantly larger distances than comparable FSO devices that must use divergent optical beams. In one embodiment, the FSO optical beam spreads over an angular range of less than one-tenth of a degree in any given direction. In one embodiment, the FSO has a link uptime of at least 99.9999% at a distance of four miles.
[0038] As both transceivers 204 and 205 share a common moving platform 209 , both transceivers generally move together in response to gimbal 206 motion. However, in one embodiment the FSO transceiver 205 is independently steerable from the mmW RF transceiver 204 using the FSM 408 . The wavefront sensor 317 measures the intensity conjugates of the arriving optical beam, and provides fine control data to the FSM control 320 . The FSM control 320 uses the control data to move and/or rotate the FSM 321 in order to precisely position the FSO optical boresight independent of the motion of the movable platform 209 . The FSO optical boresight is positioned to maximize the irradiance received at wavefront sensor 317 from an arriving optical beam.
[0039] Gimbal assembly 206 provides stabilization for the transceivers, and controls coarse and fine motion for the movable platform 209 containing the transceivers. The gimbal assembly 206 is coupled to the transceivers and uses received transmissions from remote cell sites to orient the movable platform 209 towards a remote apparatus in order to establish FSO and mmW communications links. The gimbal assembly 206 also responds to external weather influences that would affect the position and orientation of the movable platform 209 . The gimbal assembly 206 includes an Inertial Measurement Unit (IMU) 313 which provides a local frame of reference for the position, velocity, and angular rotation of the gimbal assembly 206 . The IMU 313 includes accelerometers and gyroscopes. Thus, the IMU is capable of detecting motion of the movable platform 209 due to external weather forces that cause apparatus motion, such as twist and sway.
[0040] FIG. 4 is a flowchart illustrating the process for communications link acquisition and reacquisition by the integrated communications apparatus 100 , according to one embodiment. Initially, apparatus at two cell sites are mechanically aligned 430 to point towards one another. In one embodiment, the mechanical alignment need only be performed once, upon initial installation of the apparatus.
[0041] The apparatus acquires an initial communications link with another remote apparatus by transmitting 431 a mmW RF signal on a mmW monitoring channel. For the mmW RF transceiver 204 , “channels” represent specific time and radio frequency ranges that are recognized by the electronics of the apparatus 100 to perform specific purposes, such as data transfer or link acquisition/reacquisition. The monitoring channel may be a portion of the RF data channel, or alternatively the enhanced sensitivity back channel may also be used for this function.
[0042] While the mmW RF transceiver 204 transmits 431 a signal on the mmW monitoring channel, the gimbal assembly 206 sweeps 432 over a search area using a coordinated scanning technique. The coordinated scanning technique minimizes the search area scanned to find the remote apparatus. The goal of the transmission 431 is to detect the presence of another remote apparatus, through the reception of mmW RF transmissions from the remote apparatus.
[0043] The search area being scanned or swept by the gimbal assembly 206 converges based upon the distribution of mmW RF data being received from various volumes of scanned space. High amounts of received RF and FSO signal in a particular area are indicative of a apparatus in that area. The operation of the mmW RF transceiver 204 in conjunction with the gimbal assembly 206 to obtain an initial communications link may be referred to as “coarse correction” or “coarse control.”
[0044] Concurrently with transmission 431 over the mmW monitoring channel, the FSO transceiver 205 may also transmit 433 a FSO signal. Typically, as the coordinated scanning technique focuses in on a remote apparatus, the FSO transceiver 205 will begin to receive incoming FSO transmissions from the remote apparatus at the wavefront sensor 317 . A scanning technique is applied to the FSM control 320 to scan 434 the FSM 320 over a search area in order to more precisely located the remote apparatus. In one embodiment, a centroid algorithm is applied to the FSM control 320 to help the FSM mirror 321 better locate the remote apparatus. The FSM control 320 communicates with the gimbal assembly 206 to more precisely orient the movable platform 209 to maximize communication link strength. The operation of the FSO transceiver 205 in conjunction with the gimbal assembly 206 and the FSM control 320 to obtain a stronger communications link may be referred to as “fine correction or “fine control.”
[0045] In the event that both transceivers lose connection with the remote apparatus, the mmW RF transceiver 204 transmits 435 a signal over a mmW backchannel to reacquire the communications link. The mmW backchannel is a low bandwidth mmW RF channel used to maintain coarse control of the gimbal assembly 206 when the FSO transceiver 205 cannot connect with its remote counterpart. The transmitted 435 mmW backchannel consists of a baseband signal using a spreading code, which spreads baseband signal over a low and wide frequency range, where the frequency range is low and wide relative to the frequency range of the mmW RF data channel. A baseband signal has a low frequency noise-like structure. By sequentially spreading the baseband signal structure over a wide band of low frequencies, a high degree of mitigation is achieved against natural fade-producing sources associated with atmospheric interference. This is due, in part, to the fact that atmospheric interference at the operating frequencies of the mmW RF transceiver looks like noise. In one embodiment, the baseband signal transmission includes data. In this embodiment, a received mmW RF baseband signal from an adjacent apparatus is processed by the apparatus 100 in order to recover transmitted data.
[0046] During reacquisition of the link by the FSO transceiver, the mmW RF transceiver 204 transmits 435 a signal on the mmW backchannel, the gimbal assembly 206 sweeps 436 over a search area. The apparatus 100 reduces the search area scanned using feedback provided by reception of RF transmissions from the remote apparatus over the mmW backchannel. The feedback functions to maintain coarse pointing control of gimbal assembly 206 while the FSO transceiver attempts to reacquire the optical link. Fine feedback is provided to the gimbal assembly 206 by data received at the FSO transceiver 205 ,
[0047] In one embodiment, the apparatus also monitors the health of both mmW and FSO data links in real time over the mmW backchannel. In one embodiment, health monitoring also includes information regarding the real time status of the gimbal assembly 206 . This information may be externally communicated to a user interested in monitoring the health of the communications network links. In one embodiment, the data signal sent over the backchannel from a first apparatus to a second apparatus provides control information for the intensity with which the second apparatus should transmit optical signals via the FSO transceiver from the second apparatus to the first apparatus. In this embodiment, the control information is based on the intensity of optical signals received at the FSO transceiver of the first apparatus.
Apparatus Electronics
[0048] FIG. 5 is a block diagram of the electronics of the integrated communications apparatus, according to one embodiment. Data is communicated within the apparatus 100 between the transceivers 204 and 205 , through the electronics, and out to an external interface in either an electronic format, such as gigabit Ethernet format, or in an optical format. In one embodiment, the electronics of the apparatus 100 include a stationary platform circuit board 207 and a moving platform circuit board 208 .
[0049] The stationary platform circuit board 207 may communicate between the moving platform circuit board 208 and with an external electronics interface associated with a user. External power 309 is received at the stationary platform circuit board 207 and is conditioned 317 and distributed 318 for use by the moving platform circuit board 208 or other components of the apparatus 100 . In one embodiment, the stationary platform circuit board 207 also contains drive electronics (DACs) 319 for gimbal assembly 206 , as well as drive electronics 319 for the fast steering mirror control 320 of the FSO transceiver 205 .
[0050] In one embodiment, the stationary platform circuit board 207 includes a Data Path FPGA 310 that comprises logic for processing of transceiver data 312 and an optical power control 313 . The Data Path Field Programmable Gate Array (FPGA) 310 may include or be attached to a microprocessor unit (MPU) 311 . FPGA 310 interfaces to moving platform circuit board 208 with stationary platform circuit board 207 through link serial interconnects 308 a and 308 b . Interconnects 308 allow the stationary platform circuit board 207 to control operational functionality of transceivers 204 and 205 . In one embodiment, the link serial interconnects 308 include interconnect 308 c which provides coaxial functionality and incorporates E-band baseband and intermediate frequency (IF) electronics 304 . E-baseband and IF electronics 304 ports RF data between moving platform and stationary circuit boards 207 and 208 in quadrature.
[0051] The stationary platform circuit board 207 may also include a variable optical attenuator (VOA) 315 to control the amplitude of the data received over optical fiber output 314 a from the FSO transceiver 205 . The stationary platform circuit board 207 also includes an Erbium Doped Fiber Amplifier (EDFA) 316 to control the amplitude of the data to be transmitted by the FSO transceiver 205 . The EDFA may be followed by a VOA to allow rapid high accuracy control of the transmit power level. Data received (Rx) and transmitted (Tx) by the transceivers is transported to and from the moving platform circuit board 208 to the stationary platform circuit board 207 through connection 314 . Connection 314 may be an electrical cable or optical fiber depending upon the embodiment. In one embodiment, the connection 314 a with the FSO transceiver 205 comprises an optical fiber, whereas the connection 314 b with the mmW RF transceiver 204 comprises a cable.
[0052] The moving platform circuit board 208 communicates data received at the transceivers 204 and 205 to the stationary platform circuit board 207 , and may also communicate with an external interface. In one embodiment, the moving platform circuit board 208 consists of a FPGA 303 . The moving platform FPGA 303 also includes a bi-directional external interface through link 308 b . The moving platform 303 may include or be connected to a digital signal processor (DSP) 322 . The moving platform FPGA 303 communicates with a temperature sensors 320 and serial peripheral interface (SPI) flash sensors 321 , which output to an external interface. The moving platform FPGA 303 communicates with the FSO transceiver 205 through three sensors: an inertial stabilization sensor 325 capable of measuring the motion of the moving platform 209 to provide feedback to the gimbal assembly 206 , a FSM drive electronics 324 coupled to the FSM control 320 for controlling the direction of the FSO transceiver 205 , and a quadrature cell control electronics 323 for closed-loop optical beam stabilization.
Data Transmission
[0053] Both transceivers 204 and 205 of the apparatus 100 are capable of transmitting data at more than one data carrier rate, and may transmit over more than one channel at the same time. In one embodiment, the mmW RF transceiver 204 transmits data over several channels simultaneously using a phase shift keying digital modulation scheme. In one embodiment, the FSO transceiver 205 may transmit over multiple channels simultaneously using dense wavelength division multiplexing (DWDM).
[0054] The transceivers may employ forward error control correction (FEC) to an outbound data stream in order to reduce the need for retransmission of lost bits. The transceivers may also be configured to retransmit lost data in response to a retransmission signal received from the adjacent apparatus.
[0055] The apparatus 100 is capable of transmitting data of different priorities at different times and over different transceivers depending upon link conditions. In one embodiment, data is broken out into high priority data and low priority data.
[0056] In one embodiment, if both the FSO transceiver link and mmW RF transceiver link are active, both high and low priority data are transported by the FSO transceiver 205 . Concurrently, only high priority data is also transmitted by the mmW RF transceiver 204 . This redundancy reduces the need for retransmission of lost high priority data, thereby increasing the overall speed at which high priority data is transmitted. Low priority data, in contrast, is transmitted only by the FSO transceiver 205 . The FSO transceiver 205 transmits both high and low priority data because it generally has a higher transmission capacity than the mmW RF transceiver 204 .
[0057] In the event of rain, data transmitted by the mmW RF transceiver 204 may not be received, however data transmitted by the FSO transceiver 205 will be received. The FSO transceiver 205 does not experience performance degradation due to rain because the radius of raindrops is significantly larger than the wavelength of the FSO optical carrier allowing for less cross-sectional scattering of the propagated laser beam radiation. In the event of fog or other particulate-based weather events, data transmitted by the FSO transceiver 205 may not be received, however data transmitted by the mmW RF transceiver 204 will be received. FSO transceiver 205 emissions are susceptible to interference due to clouds, dense fog, snow, airborne volcanic particulates. Their radii are sufficiently small so as to permit cross-sectional scattering of the propagated FSO optical beam resulting in a loss of power at the receiving FSO aperture. The FSO beam may also be scattered by very strong atmospheric turbulence under some circumstances. In contrast, mmW RF radiation near the E-band is larger in wavelength than these particulates, and thus is not affected by them. The E-Band wavelength is also much larger than any perturbation that can be introduced buy atmospheric turbulence, and is therefore not effected by turbulence. Thus, the apparatus 100 is able to transmit data over at least one connection under a range of different adverse weather conditions. In one embodiment, as high priority data is transmitted over both transceivers, high priority data will be received by a remote apparatus even under the above described weather conditions.
[0058] In the event that the communications link has unused available transmission bandwidth, low priority data may be transmitted as high priority data in order to ensure maximum use of available transmission capacity and to minimize delays due to transmission time.
Additional Considerations
[0059] Although the detailed description contains many specifics, these should not be construed as limiting the scope of the invention but merely as illustrating different examples and aspects of the invention. It should be appreciated that the scope of the invention includes other embodiments not discussed in detail above. Various other modifications, changes and variations which will be apparent to those skilled in the art may be made in the arrangement, operation and details of the method and apparatus disclosed herein without departing from the spirit and scope of the invention as defined in the appended claims. Therefore, the scope of the invention should be determined by the appended claims and their legal equivalents.
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A stabilized ultra-high bandwidth capacity transceiver system that combines an E-band (71-76 GHz, 81-86 GHz) millimeter wave RF transceiver with an eye-safe adaptive optics Free Space Optical (FSO) transceiver as a combined apparatus for simultaneous point-to-point commercial communications. The apparatus has a high degree of assured carrier availability under stressing environmental conditions. The apparatus establishes and maintains pointing and stabilization of mmW RF and FSO optical beams between adjacent line of sight apparatuses. The apparatus can rapidly acquire and reacquire the FSO optical carrier link in the event the optical carrier link is impaired due to adverse weather.
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This application claims benefit of Provisional Appln. 60/129,908 filed Apr. 19, 1999.
FIELD OF THE INVENTION
The invention relates to surgical stapler assemblies, and more particularly to surgical stapler assemblies with interchangeable heads for connecting tubular prostheses of different sizes with an organic duct such as a blood vessel or artery of a similar size.
BACKGROUND OF THE INVENTION
In the repair of the aorta with a tubular graft prosthesis, surgeons often wrap the end of the sectioned descending aorta with a length of PTFE felt and suture the felt to the aorta to form a cuff. The graft prosthesis is then sutured to the felt cuff to complete the procedure. Quite often, valuable time is lost attempting to suture the felt cuff onto the end of the aorta which is sometimes friable, and will not adequately hold the suture. In turn, this lengthens the time that the aorta is damped shut.
It would be desirable to have available an assembly which would rapidly attach the felt cuff to the end of the aorta so that the procedure can be done quickly and efficiently.
U.S. Pat. No. 5,346,115 to Perouse et al. discloses a surgical staple inserter for joining two ducts such as a blood vessel and a blood prosthesis. The staple inserter ejects staples in a radial direction relative to the axis of the ducts. In one embodiment, the patent discloses a staple holder surrounded by the prosthesis and containing a series of staples arranged in at least one ring. All the staples are ejected simultaneously. The staple inserter also includes an anvil outside the organic duct and a device for spacing apart the anvil and the staple holder in relation to their relative working positions. The points of the staples project from the staple inserter and hold the prosthesis in place during the insertion of the staple holder into the ducts.
One drawback of the device in Perouse et al. is that a complete assembly of the staple inserter is required for different sizes of aorta. The size of the aorta can vary from 12 to 14 mm on the small end to 24 to 26 mm on the large end. Unfortunately, the surgical staple inserter of Perouse et al. is designed for one size only.
Other U.S. Patents of interest include U.S. Pat. No. 5,855,312 to Toledano; U.S. Pat. No. 5,810,240 to Robertson; U.S. Pat. No. 5,732,872 to Bolduc et al.; U.S. Pat. No. 5,720,755 to Dakov; U.S. Pat. No. 5,292,053 to Bilotti et al.; and U.S. Pat. No. 5,188,638 to Tzakis.
SUMMARY OF THE INVENTION
The present invention uses a set of heads sized to accommodate various organic duct sizes which are interchangeably positioned on the end of the handle. The plurality of heads allows each head to be used with a single handle. Thus, by stocking a set or sets of the replaceable heads, only a small inventory of the handles is required. With just a single handle, a variety of sizes of heads are available to be used to accommodate the correct size of the patient's organic duct.
The present invention provides a surgical stapler assembly for joining a tubular prosthesis to an organic duct such as a blood vessel or artery. The surgical stapler assembly includes a handle and a set of interchangeable heads attachable to a distal end of the handle. Each head comprises a staple holder which includes a plurality of radially arranged staples, an anvil disposed concentrically opposite the staples, and an annular gap between the staples and the anvil for receiving the prosthesis and the end of the organic duct. The annular gap of each head in the set has a different median diameter for use with prostheses and organic ducts of different diameters. A plurality of hammers can be provided for ejecting the staples through the prosthesis and organic duct in the annular gap and oto the anvils.
The heads are preferably replaceably attachable to the distal end of the handle. The annular gap is preferably enlargable to facilitate insertion and removal of the organic duct into and from the annular gap, prior to and following ejection of the staples. Each of the interchangeable heads is preferably premounted with a tubular prosthesis having an inside diameter approximating an inside diameter of the annular gap. The handle can indude a proximal end operable for controlling ejection of the staples. Each head can include an inner tubular member housing the staples and an outer member carrying the anvil. The inner and outer members are preferably secured together at a proximal end of the annular gap.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the surgical stapler assembly of the present invention prior to engagement with the end of an organic duct such as a descending aorta.
FIG. 2 is a longitudinal section of a handle used in the surgical stapler assembly of the present invention.
FIG. 3 is a partial longitudinal section of one embodiment of an interchangeable head used in the surgical stapler assembly of the present invention.
FIG. 4 is a partial longitudinal section of the head of the surgical stapler assembly attached to the handle and receiving the end of an organic duct just prior to ejection of the staples.
FIG. 5 is a partial longitudinal section of one embodiment of a head of the surgical stapler assembly secured to the distal end of the handle after enlarging the annular gap for release of the organic duct stapled to the tubular prosthesis.
FIG. 6 is a view of half of an anvil segment along the lines 6 — 6 in FIG. 3 .
FIG. 7 is a partial perspective view of an internal part of the head of the surgical stapler assembly showing the arrangement of staple ejection orifices.
FIG. 8 is a section along the lines 8 — 8 in FIG. 3 .
FIG. 9 is a section along the lines 9 — 9 in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIGS. 1-2 a preferred form of the surgical stapler assembly 2 includes a handle 4 and head 6 . The handle 4 can be of a generally elongate form, and preferably to facilitate working in confined spaces, has an elongated proximal tube section 8 and a distal tube section 10 which is angled, more preferably at a right angle, with respect to the proximal tube section 8 . The head 6 includes a tube 12 which carries a cuff 14 for insertion into an organic duct 16 (see FIGS. 4 - 5 ). The cuff 14 is placed over the external surface of the tube 12 in order to be stapled to the organic duct 16 for example a blood vessel or artery, partially covering the cuff 14 at a median region of the tube 12 . The distal end of the tube 12 includes a cap 18 in the shape of a nose cone facilitating penetration of the distal end of the head 6 into the organic duct 16 . The cap 18 and the part of the tube 12 around which the cuff 14 and organic duct 16 are placed constitute a part which is internal with respect to cuff 14 and organic duct 16 . The rest of the head 6 constitutes a part which is external with respect to the cuff 14 and organic duct 16 .
A staple holder 20 of cylindrical general shape is arranged at a median section of the tube 12 . It includes hammers 22 for ejecting staples radially. The hammers 22 are controlled by the surgeon by means of a stapling wing nut 24 , mounted so as to rotate on the proximal end of the handle 4 . The wing nut 24 includes a cap 26 fitted with two operating fins 28 and is connected to the hammers 22 in the staple holder 20 by a linkage comprising a rod 30 connected to the staple holder 20 by a beveled gear 32 , a rod 34 and a drive nut 36 .
An anvil 38 is disposed outside the tube 36 , at the staple holder 20 , in order to deform the points of the staples which are ejected radially from the staple holder 20 . The anvil 38 is shown in more detail in FIGS. 3 and 6 according to one embodiment. The anvil 38 consists of two anvil segments 38 a , 38 b , each carried by a support arm 40 of generally semi-cylindrical shape, joined to a heel 42 , forming a collar connected to the tube 12 . The heel 42 is secured to the tube 12 at a proximal end thereof. A shoulder 44 is formed between the heel 42 and the tube 12 for receiving the distal end of distal section 10 in interlocking engagement. A plurality of spring-biased keepers 46 (see FIGS. 2 and 4 - 5 ) mounted on the distal end of tube 10 are received in corresponding slots 48 to connect the head 6 to the handle 4 . Keys 50 formed on the distal end of the tube 12 can also be provided to be received in a corresponding slot in the proximal end of the distal section 10 to further inhibit rotation of the head 6 with respect to the handle 4 . To release the head 6 from the handle 4 , if this is desired, the proximal ends of keepers 46 are depressed to position the distal end of the keepers 46 in a respective recess 51 .
The support arms 40 are made, for example, of a relatively elastic metallic material in order to be able to space apart, approximately radially, distal ends carrying the anvil sectors 38 a , 38 b . Such spacing facilitates the placing of the cuff 14 and of the organic duct 16 over the tube 12 , between the latter and the support arms 40 .
A locking hoop 52 allows the sectors of the anvil to be assembled together after having previously disposed the organic ducts to be stapled over the internal part of the staple inserter and having positioned the support arms 40 opposite the staple holder 20 . The hoop 52 can be displaced axially along the external surface of the support arms 40 between the stops 54 , 56 at either end thereof.
To mount the hoop 52 on support arms 40 , the support arms 40 are first mounted on the tube 12 and assembled together at their heels 42 . The hoop 52 is then placed around the support arms 40 while compressing them sufficiently so as to dear the stop 54 through the inside diameter of the hoop 52 . Altematively, the stop 54 and/or 56 can be secured to the support arms 40 after the hoop 52 is positioned therearound.
To assemble the handle 4 , the two half-handle pieces 58 a , 58 b are extended at their ends on the one hand by half-sleeves 60 a , 60 b for supporting the wing nut 24 , and on the other hand by half-sleeves 62 a , 62 b for fixing onto the outer tube of proximal section 8 . The two half-sleeves 60 a , 60 b of the handpiece 58 include two annular interact with annular channels 66 of complementary shape in the internal wall of the wing nut 24 , while allowing free rotation of the wing nut 24 on the handpiece 58 . The proximal end of the tube 8 which is fitted into the half-sleeves 62 a , 62 b of the handpiece 58 includes an annular projection 68 for axial positioning of the handpiece 58 and which interacts with an annular groove 70 of complementary shape made on the internal surfaces of the half-sleeves 62 a , 62 b .
In order to mount the handpiece 58 , the stapling wing nut 24 is first dispersed on a support. The two half-sleeves 60 a , 60 b for supporting the wing nut 24 are then fitted into the cap 26 of the wing nut 24 . This is done by juxtaposing joining edges 72 a , 72 b of the half-sleeves 60 a , 60 b which are symmetrically truncated, the effect of which is to form an angle between the two half-handles 58 a , 58 b . The proximal end 74 of the rod 30 , of square cross-section, is engaged in a hole 76 , of complementary shape, in the cap 26 of the wing nut 24 . The proximal end of the tube 8 , over which a sliding fastening hoop 78 has previously been placed, is disposed between the two half-sleeves 62 a , 62 b of the handpiece 58 . The half-handles 58 a , 58 b are dosed onto each other and the fastening hoop 78 is slid over the external surfaces of the two half-sleeves 62 a , 62 b , wedging them together.
FIGS. 3 to 9 show an embodiment of the interchangeable head 6 which includes staple holder 20 and of the corresponding anvil 38 . The staple holder 20 and the anvil 38 are disposed horizontally in FIGS. 3-5. The staple holder 20 consists of two flanges 82 , 84 firmly attached to the tube 12 and carrying a rotating pin 85 onto which is fixed a disc 86 which can rotate between the flanges 82 , 84 . The disc 86 is pushed onto the median zone of the pin 85 which includes a portion 88 with an irregular surface ensuring better connection between the disc 86 and the pin 85 . The pin 85 is adapted at one end thereof for engagement by the drive nut 36 , the end of the pin 85 having an outer dimension and shape, e.g. square or hexagonal, matching the inner dimensions and shape of the drive nut 36 .
The flange 82 is positioned axially inside the tube 12 between an edge 90 , delimiting the opening of the cap 18 , and the disc 86 . The flange 84 is positioned inside the tube 12 between a shoulder 91 , corresponding to an increase in the internal space of the tube 12 , and the disc 86 . The flanges 82 , 84 are positioned transversely with respect to the tube 12 by means of axial projections 92 , 93 which interact with notches 92 a , 93 a of complementary shape. Also, flanges 82 , 84 are respectively arranged on the edge delimiting the opening of the cap 18 and on the shoulder 91 of the tube 12 .
Staples 94 are disposed flat between opposite faces of the disc 86 and of flanges 82 , 84 , so as to constitute two superimposed rings of staples. Each ring of staples 94 includes ten staples, for example, distributed over the entire circumference of the tube 12 . FIG. 7 shows how the orifices 95 of the tube 12 are arranged in two superimposed rings, so that the orifices 95 of one ring are staggered with respect to the orifices 95 of the other ring.
FIG. 5 shows anvil segment 38 b which includes cavities 96 , of known shape, intended to receive the points of the staples in order to fold them back during stapling.
The means for ejecting the staples 94 will now be described. In this connection, reference will be made to FIGS. 3-5 and 8 - 9 . FIGS. 3-5 and 8 show that each staple 94 is ejected by a hammer 98 of generally flat shape. The hammers 98 are disposed in rings between the opposite surfaces of the disc 86 and of flanges 82 , 84 . The flanges 82 , 84 include, on the surfaces thereof opposite the disc 86 , means for guiding the staples 94 and means for guiding the hammers 98 . The means for guiding the staples 94 consist of radially extending recesses 100 in the surfaces of the flanges 82 , 84 , in which recesses the staples are housed. The means for guiding the hammers 98 consist of radial grooves 102 arranged on the surfaces of the flanges, in the middles of the respective recesses 100 , which interact with guiding projections 104 disposed on respective faces of the hammers 98 . The disc 86 includes means for driving the hammers 98 , which means consist of spiral channels 106 , at constant pitch, arranged symmetrically in opposite faces of the disc. The spiral channels 106 interact with respective drive projections 108 disposed on respective faces of the hammers 98 .
FIG. 9 shows how the projections 108 of the hammers 98 are disposed in the spiral ribs 106 of the disc 86 . There are ten projections 108 , corresponding to ten hammers 98 , which simultaneously eject each ring of ten staples. The hammers 98 are set in their initial position, before stapling, at the center of the disc 86 . The position of the projection 108 on each hammer 98 depends on the angular position of the latter in the staple holder. As the spiral channel 106 has a constant pitch, the rotation of the disc 86 in the clockwise direction, along arrow H in FIG. 9, simultaneously drives all the hammers 98 , displacing them radially by an equal distance.
The mounting of the staple holder 20 according to this embodiment of the invention will now be described. In a first step, the cap 18 is placed on a support. There are then successively assembled the first flange 82 , on the cap 18 , the disc 86 fixed on the pin 85 , and the second flange 84 . The hammers 98 are next introduced into the staple holder 20 . Since the position of the drive projection 108 on each hammer 98 is a function of the angular position of the latter in the staple holder 20 , it is expedient to dispose the various hammers 98 in the staple holder 32 in a well-defined order. For this purpose, the first step is introducing the first hammer 98 of the series into the staple holder by engaging the drive projection 108 in the spiral channel 106 , through the periphery of the disc 86 , at a recess 100 for guiding the staples. The same procedure is repeated with the other hammers 98 of the series, in the order in which they are disposed in the staple holder. All the hammers 98 are set in their initial position, at the center of the disc 86 , by rotating the disc 86 fully in the counterclockwise direction. The cap 28 /staple holder 20 assembly is then disposed in the distal end of the tube 12 . The means for axial positioning and rotational positioning of the flanges 82 , 84 which were described hereinabove ensure the correspondence between the orifices 95 for ejecting the staples from the tube 12 and the recesses 100 for guiding the staples 94 . The staples 94 are introduced into the staple holder 20 through the orifices 95 while orienting their points outwards and while placing the crosspiece of each staple 94 in contact with the corresponding hammer 98 .
In the use of the assembly 2 to repair a damaged descending aorta, for example, the aorta is sectioned and its exposed diameter is measured. A head 6 having a tube 12 /cuff 14 of a diameter about the same as the end of the aorta is selected. For this application, the set of interchangeable heads 6 are provided in 2 mm increments from 12 mm to 26 mm outside diameter. Owing to the elasticity of the aorta, it is better to use the next larger size of head 6 as the aorta can be stretched slightly. The head 6 is then attached to the handle 4 , first aligning the drive nut 36 with the proximal end of the pin 85 , and then the slots 48 with the keeper 46 which is snapped into place to securely connect the selected head 6 with the handle 4 . With the hoop 52 positioned adjacent the proximal stop 56 , the end of the aorta 16 is slid onto the cap 18 and over the tube 12 and premounted cuff 14 so as to be disposed in the annular gap between the staple holder 20 and the anvil segments 38 a , 38 b . The hoop 52 is then advanced in position next to the distal stop 54 . Then the wing nut 24 is rotated while firmly gripping the handpiece 58 to eject the staples 94 to secure the cuff 14 to the aorta 16 . The hoop 52 is then retracted in position next to the proximal stop 56 and the assembly 2 is withdrawn from the cuff 14 and aorta 16 . The graft prosthesis (not shown) can then be attached to the cuff 14 by conventional suturing and or stapling. The assembly 2 can be sterilized for reuse and a new cuff 14 mounted in the interchangeable head 6 , or disposed of.
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A surgical stapler assembly for joining a tubular prosthesis to an organic duct such as a blood vessel or artery is disclosed. The assembly has a handle and a set of interchangeable heads attachable to a distal end of the handle. Each head has a staple holder housing a plurality of radially arrayed staples, a plurality of anvils disposed concentrically opposite said staples and an annular gap between the staples and the anvils for receiving the prosthesis and an end of the organic duct. The annular gap of each head in the set has a different median diameter for use with prostheses and organic ducts of different diameters. Hammers are provided to eject the staples through the prosthesis and organic duct in the annular gap and onto the anvils. The heads can be replaceably attachable to the distal end of the handle. The annular gap can be enlarged to facilitate insertion and removal of the organic duct into and from the annular gap prior to and following ejection of the staples. The interchangeable heads can come with a pre-mounted tubular prosthesis having an inside diameter approximating an inside diameter of the annular gap.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method of demand management and control for limited pressure head or gravity fed fluid closed conduit networks, and relates particularly, though not exclusively, to a method of demand management and control for limited pressure head or gravity fed water irrigation pipe networks.
BACKGROUND OF THE INVENTION
[0002] In our U.S. Pat. No. 7,152,001, the entirety of which is herein incorporated, there is disclosed a computer based system for predicting the fluid level in a fluid flow network. The system has been very successful as it can use past and present measurements of parameters to predict and control fluid level and flow. The system gathers data from timed fluid levels and opening positions of regulators or valves to provide a model from which fluid levels and flow can be determined in real time.
[0003] In our International Patent Application No. PCT/AU2012/000907, the entirety of which is herein incorporated, there is disclosed a method of demand management for fluid networks. The method was applicable to both a closed conduits (pipeline network) and open conduits (channel networks), Gravity pipe networks typically operate within limited pressure head and therefore are constrained in their capability to meet demand.
[0004] Known models for pipe networks would be used in the management of demand for these networks. Data from the SCADA system would be used to calibrate and continually fine-tune the model of the pipe conveyance network based on system identification techniques. Flow measurement and pressure head measurements would be located at points on the pipe network that would be deemed necessary to calibrate the model to the desired accuracy. The supply points to users are the primary form of control used with a pipe network. The controller for a pipe network is much simpler than it is for a channel network with the principle form of control being maintaining the flow at the supply point equal to that of the order.
[0005] Control and management of demand is especially applicable to gravity pipe networks commonly used for the supply of irrigation water. Difficulties have arisen to implement such systems as gravity pipe networks typically operate within limited pressure head and therefore are constrained in their capability to continually meet demand. Gravity pipelines also typically operate at lower pressure heads where there will be greater interaction between flows at outlets due to valve operations. Accordingly, assuming all the parameters such as pipe diameter, flow rate, valve size, etc being the same, the higher the static pressure head e.g. from pumping), the less sensitive the impact of flow fluctuations due to valve operations (e.g. valves opening or closing) on other valves in operation.
[0006] FIG. 1 illustrates why operating valves are less sensitive to flow variations in the supply pipeline (e.g. from other opening and closing valves) with a higher pressure head in the pipeline FIG. 1 shows a graph of the hydraulic grade line or pressure head against the valve position for a high pressure at line 10 and for a low pressure or gravity fed hydraulic grade line or pressure head at line 12 . Gravity fed pipe 14 is shown on a grade with two valves 16 and 18 . Although pipe 14 is shown on a grade, it could be horizontal if the water supply is elevated to provide the required pressure head. For line 10 , pipe 14 would be coupled to a pump (not shown) to produce a high-pressure head. The explanation now follows:
1. Assume the one physical pipeline 14 operating at either a Low Pressure (LP) state and at a High Pressure (HP) state, and for a specific operating valve supplying fluid off the pipeline 14 . 2. Assume initially the supply pipeline 14 is operating at the same flow rate Q 1 in both states. 3. A change in flow in the supply pipeline 14 (due to other valves 16 , 18 starting and stopping) occurs for both states.
[0000] Δ Q=Q 1 −Q 2
4. The change in pressure head, Δh, at the operating valve 16 due to the change in flow ΔQ, is the same for both states. (The known pipeline flow versus pressure head equations, e.g. Colebrook-White equation, Manning's Formulae are applicable) 5. The head loss across valve 16 is determined as follows;
[0000]
h
=
K
(
v
2
2
g
)
[0000] where
h=pressure loss in terms of fluid head, i.e. fluid head loss K=the valve ‘K’ factor (assume constant) for the specified valve opening v=velocity of fluid g=acceleration due to gravity 6. Assume the same initial flow, and therefore velocity, through the operating valve 16 in both the LP and HP states are equal
[0000]
v
LP
1
=
v
HP
1
h
LP
1
K
LP
=
h
HP
1
K
HP
7. With h LP1 <<h HP1
K LP <<K HP
where K LP and K HP represent the different K factors for the different valve openings in either pressure state i.e. valve 16 will be at a greater opening in the LP state than the HP state.
8. When a pressure head change, Δh, is introduced, the change in pressure head across valve 16 for each state h Lp2 =h LP1 −Δh, and h HP2 =h HP2 −Δh respectively. The relative change in head across the valve is greatest in LP state than the RP state,
9, Assuming valve 16 remains in the same opening position for each state, and therefore the K factors remain the same, the new velocity for each state is
[0000] v LP2 =√{square root over (( h LP1 −Δh )2 g/K LP )}
[0000] v HP2 =√{square root over (( h HP1 −Δh )2 g/K HP )}
10 The resulting velocities for each state due to the pressure head change. Δh, will see;
[0000] ( v LP2 −v LP1 )>>( v HP2 −v HP1 )
[0000] The change in velocity, and therefore flow through the valve is much greater for the LP state than for the HP state.
[0022] Higher pressure (e.g. pumped) pipelines with smaller diameter valves and flow meters have less interaction between operating valves than low-pressure pipelines with larger diameter valves and flow meters. In high pressure systems the valves can be manually positioned to a set opening to achieve a certain flow, and the flow will not be impacted significantly by the operation of the other valves (e.g. valves opening or closing) in the pipeline. Whereas, low-pressure pipelines require an integrated control and demand management system to manage the valve interaction within the tight hydraulic grade line conditions.
[0023] FIG. 2 shows pipeline 14 separated from FIG. 1 and illustrates the maximum supply pressure 22 which must maintain the pipeline full to ensure the accuracy of the flow meters (not shown) associated with valves 16 , 18 , and 20 . It is important to keep the pipeline full to make the control problem simple and tractable as a “pipe not full” scenario will significantly change the physics that governs the dynamics of pipe flow. Pipe flow transitioning between “pipe full” and “pipe not full” states will make achieving robust control intractable. Maintaining the hydraulic grade line 12 associated with the pipeline 14 above the maximum supply pressure 22 will also ensure that the pressure head at the valves 16 , 18 and 20 are high enough to guarantee the flow rate the valves were designed for. The low-pressure head or hydraulic grade line 12 associated with pipeline 14 will potentially result in increased controller interaction between the discrete control actions necessary to maintain desired flows at the valves. This is further compounded with gravity pipelines where the flow capacity at the valves is high in relation to the overall flow capacity of the main trunk pipeline The action of opening or closing valves will impact the pressure head, and therefore flow, at all other valves on the pipeline 14 that are operating. Therefore there will be interaction between various automated valves operating off the pipeline. In this low energy pipeline, the control will be subject to instability. Each movement in a valve has a level of interaction with all the other operating valves plus supply level variation at the source or at the outlet (on-farm). Because of the low pressure in the pipeline 14 , the hydraulic grade line 12 is very sensitive to the operation of the valve/outlets.
[0024] This sensitivity is illustrated in FIG. 3 where a graph of flow and time is shown. Line 24 illustrates valve 16 being already open and the effect that the opening of valve 18 has on the network. Line 26 illustrates the flow of valve 18 . Both valves 16 and 18 are trying to maintain their preselected flow rate but the valves produce an unstable jittery interaction between the valves. The interaction is fairly minor on the flow through valve 16 shown by the changes in flow at 28 but there is a major interaction on the stability of flow through valve 18 shown by the changes in flow at 30 . Furthermore, all the additional valves e.g. valve 20 will also be effected by this interaction. The network becomes extremely unstable and this is a key reason why gravity feed irrigation systems have found little favour with water suppliers and users.
OBJECTS OF THE INVENTION
[0025] It is an object of the present invention to provide a method of demand management and control of limited pressure head or gravity fed fluid pipe networks for closed conduit fluid networks to maintain a requested flow rate despite variations in the pressure head in said fluid network.
[0026] A further object of the present invention to provide a method of demand management and control of limited pressure head or gravity fed fluid pipe networks for closed conduit fluid networks that avoids instability that can occur from the interaction between operating valves.
SUMMARY OF THE INVENTION
[0027] The present invention in one aspect provides a method of demand management and control of limited pressure head or gravity fed fluid pipe networks, said method including the steps of providing a computer controlled fluid network for delivery of fluid through a plurality of valves, maintaining a real time database within said computer controlled fluid network of predetermined parameters including flow schedules and capabilities of said plurality of valves, requesting, through a user interface, a flow rate and time of delivery of said fluid from the fluid network to at least one of said plurality of valves, determining, using said predetermined parameters from said real time database, the availability of providing said delivery and flow rate of said fluid from the fluid network to said at least one of said plurality of valves based on hydraulic capacity of said fluid network, and, if said hydraulic capacity is available, calculating parameters using said real time database to deliver said fluid to said at least one of said plurality of valves through said computer controlled fluid network, whereby each of said plurality of valves is monitored and adjustably controlled to provide said flow rate and delivery through said at least one of said plurality of valves in unison with the monitoring and controlling of the others of said plurality of valves to maintain the flow and manage the pressure head within said fluid pipe network between predetermined limits.
[0028] Preferably the method further includes pre-empting the valve position of at least one of the others of said plurality of operating valves to maintain their flow rate in anticipation of the variation of pressure head in the fluid pipe network due to said delivery through said at least one of said plurality of valves. The method may also include a respective feedback controller associated with each of said plurality of valves to allow fine-tuning of the valve position of each valve. A respective feed-forward controller may also be provided to vary the valve position of said valves to a best estimate position based on one or more of the following: monitored hydraulic capacity of said fluid pipe network; predicted pressure head change at the respective valves based on future flow schedule maintained in the real time database; and valve rating associated with the respective valves. It is proposed that said feed-forward and feedback controllers are associated with respective valves.
[0029] The invention may also use data from an interface to calibrate and continually fine tune the valve rating for the respective valves using data fitting techniques.
[0030] In yet a further embodiment there is provided a supervisory control layer within said computer control to monitor and control the feed-forward and feedback controllers for each valve, to prevent the interaction between the various operating valves, maintain the pressure head within said fluid pipe network between predetermined limits, and handle exception events as per predetermined business rules.
[0031] Preferably the method further includes the steps of allowing a plurality of customers to access said user interface and said computer controlled fluid network determining a priority and weighting of flow rate and time of delivery requests of said fluid to ensure continuance of said hydraulic capacity. The priority and weighting of delivery requests may include tariff structures for said customers based on best use of available hydraulic capacity.
[0032] In a further embodiment data from an interface is used to calibrate and continually fine tune the computer controlled fluid network using a model of the fluid pipe network based on system identification techniques. The method may also include the step of rescheduling said flow rate and time of delivery of said fluid from the fluid network if said hydraulic capacity is not available.
[0033] In a practical embodiment the method includes the step of said computer controlled fluid network controlling operation of a hybrid pump to maintain pressure head. The plurality of valves may include bi-foldable harder members pivoting along a central axis to provide an approximate linear relationship between the opening of the bi-foldable barrier members and the fluid flow.
[0034] Preferably said predetermined parameters includes business rules and constraints to allow for further variations of said flow rate and time of delivery of said fluid through any valve. The method may include the step of any subsequent flow rate and time delivery request resulting in the maximum and minimum thresholds of flow limits through said fluid network being breached will be denied or rescheduled to allow said subsequent request to proceed based on said calculated parameters.
[0035] The invention also provides a method of demand management and control of limited pressure head or gravity fed fluid pipe networks, said method including the steps of providing a computer controlled fluid network for delivery of fluid through a plurality of valves, maintaining a real time database within said computer controlled fluid network of predetermined parameters including flow schedules and capabilities of said plurality of valves to provide a. model of the fluid pipe network, requesting, through a user interface, a flow rate and time of delivery of said fluid from the fluid network to at least one of said plurality of valves, determining, using said predetermined parameters from said real time database, the availability of providing said delivery and flow rate of said fluid from the fluid network to said at least one of said plurality of valves based on hydraulic capacity of said fluid network, and, if said hydraulic capacity is available, calculating parameters using said real time database to deliver said fluid to said at least one of said plurality of valves through said computer controlled fluid network, whereby each of said plurality of valves is monitored and adjustably controlled to provide said flow rate and delivery through said at least one of said plurality of valves in unison with the monitoring and controlling of the others of said plurality of valves to maintain the flow and manage the pressure head within said fluid pipe network between predetermined limits.
[0036] The invention also relates to a system that uses the methods as previously described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The structure and functional features of a preferred embodiment of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawing, in which:
[0038] FIG. 1 is a graph of the hydraulic grade line or pressure head against the valve position for a high pressure irrigation system and for a low pressure or gravity fed hydraulic grade line or pressure head irrigation system;
[0039] FIG. 2 shows a schematic drawing of the low pressure or gravity fed hydraulic grade line or pressure head irrigation system with the valves and hydraulic grade line;
[0040] FIG. 3 is a graph of the flow and time for switching of valves shown in FIG. 2 showing the unstable behavior of the valves;
[0041] FIG. 4 is a block diagram of the architecture of the low pressure or gravity fed irrigation system according to a preferred embodiment of the present invention;
[0042] FIG. 5 is a similar drawing to that of FIG. 4 overlaid with a low pressure or gravity fed pipeline;
[0043] FIG. 6 is graphical representation of the valve operation to bias towards a high pressure head;
[0044] FIG. 7 is a similar view to that of FIG. 3 showing the stable behavior of the valves using the system shown in FIG. 4 ; and
[0045] FIG. 8 is a graphical representation where a hybrid pump is installed in the low pressure or gravity fed irrigation system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0046] FIG. 4 shows a flow diagram of a demand management and control system 40 for a gravity fed irrigation network 42 ( FIG. 5 ). The system 40 has a user interface 44 which allows customers to select a time frame and flow rate for valves 16 , 18 and 20 . The number of users and valves is not limited but is managed by the system 40 . Interface 44 can be a computer, keyboard or an Internet based application to allow the user to enter their requests 46 into system 40 . The requests 46 and the returned confirmations to the user are monitored by a demand management system 48 implemented in a central computer 50 . The demand management system 48 includes a real time database that maintains predetermined parameters including flow schedules, capabilities of valves, business and control rules A supervisory layer 52 is also implemented in the central computer 50 . Supervisory layer 52 is linked to the demand management system 48 through port 54 and updates and receives flow schedules and constraint information.
[0047] Supervisory layer 52 communicates with each valve 16 , 18 and 20 to cause the valves to be controlled through port 56 and to receive the measured flow and performance information through port 58 . Each valve 16 , 18 and 20 has a valve control interface 60 although FIG. 4 only shows one interface 60 . Each valve control interface 60 can be in the form of a remote terminal unit (RTU) or programmable logic controller (PLC). It is evident that each valve will require a respective valve control interface. The location of the respective valve control interface(s) 60 can be with the central computer 50 , or remotely located with the respective valve.
[0048] Valve 16 is typically of the type shown in FIGS. 17 to 79 of International Patent Application No. PCT/AU2012/000328, the contents of which are incorporated herein. Valve 16 will be associated with a flow meter (not shown), typically of the type shown in International Patent Application No. PCT/AU2010/001052, the contents of which are incorporated herein. The advantage of this type of valve is the approximately linear relationship between the valve opening (angular position) and flow. This ensures a relatively accurate flow setting is achieved using the predetermined valve opening. Other valve, mechanisms, such as butterfly valves that are commonly used in the water industry, do not possess this linear characteristic and would therefore have difficulty in achieving the required valve rating (to be described later) and the associated control. The preferred embodiment is not limited to these type of valves or flow meters but these valves and flow meters are well suited to the task. Each flow meter will provide the measured flow and performance information through port 58 . Each valve 16 has a feed forward controller 62 and a feedback controller 64 whose outputs 66 , 68 cause actuation of valve 16 via signal 69 . The flow rate is measured by the flow meter (not shown) and sent to port 58 , to feedback controller 64 through signal 71 and to a valve calibration section 70 . The flow order 72 from port 56 for the valve 16 is delivered to both the feed forward controller 62 and the feedback controller 64 . Typically, the feed forward controller 62 will lead the action of the feedback controller 64 using an optional delay switch 74 . It is preferred that both the feed forward controller 62 and the feedback controller 64 be provided but the system can also function with only one of these controllers.
[0049] Control strategy for low energy pipelines is one of managing the interactions of the controllers of each valve in a defined control methodology. Knowledge of the dynamics of the pipe 14 through the fluid network model will be used to design controllers using already well known classical control theory, and the knowledge of the future demand. The valve rating and measurement of the current pressure head conditions in the pipe 14 will be used to feed-forward to the valve 16 movements through controller 62 . The valve rating is the derived relationship between;
the valve opening, the differential pressure head at the valve 16 , and the flow.
[0053] The valve rating will be calibrated during normal operation by the valve calibration section 70 using the data recorded for the aforementioned parameters during the normal operation of the valve 1 $. The valve rating is derived using System Identification techniques. The adjusted valve rating will be sent to valve 16 at 76 and the valve opening will be returned to valve calibration section 70 through signal 78 , The valve rating allows a predetermined control action to send valve 16 to a particular opening for a known pressure head in order to achieve a desired flow. The valve rating facilitates a bulk control adjustment without relying on feedback control using the flow measurement.
[0054] The system 40 provides control such that that hydraulic grade line is biased towards the high end of the spectrum. With reference to FIG. 6 it shows that valve 16 is operating and valves 18 and 20 are about to open. FIG. 6 graphically shows the static, as opposed to the dynamic, operation of the three valves. Valve 16 is due to stop at point 82 and valves 18 and 20 are to open at the same time. By offsetting the opening of valves 18 and 20 to points 84 and 86 the closing event of valve 16 will be initiated first to make extra pressure head 90 available as can be seen from the accumulative pressure head line 88 . Thus the closing action of one or more valves will always lead (advance in time) any opening action of other valves. This control sequence ensures fluctuations in the pressure head (hydraulic grade line) due to control actions always result in a pressure greater than that predicted by the model and ensures that the pressure head does not drop below that predicted by the model within the demand management system 48 . It is important the hydraulic grade line does not drop below a minimum supply level at valve as this can result in the pipe becoming “not full” and flow measurement would likely to be in error. In addition, maintaining the hydraulic grade line above a critical minimum level for valves is an important object of the low energy pipeline to guarantee an ordered flow can be achieved through the network. The command to deliver a flow at the valve will be provided by the demand management system 48 once the order passes the capacity checks. When the time arrives to open the valve, the feed-forward controller 62 kicks in first and moves the valve to a best estimate position to deliver the requested flow based on the local pressure head and valve rating. The feedback controller 64 only does the fine adjustments. In the preferred embodiment there will be an ability to use the feedback controller 64 or the feed forward controller 62 individually, or in combination as discussed previously. Such a methodology will minimize the transients in the pipeline and hence the interactions. This is a uniqueness of the solution
[0055] FIG. 7 is a similar view to that of FIG. 3 showing the stable behaviour of the valves using the system shown in FIG. 4 . Line 24 illustrates valve 16 being already open and the effect that the opening of valve 18 has on the network. Line 26 illustrates the flow of valve 18 . Both valves 16 and 18 are trying to maintain their preselected flow rate. The major jittery interaction shown in FIG. 3 at 30 has been substantially reduced in FIG. 7 using the system of this preferred embodiment. Similarly, the jittery interaction show in FIG. 3 at 28 has also been substantially reduced. The improvement in control and steady flows through the valves even when multiple valves are operating is evident.
[0056] The invention can also be used in association with irrigation system that include a hybrid pump for increasing the flow rate when an increase in flow rate is required. Such a system is shown in our Australian Patent Application Nos. 2012905225 and 2012905508, the contents of which are herein incorporated. FIG. 1 of these applications disclose a main pipeline 20 and a branch pipeline 30 that opens into main pipeline 20 . The branch pipeline 30 has a low head lift pump 34 that provides an increased flow rate when required by the system. An inlet gate 22 on main pipeline 20 will be closed when pump 34 is operating. In FIG. 3 of these applications a further embodiment is shown where branch pipeline 30 is omitted and an inline pump 36 is provided in the main pipeline 20 . The effect of the hybrid pump 34 of FIG. 1 with inlet gate 22 of Australian Patent Application Nos 2012905225 and 2012905508 is shown in FIG. 8 . The graph shows pressure against time with line 92 showing the cumulative pressure head. The hybrid pump is turned on at point 94 but the pressure does not increase until the inlet gate is closed at point 96 . The pressure will increase to the pressure shown at point 98 . The increase in pressure will remain whilst the inlet gate is closed and the hybrid pump operates. Lines 100 , 102 and 104 coincide with the movements of respective valves 20 , 18 and 16 , Valves 20 , 18 and 16 are all open at point 106 at various flow rates and the system 40 will instruct the valves to adjust their valve openings to maintain their respective flow rates as the increased pressure from the hybrid pump is applied.
[0057] The use of a hybrid pump will also have an impact on the hydraulic grade line when the pump is starting up or shutting down. The operation of the associated inlet gate (closing) at the pipe inlet allows for the gradual input of the raised pressure head from the pump. This would begin once the pump has been turned on. As the gate closes, the pressure head in the pipeline will increase. This will be undertaken gradually and potentially in a stepwise approach with corresponding offset (leading) valve adjustments occurring at each step. The step and the delay will be a function of the dynamics of the pipe such that valve interactions are kept to a minimum. Similarly the inlet gate could open gradually prior to the pump shutting down. The corresponding offset (lagging) valve adjustments would occur in a sequence with a stepwise opening of the inlet gate. Where there is a control objective to keep the hydraulic grade line below a particular maximum operating pressure the opening of a valve would lead the corresponding closing of another valve. The system would be programmed so that these circumstances can be identified and the appropriate control action taken.
[0058] The supervisory layer 52 will monitor the performance of the pipe network 42 holistically and will have information about the topology. The supervisory layer 52 can include high level rules to operate the valves 16 , 18 , 20 to bias them towards a high pressure head, rules to mitigate the effects of interaction, and rules to follow during exception events. Interactions between controllers for each valve will be monitored by supervisory layer 52 through a further set of rules. Performance will be continuously monitored and deterioration in performance identified. An automatic rule based check will be performed to progressively turn off the feedback component of the valves in the network if control loop interaction is observed until the poorly performing valve is identified. Once identified, the poorly performing valve will have its control suspended, while the others will have the feedback turned back on.
[0059] The invention will be understood to embrace many further modifications as will be readily apparent to persons skilled in the art and which will be deemed to reside within the broad scope and ambit of the invention, there having been set forth herein only the broad nature of the invention and certain specific embodiments by way of example.
[0060] Throughout this specification and the claims which follow, unless the context requires otherwise, the word “'comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
[0061] The reference to any prior art in this specification is not and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge in Australia.
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A method of demand management and control of fluid pipe networks including providing a computer controlled fluid network for delivery of fluid through a plurality of valves, maintaining a real time database of predetermined parameters including flow schedules and valve capabilities, requesting a flow rate and time of delivery of said to at least one of said plurality of valves, determining availability of providing delivery and flow rate of fluid to the at least one of said plurality of valves based on hydraulic capacity of the fluid network, and calculating parameters using the database to deliver fluid to the at least one of said plurality of valves, whereby each of the plurality of valves is monitored and adjustably controlled to provide the flow rate and delivery through the at least one of said plurality of valves and manage the pressure head within said fluid pipe network between predetermined limits.
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RELATED APPLICATIONS
This is a continuation of application Ser. No. 08/644,422, filed May 10, 1996 and now U.S. Pat. No. 5,602,741 issued Feb. 11, 1997, which is a continuation of application Ser. No. 08/199,387, filed Feb. 18, 1994, and now U.S. Pat. No. 5,519,620, issued May 21, 1996.
A copending U.S. patent application Ser. No. 08/026,547, filed Mar. 4, 1993, by Nicholas Charles TALBOT, et al., and titled "LOCATION AND GENERATION OF HIGH ACCURACY SURVEY CONTROL MARKS USING SATELLITES", is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to navigation systems and industrial control systems and more specifically to combinations of navigation and industrial controls that provide centimeter accuracy in the positioning and movement of operating machinery and robots.
2. Description of the Prior Art
When originally conceived, the global positioning system (GPS) that was made operational by the United States Government was not foreseen as being able to provide centimeter-level position accuracies. Such accuracies are now commonplace.
Extremely accurate GPS receivers depend on phase measurements of the radio carriers that they receive from various orbiting GPS satellites. Less accurate GPS receivers simply develop the pseudoranges to each visible satellite based on the time codes being sent. Within the granularity of a single time code, the carrier phase can be measured and used to compute range distance as a multiple of the fundamental carrier wavelength. GPS signal transmissions are on two synchronous, but separate, carrier frequencies "L1" and "L2", with wavelengths of nineteen and twenty-four centimeters, respectively. Thus within nineteen or twenty-four centimeters, the phase of the GPS carrier signal will change 360°.
However, the number of whole cycle (360°) carrier phase shifts between a particular GPS satellite and the GPS receiver must be resolved. At the receiver, every cycle will appear the same. Therefore there is an "integer ambiguity". The computational resolution of the integer ambiguity has traditionally been an intensive arithmetic problem for the computers used to implement GPS receivers. The traditional approaches to such integer ambiguity resolution have prevented on-the-fly solution measurement updates for moving GPS receivers with centimeter accurate outputs. Very often, such highly accurate GPS receivers have required long periods of motionlessness to produce a first and subsequent position fix.
There are numerous prior art methods for resolving integer ambiguities. These include integer searches, multiple antennas, multiple GPS observables, motion-based approaches, and external aiding. Search techniques often require significant computation time and are vulnerable to erroneous solutions or when only a few satellites are visible. More antennas can improve reliability considerably. If carried to an extreme, a phased array of antennas results whereby the integers are completely unambiguous and searching is unnecessary. But for economy, the minimum number of antennas required to quickly and unambiguously resolve the integers, even in the presence of noise, is preferred.
One method for integer resolution is to make use of the other observables that modulate a GPS timer. The pseudo-random code can be used as a coarse indicator of differential range, although it is very susceptible to multipath problems. Differentiating the L1 and L2 carriers provides a longer effective wavelength, and reduces the search space. However, dual frequency receivers are expensive because they are more complicated. Motion-based integer resolution methods make use of additional information provided by platform or satellite motion. But such motion may not always be present when it is needed.
Another prior art method and apparatus for precision attitude determination and kinematic positioning is described by Hatch, in U.S. Pat. No. 4,963,889, comprises the steps of determining the approximate initial relative position of a secondary antenna that is freely movable with respect to a reference antenna; making carrier phase measurements based on the reception of "N" number of satellites, where N is the minimum number of satellites needed to compute the relative position of the secondary antenna; deriving from the carrier phase measurements an initial set of potential solutions for the relative position, wherein the initial set of potential solutions all fall within a region of uncertainty defined by a sphere having a radius equal to the maximum distance between the two antennas, and wherein multiple potential solutions arise because of whole-cycle ambiguity of the carrier signal; making redundant carrier phase measurements based on the reception of a carrier signal from an additional satellite (N+1); and eliminating false solutions from the initial set of potential solutions, based on a comparison of the redundant carrier phase measurements with the initial set of potential solutions, to reduce number of potential solutions to close to one, whereby the number of potential solutions is not increased by use of the redundant carrier phase measurements.
"Deriving from the carrier phase measurements an initial set of potential solutions" means that the initial set are derived from just two satellites. The rest of the Hatch specification explains why N is exactly two in the case of attitude determination. Planar intersections of wave fronts are formed from the two satellites, thus obtaining a collection of parallel lines. The intersection points of these lines and a baseline sphere are determined, producing the initial set of potential solutions. For example, as explained at column 12, line 35 of Hatch, there are 188 points or potential solutions in the initial set. In the Hatch method, "eliminating false solutions from the initial set of potential solutions," means eliminating 187 of those 188 points. The idea of potential solutions refers to the initial set of 188 points.
Hatch forms an initial collection of around 188 potential solutions using just two satellites, and then uses phase measurements of the remaining satellites to whittle away at that small initial collection, leaving only one candidate solution if phase measurements are accurate enough. Hatch avoids having to deal with large numbers of integer combinations.
Donald Knight, in U.S. Pat. No. 5,296,861, titled "METHOD AND APPARATUS FOR MAXIMUM LIKELIHOOD ESTIMATION DIRECT INTEGER SEARCH IN DIFFERENTIAL CARRIER PHASE ATTITUDE DETERMINATION SYSTEMS", and incorporated herein by reference, describes a method of reducing the mathematical intensity of integer ambiguity resolution.
Aside from making carrier phase measurements and determining a region of uncertainty, Hatch's method is essentially a two-step method, which is a way to avoid the problem of large numbers. The essence of the Knight patent is to do the opposite, plunging into a sea of possible solutions, even if there are trillions of them, and finding the single, best solution out of the entire product space of possibilities.
If ten different whole cycle values can be added to the first difference phase measurements from each of four satellites, then Knight defines 10 4 or 10,000 possible acceptable solutions. Knight then finds the one-and-only solution out of 10,000 that matches the measured phase data better than all 9,999 other combinations. If eight satellites are available (which does happen), then Knight finds the single best solution out of 10 8 or 100 million possibilities. If two antenna pairs are present, then the number becomes (10 8 ) 2 =10 16 . Thus whereas Hatch uses a two-step method of avoiding large numbers, Knight provides a practical method for finding the single best solution in a solution space with thousands or millions of possibilities. Hatch even suggests that the Knight approach is incorrect. For example, at column 8, Line 63, Hatch states: "if ten different whole cycle values can be added to the first differences from each of the four satellites, then one might expect 10 3 or 10,000 possible solutions within the uncertainty region . . . . Indeed, some authors have defined the number of possible acceptable solutions in exactly this fashion."
Knight describes a method that is more computationally intensive than Hatch's, and has proven to be reliable and workable in commercially-viable applications. Hatch's method avoids the problem of large numbers, and does best under conditions in which the problem of large numbers does not exist, e.g., under conditions where the myriad of possible solutions collapse into a handful. In the real world, conditions are usually not optimum, which would require the corresponding equipment that uses Hatch's method to be more complex, in order to achieve the same results as the present invention's.
Hatch's two-step method includes preliminary steps involving making carrier phase measurements, and then numbering them one through N, followed by an (N+1) th measurement. It could be expected that any similar apparatus will make carrier phase measurements, and the basic idea of interferometry is conventional, regardless of how the carrier phase measurements are numbered. Such preliminary steps define which carrier phase measurements are involved in generating an initial set of potential solutions, and which carrier phase measurement is defined to be the redundant measurement for eliminating potential solutions. As applied to attitude determination, the step of determining the approximate relative position of the secondary antenna equates to measuring the distance between the antennas, and noticing that the secondary antenna has to lie on a sphere centered at the main antenna.
Hatch's method involving a "plurality N of satellites" is not the same as a "plurality of satellites". As applied to attitude determination, N is exactly two. As applied to kinematic surveying, N is exactly four. Hatch makes this explicit in FIG. 7, blocks 58 and 62, and states at column 12, line 3, "The first computations to be performed in an attitude determination application are to compute the entire set of potential solutions based on the carrier phase measurements from two satellites. One of the significant features of the method described is the use of only two of the satellites to determine the set of potential solutions, rather than more than two satellites. Hatch explains that only a plurality of N=2 satellites are required" . . . in the attitude determination application, . . . there is! only a two dimensional uncertainty region corresponding to the surface . . . . Thus only two satellites are needed to define all the potential solutions that can exist on the two dimensional uncertainty region . . . . The attitude detection application is a two dimensional uncertainty problem, requiring two satellites to define all of the potential solutions . . . . The final broad step in the method of the invention is eliminating false potential solutions based on redundant information from additional satellites, i.e. additional to the minimum two . . . satellites required to define all of the potential solutions.
The phrases "initial set", "initial set of potential solutions" and "possible solution", refer specifically to the result obtainable by applying the first step of Hatch's two-step method. This "initial set of potential solutions" is to be generated from the received carrier signals of two and only two satellites, since the teaching is that "only two satellites are required to define all of the potential solutions."
The notion of "potential solutions" is thus restricted to 188 points, or to some such number in a similar example, but certainly not 10,000 solutions. It is also very clear that "eliminating false solutions from the initial set of potential solutions" means eliminating 187 points out of 188 points.
Hatch contends that it is not necessary to consider 10,000 possible solutions, because "the uncertainty region is two dimensional" and the measurements from any two satellites span the region of uncertainty. Using two satellites results in a collection of only 188 possibilities. Hatch contends that the correct solution is one of those 188 points, and that those 188 points are the only possibilities, that those other myriad of possibilities do not exist.
The "initial set of potential solutions" of Hatch cannot be extended to cover an entire product space of 10,000 solutions, because the essence of the two-step method is avoiding the problem of large numbers. Hatch proposes reducing the dimensionally of the solution space to the bare minimum and declares that the right answer has to lie within that reduced solution space, and that only the first measurements corresponding in number to the bare dimensionally are required to determine all the possible solutions.
Knight does not include an initial set. The method of Knight is to search for the right answer somewhere among 10,000 possibilities and finds the single best match out of such possibilities. There is no reason to stop and look at 188 possibilities when the remainder of 10,000 possibilities have to be searched. Furthermore, those 188 possibilities defined by Hatch do not resemble anything in Knight. Knight does not involve deriving from the carrier phase measurements an initial set of potential solutions for the relative position. Furthermore, Hatch generates those 188 points using a nonlinear operation on the carrier phase measurements of two satellites, something that Knight does not.
Hatch eliminates false solutions from the initial set of potential solutions, whereby the number of potential solutions is not increased by use of the redundant carrier phase measurements. Knight does not deal with Hatch's "initial set", whether to create it or eliminate from it. Most of the time, in a commercially-viable apparatus, the right solution will not be found in such an initial set.
If carrier phases could be measured perfectly, without radio reflections, reception noise, non-common antenna phase center motion, temperature sensitive drifts and other corruption of the measured phase data, then the attitude determination problem really would be two-dimensional. The right solution for position of the secondary antenna might then be found within Hatch's initial set of 188 potential solutions. Determining the right solution would be a simple matter of eliminating 187 false solutions by comparison with the third carrier phase measurement. As long as phase measurement errors are small enough, the two-step method based on near perfect measurements is satisfactory. Though there is some small perturbation in computed results, the right answer comes out in the end most of the time. Phase measurement errors of about two degrees RMS are usually tolerable.
Only one whole cycle value results in a surface that passes closer to a specific potential solution than any other whole cycle value. The problem is that phase measurements contain error, and geometric considerations amplify this error when measurements are processed in a computing apparatus. There is only one surface that passes closer to a specific potential solution than any other, but unfortunately, the surface that passes closest is often the wrong surface. Another surface farther away may be the right one. Not only can the surface be in the wrong place due to measurement error, Hatch's potential solution may be in the wrong place as well, due to error effects that are worse for the potential solution than the surface.
The supposed potential solution is actually a computational result that is often badly perturbed by phase measurement error combined with geometrical dilution of precision. A scissors effect can amplify measurement errors that distort the planes. Subsequently, the formation of intersections of lines with a sphere introduces a nonlinear operation on noisy data which greatly amplifies some of the errors. Hatch actually chooses the two satellites closest together in order to form an initial set with fewer than 188 points, whereas considerations of error sensitivity would dictate the opposite.
Hatch teaches that only one of the whole cycle values passes closer to a specific potential solution than any other. The two-step Hatch method prescribes that only the closest whole cycle value (from the additional satellite data) is selected for each of the potential solutions whereby the number of potential solutions is not increased. At some point, as phase measurement errors are increased, corresponding to less favorable operating conditions, the prescription begins picking the wrong whole cycle values a significant fraction of the time. Using Hatch's method, there is no way to pursue any option but the closest, and processing a phase measurement with the wrong whole cycle value added to it further accelerates the deterioration of computed results.
By comparison, all of the whole cycle values are tried as possibilities in the Knight method. An integer combination that looks very poor initially becomes more attractive as the solution progresses, eventually finishing as the best possible solution out of 10,000 or more. Every possible integer combination is pursued until, taken as a whole, it can be decided that the combination under development is less likely than another combination that has been completely finished and weighed with all satellite data included. The Knight method does not minimize the solution space dimensionally to the bare minimum and then restricts attention to an "initial set of solutions" obtained with only the data of the first measurements corresponding to that bare dimensionally. Most of the time, under real world conditions, the right answer simply is not to be found. The job of finding the right solution cannot be accomplished by avoiding the problem of large numbers.
Benjamin W. Remondi, reported the status of differential GPS (DGPS) accuracy and on-the-fly (OTF) kinematic GPS (KGPS) in a paper titled, "On-The-Fly Kinematic GPS Results Using Full-Wavelength Dual-Frequency Carrier Ranges".
On-the-fly real-time kinematic (OTF-RTK) positioning systems are useful in earth moving machinery control and guidance, robotic applications and the placement of structures, such as bridge sections. For example, in Japan, a particular construction project in Tokyo Bay requires the highly accurate placement of bridge pilings and sections in the bay from the decks of ships that are rolling and drifting with the sea. Highly accurate OTF-RTK control systems are also useful in guiding unattended bulldozers in the path of volcano lava flows to redirect the flow of lava in hot, hostile environments.
Philip M. Clegg describes an automated earth grading system in U.S. Pat. No. 4,807,131. A powered grading machine is combined with a laser level to control the blade of the grader. The control system described includes an elevation control, a location positioning device, a grader-blade tilt detector, a digital terrain model, a digital computer for terrain comparisons, a blade servo controller and a visual display unit. The automated moving of earth for a wide-range of engineering applications is described. The system computes the location and elevation of a grader-blade and then compares this with a corresponding design height/grade specified in a computerized digital terrain model. If the design height is lower than the current height of the blade, then a cut is required, and the blade is lowered automatically or manually by an operator.
Of particular interest is the use of satellite-based positioning systems, such as the global positioning system (GPS). Clegg mentions the use of celestial satellite positioning systems for the location of the grader. Many engineering applications require precise horizontal and vertical positioning. Centimeter-level GPS is typically achieved by using carrier phase and solving an integer lane ambiguity problem. Clegg does not teach the specifics of GPS nor how it might be used with his device.
The carrier phase ambiguity resolution problem has been the focus of a great deal of attention from research communities. In essence, the integer number of carrier cycles that existed between GPS receiver and satellite at the time that the signal was acquired must be determined. Direct range measurements, combined with the satellite geometry, allow the correct integer carrier phase ambiguities to be determined for a plurality of satellites tracked at two or more sites. Ambiguity resolution techniques that only use GPS measurements have become computationally efficient. The use of additional sensors such as a laser level, electronic distance meter, a compass, a tape, etc., provide valuable constraints that limit the number of possible integer ambiguities that need to be considered in a search for the correct set. For example see, INTEGRATED TERRESTRIAL SURVEY AND SATELLITE POSITIONING SYSTEM, filed Jul. 1, 1993, U.S. patent application Ser. No. 08/086,665.
SUMMARY OF THE PRESENT INVENTION
It is therefore an object of the present invention to provide a on-the-fly real-time kinematic system.
It is a further object of the present invention to provide a remote-controlled servo system with centimeter accuracy for industrial applications.
It is another object of the present invention to provide an apparatus that provides high frequency on-the-fly real-time kinematic updates.
Briefly, a system embodiment of the present invention comprises a fixed and a roving pair of four-observable GPS receivers and a communication link between them for double differencing code and carrier measurements. Carrier phase integer ambiguities are resolved efficiently by searching the simultaneous narrow-lane intersections of both the L1 and L2 wave fronts propagated by the GPS satellites being tracked. External constraint information, such as elevation, is additionally used to speed up integer ambiguity resolution. Data between the reference station and the rover is communicated in compressed form at a regular time interval, e.g., once a second at each epoch, and demi-measurements of carrier phase are obtained at a more frequent rate, e.g., ten times a second, and used to propagate solutions between epochs.
An advantage of the present invention is that a system is provided that does not require reference point initialization, but rather can initialize itself on-the-fly.
Another advantage of the present invention is that a system is provided that has centimeter level position accuracies.
A further advantage of the present invention is that a system is provided that outputs real-time kinematic position solutions in local coordinate formats.
These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the preferred embodiment which is illustrated in the drawing figures.
IN THE DRAWINGS
FIG. 1 is a schematic diagram of a GPS-based on-the-fly real-time kinematic system embodiment of the present invention;
FIG. 2 is a diagram representing the whole-cycle carrier phase wave fronts of signals propagated by three GPS satellites and their resulting interference pattern and intersections;
FIG. 3 is a block diagram of the reference station and rover of FIG. 1; and
FIG. 4 is a block diagram of a vehicle remote control system embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a on-the-fly (OTF) real-time kinematic (RTK) system embodiment of the present invention, referred to by the general reference numeral 10. System 10 comprises a reference station 12 and a rover 14. On-the-fly ambiguity resolution techniques are used to enable the acquisition of integer phase ambiguities while rover 14 is moving. Such OTF ambiguity resolution avoids the phase continuity requirement of prior art kinematic positioning systems.
A first through third satellite vehicle (SV1-SV3) 16-18 transmit pseudo random number (PRN) codes on two carrier frequencies L1 and L2 (1575.42 MHz and 1227.60 MHz) that are approximately nineteen and twenty-four centimeters in wavelength. Satellite vehicles 16-18 represent the satellite vehicles that may be accessible to reference station 12 and rover 14, e.g., the global positioning system (GPS) satellites operated by the United States Government.
Reference station 12 and rover 14 are three-observable or four-observable type GPS receivers. A three-observable GPS receiver can track L1 code, L1 carrier phase and L2 carrier phase. A four-observable GPS receiver can measure both carrier phase and code on both L1 and L2 frequencies. Reference station 12 communicates its observations to rover 14 via a data link 19. Four-observable measurements are preferred over three-observable receivers. Four-observable measurements provide a wealth of information that can be exploited during data reduction. The present invention is not limited to four-observable measurements, but also includes three-observable measurement. Dual-frequency phase combinations, such as "wide-lane" (eighty-six centimeter wavelength) and ionosphere-free observables are two such conventional phase combinations. A precision code (P-code) carried on the L2 carrier may periodically be encrypted to a secret "Y-code". When encryption is active, reference station 12 and rover 14 switch to a mode in which four observables are maintained by full-cycle L1 and L2 phase measurements, precise L1 coarse acquisition (C/A) code and cross-correlated Y-code data. The cross-correlation technique relies on the fact that both the L1 and L2 Y-codes are identical, although the Y-code itself is not necessarily known. The difference in group delay between the L1 and L2 signals is precisely determined by a cross-correlation technique. The cross-correlation observation is added to the L1 C/A-code observable to derive an L2 range measurement which is used in a variety of ways during data reduction.
Since dual-frequency GPS receivers are more complex and typically more expensive than single frequency receivers, and since three-observable or four-observable measurements are not strictly required in every instance, alternative embodiments of the present invention may substitute single frequency, e.g., L1 code and phase, measurement. Such single-frequency receivers may be used in reference station 12 and the rover 14.
In FIG. 1, each of a plurality of transmitted signals 20-25 comprise a combination of the L1 and L2 carriers. The transmission of signals 20 and 21 includes a satellite clock error that results in a ranging distance error 26. The transmission of signals 22 and 23 includes a satellite clock error that results in a ranging distance error 28. Similarly, the transmission of signals 24 and 25 includes a satellite clock error that results in a ranging distance error 30. Reference station 12 introduces a receiver clock error that results in a ranging distance error 32 common to satellite vehicles 16-18. Rover 14 also introduces a receiver clock error that results in a ranging distance error 34 that is common to satellite vehicles 16-18. Conventional double-differencing techniques are used in rover 14 to subtract out errors 26, 28, 30, 32 and 34 to yield PRN and phase measurements which have greatly reduced satellite-common and receiver-common errors.
Each signal 20-25 has an unknown number of whole-cycle carrier phase transitions between each satellite vehicle 16-28 and the reference station 12 and the rover 14. An interference pattern that results at various observation points amongst these signals 20-25 is used to identify the otherwise ambiguous signal intersections.
FIG. 2 illustrates, in simplified two-dimensional form, the carrier wave fronts generated by three satellites SV1-SV3. At carrier frequency L1, each wave front is separated from the next by nineteen centimeters. PRN code measurements are too coarse to sort out which wave front is which within any one given neighborhood of wave fronts. The wave fronts are thus ambiguous and represent the well-known carrier phase integer ambiguity problem. The wave fronts from two satellite vehicles, e.g., SV1 and SV2, intersect at a number of points, represented by points 50-58. Without more, each of points 50-58 is indistinguishable from the other. Using the wave fronts from a third satellite vehicle, e.g., SV3, only the intersections represented by points 50, 55 and 57 are coincident with all three wave fronts. A fourth satellite vehicle's wave fronts could be used to resolve between even these intersections to uniquely identify the best solution to the integer ambiguity problem.
System 10 uses both L1 and L2 wave fronts simultaneously to reduce the number of visible satellite vehicles necessary to solve the integer ambiguity problem and to yield high quality results where the best solution is widely separated from the second best solution. The search through the solution tree described by the Knight method is thus shortened and simplified, making OTF operation feasible. In FIG. 2, the grid of wave fronts shown would be supplemented by a second, superimposed grid with a different separation distance between adjacent wave fronts. For L1 and L2, one such grid has the wave fronts separated by approximately nineteen centimeters and the other grid has its wave fronts separated by twenty-four centimeters. This provides a larger number of wave front intersections, but reduces the number of intersection points that are coincident for all the visible satellite vehicles. The search for the unique solution is thus simplified because the number of potential candidates is reduced.
System 10 also provides integer ambiguity solutions based on externally provided constraints, e.g., altitude. For example, given that FIG. 2 is drawn in the vertical plane with respect to the earth, an altitude 60 when used as a constraint, can be used to select point 50 from the field of points 50, 55 and 57 as a unique solution to the integer ambiguity problem. Such constraints are useful in reducing the mathematics search problem and are effective when fewer satellite vehicles are visible.
Real-time kinematic positioning provides for the precise estimation of the location of a stationary or moving rover relative to a reference site. A reference site is established at a point whose location is known relative to the satellite coordinate datum. A reference satellite receiver collects carrier phase, code measurements and data to the satellites at a regular interval, e.g., once every second or epoch. Time-tagged measurements and additional information is transmitted to one or more roving units via a modem/radio or telephone etc. At a rover unit, the reference station data is merged with locally collected satellite measurements at the lowest common measurement update rate (e.g., every second). There is a finite delay in the position solution that is computed from the raw reference and rover stations. The solution delay is a function of the radio/modem bandwidth, any delays in the reference station measurement system and the rover station measurement and position update systems.
The solution latency has minimal impact for a static situation where the reference and rover are stationary. However, when the rover is attempting to navigate while moving, the solution latency causes the displayed position to lag the actual location of the user.
In addition to the solution latency, the measurement update rate used in a system governs how often the user position will be updated. For high precise/dynamic applications, a fast update rate of ten to fifty Hertz is desirable. The bandwidth of the datalink between the reference and rover sites places a limit on the measurement update rate of the system. Even with a data compression algorithm, a maximum update rate is reached.
FIG. 3 illustrates the construction of reference station 12 and rover 14. Reference station 12 inputs the signals 20, 22 and 24 (both L1 and L2) into a downconverter 70. A correlator 72 extracts information from an intermediate frequency signal produced by the downconverter 70 and feeds such carrier and code information out to a PRN code measurement unit 74 and a carrier phase measurement unit 76. The epoch, which occurs at one second intervals, is used to trigger the four-observable measurements related to signals represented by signals 20, 22 and 24, and to time tag such measurements in a time tag unit 78. Time-tagged data is then fed to a data compression unit 80 for radio transmission out by a transmitter 82. The compression of data and obtaining of measurements at each one second epoch keep the volume of data required to be carried by the data link 19 to rover 14 to a reasonable level. For example, a 2400 baud channel can be used to carry the information obtained by the reference station 12.
The rover 14 receives signals represented by signals 21, 23 and 25 and produces an intermediate frequency composite from them in a downconverter 90. A correlator 92 extracts information from the intermediate frequency that is supplied to a PRN code measurement unit 94 and a carrier phase measurement 96. Four observables for each signal 21, 23 and 25 are provided to a double differencing unit 98 at the one second epoch rate. A radio receiver (or datalink subsystem) 100 receives the data from the reference station 12 over data link 19 and a data decompression unit 102 extracts the original time-tagged data. Double differencing unit 98 combines the measurements taken at both the reference station 12 and the rover 14 to eliminate clock errors 26, 28, 30 32 and 34 (FIG. 1). Unbiased measurements are then made available to a propagation unit 104 at a demi-measurement rate of ten per second.
Once a pair of main measurement epochs has been obtained, as identified by their respective time tags, a demi-measurement propagation process can begin. All of the demi-epochs in the rover 14 are used to propagate forward a last main measurement update obtained at an epoch. Demi-measurement updates are more frequent than the main measurement updates and therefore can catch up quickly with the current epoch time. In this way, the demi-measurement propagation reduces solution latency and also gives the user a more continuous location estimate.
Demi-measurement propagation introduces some small errors into the user position. GPS has an intentional dither on the civilian signals. Dithering is typically on the order of one centimeter per second squared. As long as the main epoch updates are obtained every second, and the main epoch solution latency is less than one second, the demi-measurement propagation errors should be less than 0.5×1.0 cm/s 2 , times the current dilution of precision (DOP). Under normal conditions, errors of two centimeters or less would be experienced.
FIG. 3 further illustrates an integer resolution unit 106 that uses the four observables of L1 and L2 code and phase from the visible satellite vehicles 16-18 to quickly determine a unique solution to the integer ambiguity problem. A height restraint unit 107 connected to the interger resolution unit 106 reduces the search space of ambiguous carrier phase intergers by introducing at least one of an elevation, separation, distance and orientation constraint. A navigation computer 108 is used to solve the position of rover 14 to within a few centimeters on-the-fly ten times a second. A datum transformer 110 is used to convert from other formats, such as WGS-84, to a local coordinate format, e.g., northern-east-elevation (NEE) format so that the precise measurements obtained will conform to the datums used in local topographic maps, for example. An ellipsoid-to-geoid converter 112 corrects for variations in the geoid-spheroid separation that might exist in the geographical area of use.
FIG. 4 illustrates a remote vehicle control system 120 which comprises a remote controlled vehicle 122, a remote control unit 124 and a reference station 126. A radio link 128 provides GPS signal measurement data to a rover 130. Reference station 126, radio link 128 and rover 130 are similar in construction and function to reference station 12, data link 19 and rover 14 illustrated in FIGS. 1 and 3. OTF-RTK local coordinate data is communicated near continuously over a radio link 132 to a controller 134. A mathematical model 136 provides guidance plan information for vehicle 122. For example, such information may be the flight path for a plane when vehicle 122 is an airplane, or the information may be the model extracted from a topographic survey of a coal seam in the earth when the vehicle 122 is an open-pit coal excavator. The controller 134 compares the math model information to the position information and issues a servo control signal 138 to a servo unit 140. Such control may be automatic, and include proportional plus integral plus differential (PID) control. A camera 142 provides a video representation of the area surrounding vehicle 122 over a radio link 144 to a monitor (CRT) 146.
The remote vehicle control system 120 may be incorporated into an earth moving and grading system, e.g., as described by Clegg, in U.S. Pat. No. 4,807,131, and incorporated herein by reference. Essentially, the laser equipment disclosed by Clegg is replaced by the elements of system 10, illustrated in FIG. 1 of the present specification. Such a-configuration allows robotic control at the rover unit which can adjust a mechanism according to a comparison between GPS position determinations and a predetermined construction model. Such construction models include placements for bridge pilings, coal seam excavation in open-pit mines, and unmanned vehicles.
Although the present invention has been described in terms of the presently preferred embodiment, it is to be understood that the disclosure is not to be interpreted as limiting. Various alterations and modifications will no doubt become apparent to those skilled in the art after having read the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alterations and modifications as fall within the true spirit and scope of the invention.
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A system embodiment of the present invention comprises a fixed and a roving pair of four-observable GPS receivers and a communication link between them for double differencing code and carrier measurements. Carrier phase integer ambiguities are resolved efficiently by searching the simultaneous narrow-lane intersections of both the L1 and L2 wave fronts propagated by the GPS satellites being tracked. External constraint information, such as elevation, is additionally used to speed up integer ambiguity resolution. Data between the reference station and the rover is communicated in compressed form at a regular interval, e.g., once a second at each epoch, and demi-measurements of carrier phase are obtained more frequently, e.g., ten times a second, and used to propagate solutions between epochs.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of International application PCT/GB01/02919, entitled “Keyless Access Sensor System” filed Jun. 29, 2001 and published as International Publication No. WO 02/02893 A1, the entire content of which is expressly incorporated herein by reference thereto.
BACKGROUND
The present invention relates to a keyless access sensor system and its associated sensor device for keyless access particularly, but not exclusively, for use in allowing access by an authorized user to a vehicle, building or the like. The invention also relates to a method of using a keyless access sensor system to control entry of authorized persons and to a circuit for processing signals in a keyless access sensor system.
It is important, for many reasons, to control access to premises, vehicles and personal property so that only authorized users are allowed access. Typically this is done using keys which fit a lock to allow the user of the key to open the lock and gain entry. One problem with the existing key and lock arrangements is that loss or damage to the key can render access impossible. In addition, if the key lock itself is blocked or damaged this can also prevent access. One other problem is that the use of a key requires a specific action such as unlocking a door latch with the key from the authorized person before an action of opening the door associated with the door latch. This specific action is very often not easy to accomplish, is not ergonomic and is time-consuming.
A number of solutions have been proposed to try to overcome these disadvantages. With security devices for cars, it is well known that a keyless fob can be used, such that actuation of a button on the fob generates an infrared (IR) or radio frequency (RF) signal which is detected by a sensor in the vehicle which unlocks the doors. A key is still required by the user in order to operate the ignition system. The fob also contains a lock button which generates a similar IR or RF signal to lock the vehicle. Such vehicle keyless access systems have been known for a number of years. Such systems operate on the basis that when the IR or RF “open” signal is generated by the fob, the signal is used to actuate a mechanism which unlocks the car door so that when the user pulls on the handle, the door is already unlocked. Similar arrangements may be used for building entry.
One problem with this arrangement is that the user still has to initiate a specific action such as, in the case of a fob, taking the fob in his hand and pressing on the fob button, or in the case of a magnetic card or the like, inserting the card in a slot or to present it in front of a card reader/detector or the like, in order to unlock the door and have access to the vehicle, these specific actions being time-consuming and not ergonomic.
One other problem with this arrangement is that if the user decides not to enter the vehicle but forgets to actuate the “lock” signal, the car and/or building remains open and is thus vulnerable. In addition, with existing keyless locking systems, particularly for vehicles, a conventional locking mechanism is used which is susceptible to interference by thieves to gain access to the car. For buildings, conventional locks are actuated in the same way and are susceptible to the same procedures by intruders to gain access to the premises.
It is desirable to provide a system which obviates or mitigates at least one of the above mentioned problems, and this is now provided by the present invention.
SUMMARY OF THE INVENTION
The desired features are achieved by providing a keyless access sensor system for use with a keyless access control mechanism (KACM) for controlling the operation of a locking device without any specific action from the user. The KACM receives a signal from a sensor device for keyless access to create a first output signal before the user has begun any action on the handle in order to open the door. The first output signal is sent to a general processor, which initiates a recognition process and, after recognition of the authorized user the general processor then generates an unlocking signal which unlocks the locking device before the authorized user will have fully accomplished the action of opening the door. Thus the authorized user is allowed to open the door without any specific un-ergonomic and time-consuming additional action to the simple action of actuating the handle to open the door. A signal is generated by a device, such as a fob, card or the like, carrying a unique digital or analog identification in response to RF or IR interrogation from the general processor after it receives the output signal from the sensor device for keyless access. In response to the unlocking signal, the locking device is opened for a predetermined time allowing a user entry to a car or building premises or the like.
The sensor device for keyless access generates a primary beam of electromagnetic radiation, particularly in the optical wavelength range and, more particularly, it is a pulsed beam, this beam being located near a door handle. In the case of a vehicle, the beam is located between the door panel and the inside of the handle. Alternatively, the beam is located between the two extremities of the handle and parallel to the door panel in order to detect and anticipate any action of opening the door made by the user. When a user inserts his hand to fully or partially interrupt or reflect the beam after the system is primed, the system detects this modification of the beam characteristics and generates the output signal which is used in anticipation with the user ID to create a control signal to unlock or open the door before any action on the door handle. The sensor device for keyless access may include a backup switch which will provide a signal to the general processor in case the modification of the primary beam characteristics due to the presence of the hand is not detected by the sensor system for whatever reason. This backup switch will be activated by the mechanical action of the user on the door handle in order to open the door. The signal issued from the backup switch will then initiate the user ID sequence and will then allow the unlocking of the door with a delay due to the lack of anticipation in the detection of the action of opening the door by the user. The backup switch may be a mechanical switch or an optical switch or the like. The sensor device for keyless access device may also include a locking switch, which purpose is to cause locking of the door when this locking switch is actuated by the user when he exits the door. In the case of a vehicle the locking switch is locatable on the handle for easy actuation by the user.
In the preferred arrangement, an incident beam is an infrared beam generated by a light emitting device (LED) and is detected by an optical sensing element. After the user inserts his hand to fully or partially interrupt or reflect the beam, a signal processing circuit detects when the interruption or modification of the beam of optical pulses lasts longer than a predetermined time and then generates the output signal to the general processor.
In the preferred arrangement, the sensor device for keyless access is a low power consumption sensor based on smart monitoring of the internal electrical function of the sensor in order to reduce to minimize the overall sensor electrical consumption.
In the preferred arrangement, the sensor device for keyless access is ambient light protected by measuring the level of the ambient light before producing any pulse of the optical beam, in a way which protects the sensor against any external parasitic optical light.
Conveniently, the access multi-sensor device includes an optical adaptive feedback arrangement which prevents the sensor from false detection which may be caused by slow variation of the optical beam characteristics due to, for example, the accumulation of dust or deterioration on the sensor external surface, the variation of electro-optical characteristic of the light emitting device or the variation of the optical sensing element during the sensor's lifetime.
With this arrangement a traditional key lock is not required and, consequently, it is not vulnerable to illegal entry in the same way as traditional locks. When the system is applied to vehicles, the user has no specific manual action to perform to unlock the vehicle, thus improving the ergonomics and access time to the vehicle. The main requirement is a handle or the like, a beam and an access control mechanism which generates a beam of electromagnetic radiation between the handle and the door or between the two extremities of the handle parallel to the door panel so that the beam can be fully or partially interrupted or reflected by a user, for example, when the user inserts his hand between the handle and the door. Such a beam may be modified by other means, such as a card or the like swiped through a slot to generate a-control signal for controlling a locking mechanism.
A particular advantage of this arrangement for use with vehicles is the low power consumption of the sensor circuit, especially in the standby mode. This low power consumption is obtained by having an ultra low consumption sensor device for keyless access and by having the general processor in a standby mode when the car is parked. When the vehicle is parked, the device is ‘woken up’ by a user interrupting or modifying the beam characteristics and only then does the general processor wake up from its standby mode and cause a RF or IR beam to be generated to verify the user ID. Thus, the RF beam is only generated in response to an access request thereby minimizing power consumption.
Another particular advantage of this arrangement for the use by vehicles is that it will still be fully functional even in harsh environments due to bright artificial lights in towns by night, or high temperature or presence of dust on the car, or the like. This functionality is provided by the optical adaptive feedback system and the ambient light protection function of the sensor device.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
These and other aspects of the present invention will become apparent from the following description, when taken in combination with the accompanying drawings, in which:
FIG. 1 is an exploded view of a car door handle assembly incorporating a sensor system in accordance with a first embodiment of the present invention;
FIG. 2 depicts an assembled and partly cut-away view of the car door handle assembly of FIG. 1 incorporating the sensor system in accordance with the first embodiment of the present invention;
FIG. 3 is a perspective view of an assembled sensor unit as shown in the drawings of FIGS. 1 and 2 ;
FIG. 4 depicts an exploded view of the sensor unit shown in FIG. 3 ;
FIG. 5 is a general block diagram of the sensor device used in FIGS. 1 to 4 ;
FIG. 6 is a circuit diagram of the sensor device used in FIGS. 1 to 4 ;
FIGS. 7 a to 7 j depict timing diagrams of signals used to control the operation of the circuit of FIG. 6 and waveform diagrams depicting signals at various parts of the circuit of FIG. 6 ;
FIG. 8 depicts a handle assembly similar to that shown in FIG. 2 but using a sensor device in accordance with an alternative embodiment of the present invention, and
FIGS. 9 a , 9 b and 10 show further embodiments of sensor devices in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to one aspect of the present invention, there is provided a sensor system for use with a keyless access control system, the sensor system comprising:
an electromagnetic radiation generating element for generating an incident beam of electromagnetic radiation in the form of a pulse train;
an electromagnetic sensing element for sensing the incident beam, and
a signal processor coupled to the sensing element for detecting an interruption to, or modification of, the incident beam, the signal processor including a timer for detecting when the duration of the interruption or modification of the incident beam is greater than a predetermined by detecting the presence of absence of a predetermined number of pulses varying from a predetermined level, the signal processor for providing an output signal to an access control mechanism when the presence of absence of a predetermined number of pulses are counted.
Preferably, the system includes a backup switch for sensing a mechanical opening action of the access control mechanism.
Preferably, the absence of a predetermined number of pulses less than a preset level results in the output signal being generated.
Alternatively, the presence of a predetermined number of pulses greater than a preset level results in the output signal being generated.
Preferably, the sensing element is disposed adjacent to the electromagnetic radiation generating element for detecting a partial or total interruption or modification of the incident beam.
Preferably also, the system includes an optional locking switch for manually locking the access control mechanism.
Conveniently, the optional backup switch is an optical switch and the optional locking switch is an optical switch.
Preferably, the electromagnetic radiation generating element generates an incident beam of optical radiation. Conveniently, the incident beam is an infrared beam. Conveniently, the wavelength is between 780 and 950 nanometers.
According to a further aspect of the present invention, there is provided a method of providing keyless access to a locked device or structure, the method comprising the steps of:
generating an incident beam of electromagnetic radiation, the incident beam being a pulse train,
sensing the incident beam of electromagnetic radiation,
sensing an partial or total interruption or modification to the incident beam lasting longer than a predetermined timed by detecting the presence or absence of a predetermined number of pulses varying from a predetermined level, and
generating an output control signal when the predetermined number of pulses are counted as the result of the partial or total interruption or modification, and processing the generated control signal to produce an actuation signal for opening the access mechanism.
Preferably, the method includes the step of generating a backup interruption signal as a result of a mechanical action on the handle of the access mechanism, and processing the generated interruption signal to produce an output control signal for unlocking or opening the access mechanism.
Preferably, the method includes the step of generating a locking signal as a result of an action on the locking switch.
According to a further aspect of the present invention, there is provided a circuit for use in an electromagnetic radiation sensing system, the circuit comprising:
a circuit power supply regulator;
an output stage with an optical source for emitting pulses of electromagnetic radiation of a predetermined duration;
a sensing and amplification stage for detecting pulses emitted by the optical source;
a timing circuit coupled to the power supply regulator for generating timing signals and an internal power supply, the timing signals and the internal timing power supply being fed to the amplification stage and to the output stage for synchronizing the emission and detecting of light pulses varying from a predetermined level, and a pulse counter for counting the pulses, the pulse counter generating an output signal in response to a predetermined number of pulses being counted.
Preferably also, the timing signals are also used to detect and remove ambient light noise.
Preferably, the circuitry is partially or totally realized in a monolithic ASIC (Application Specific Integrated Circuit).
Preferably, the ASIC includes the optical sensing element.
According to a further aspect of the invention there is provided a sensor device for use with a keyless access control mechanism, the sensor device comprising:
a post for incorporation into one end of a door handle;
an electromagnetic radiation emitter and receiver located in the post for generating an incident beam of electromagnetic radiation substantially parallel to the handle, and for receiving a reflected beam of electromagnetic radiation;
a signal processing circuit coupled to the emitter and receiver for detecting a partial or total interruption or modification of the incident beam, the signal processing unit generating an output signal when the interruption or modification to the beam is detected for transmitting to an access control mechanism.
Reference is first made to FIG. 1 of the drawings which depicts a car door handle assembly, generally indicated by reference numeral 10 . The assembly consists of a door bracket assembly 12 , a door handle 14 and an access sensor device 16 . The door bracket assembly and the sensor device 16 are disposed beneath the door skin 18 . In this embodiment the door skin 18 defines an aperture 20 which receives a lens protector assembly 22 through which an infrared (IR) beam generated by the sensor device 16 passes to be reflected by a mirror 23 back to the sensor device 16 , as will be later described in detail.
Reference is now made to FIG. 2 of the drawings which depicts a cross-section of the door handle assembly 10 shown in FIG. 1 . In this diagram it will be seen that the sensor device 16 has a light emitting diode (LED) 24 which emits incident IR beam 26 which is reflected by the mirror 23 disposed in the inside 28 of the door handle 14 and the reflected beam 30 is detected by a photo-transistor 32 . As will be described, the IR beam is provided by a 1 KHz pulse frequency, to minimize power consumption. As long as the pulses are emitted and are detected by the circuit, a signal is provided from the circuit output which maintains the door in a locked position. As will also be described, if the IR beam is partially or totally interrupted or modified the beam level detected is compared with preceding pulse levels and if a reduced signal level is detected for a predetermined number of pulses, taking about 3 milliseconds, in this embodiment three pulses, the sensor interprets this as an authorized user wishing to open the door and provides an output signal which is fed to a general processor of a control module which generates a RF signal for interrogating a user's digital ID on a card. When a satisfactory response is obtained, i.e. the user's ID matches e stored digital data and a control signal is generated by the processor to unlock the locking mechanism and allows the door to be opened.
Reference is now made to FIGS. 3 and 4 of the drawings, which depict the sensor device 16 . The device 16 consists of four principal parts, as best seen in FIG. 4 : an optical enclosure 34 ; an electromagnetic shield 36 ; a printed circuit board assembly 38 , and an optical enclosure cover 40 . The optical enclosure cover 40 has a connector interface 42 which interfaces with the vehicle control conductors. The printed circuit board assembly contains a microswitch 44 which can be operated via a flexible membrane 46 disposed in the optical enclosure cover for detecting the beginning of handle motion, i.e. within a 3 mm movement. The microswitch 44 is a backup to the optical detection system to allow a user to unlock or open the door if the optical sensor fails, the signal from the backup switch replaces the signal from the sensor and is dealt with by the general processor in the same way to allow unlocking of the door. A dual lens 48 is disposed in the recess 50 in the optical enclosure for covering the LED and photo-transistor as shown in FIG. 2 .
FIG. 5 shows a block diagram of the circuit used in the sensor device 16 . A control module 52 interfaces with the circuit and is coupled to current power supply 54 which supplies power to the main circuit components; pulse generator circuitry 56 ; signal processing circuit 58 for processing the output from the photo-transistor 32 , and output circuit 60 for providing an output to the control module 52 , and the microswitch 44 .
The pulse generator 56 generates pulses at a rate of 1 KHz and the frequency signal is fed to the LED 24 and to the signal processing circuitry 58 to synchronize detection of signals by the photo-transistor 32 . As long as both sets of pulses are received, a counter in the processing circuitry 58 is continually reset to zero and the output circuitry 60 does not generate an output signal. When the light beam is interrupted such that a predetermined number of light pulses, in this case three, are not received by the photo-transistor, the signal processing circuitry 58 detects this and actuates the output circuitry 60 to generate an output signal to the control module 52 . The control module 52 , in turn, causes a RF signal to be generated and when a suitable response is received confirming the ID of a user, the control module 52 sends a signal to unlock the door. This response time is about 3.0 to 3.5 milliseconds (MS) and by the time the user pulls the door handle 14 , the door is already unlocked.
Reference is now made to FIGS. 6 and 7 of the drawings. FIG. 6 is a circuit diagram of the circuitry used to generate the pulsed IR signal, for detecting the signals reflected from the mirror 23 and also for detecting when the reflected signal is interrupted. FIGS. 7 a to 7 j depict the various signals associated with the circuit of FIG. 5 .
The circuit of FIG. 6 is designed to minimize power consumption and, consequently, in power supply 54 the supply current is limited by a 27 kΩ resistance R 29 in series with the supply which is normally between 9V and 16V. If the operating voltage is +5V, the supply current is equal to the quotient of the supply voltage tess 5V divided by the value of resistance R 29 . For example, for a 9V power supply, the supply current will be 150 A, and for a 24V power supply, the current will be 700 A. This is so that 4.7 μF capacitor C 9 can be charged sufficiently rapidly to enable the LED 24 to be driven at currents up to 100 mA in pulse mode as will be described.
The available supply voltage to transistor Q 9 is set by avalanche diode D 1 . Just after a measurement is taken, C 9 has been partially discharged and the voltage across C 9 is too low to maintain the operating voltage of 5V (several dozens of mV below the set voltage) and the constant supply current recharges capacitor C 9 , the voltage of which rises until the set voltage level. At this time, the transistor Q 9 conducts sufficiently to trigger the flip-flop formed by the two NOR gates 70 , 72 in IC 3 A, IC 3 B and the next measurement is initiated by synchronization signal S 1 falling to zero volts as shown in FIG. 7 a . Capacitor C 7 filters high frequency variations in the power supply which may otherwise produce inadvertent signals.
Voltage level setting is principally achieved by avalanche diode D 1 which behaves like a Zener diode and is designed to operate with a weak current. The operating current is set by resistance R 30 and is about 20 A. This current value is a function of the variation in the base emitter voltage of Q 9 and temperature and the value decreases slightly at high temperatures and rises slightly at lower temperatures, varying about 1 A per 15° C. At this operating current the avalanche diode is stable at a voltage of about 4.4 V. The operating voltage (+5 V) is equal to the avalanche diode voltage (4.4 V) increased by V be (−0.6 V) of resistor Q 9 .
The system is protected against excessive voltage by a shunt regulator formed by avalanche diode D 1 and the base-emitter junction of transistor Q 9 . The system is limited to supplying voltage less than 6.5 V even for an input voltage greater than 100 V. The shunt regulator allows a supply current as high as 3.5 mA resulting from 100 V continuous input supply. However, resistance R 29 is limited to the power dissipation of 0.1 W which corresponds to a permanent over-voltage of 57 V.
For polarity inversion, resistance R 29 limits the current without damaging the diodes in the substrates of the CMOS and HCMOS.
The operation of the circuit will be explained by describing how parts of the circuit are set up to generate various voltages and timing signals and then the generation and detection of pulses will be described.
A measurement is initiated by transistor Q 9 . The collector voltage is always around half of the supply voltage. This voltage rises when the available energy in C 9 is sufficient to perform a measurement. When the voltage reaches the threshold level of NOR gate 72 , the output changes state and the flip-flop formed by NOR gates 70 , 72 memorizes the sequence of measurements from the start (S 1 — FIG. 7 a ). When the measurement is complete, the output of Q 9 resets the flip-flop. The R 28 , C 11 combination at the input of gate 70 and gate 74 is to provide a reset in case the system starts in a “hang-up” consumption mode with no oscillator providing a clock signal.
Due to the R 29 , C 9 time constant, the establishment of the 5V level is relatively slow. The flip-flop formed by NOR gates 70 , 72 in IC 3 a and IC 3 b begins operating at a low voltage of 1 V to 1.5 V, before many other components on the circuit. The flip-flop can begin working with the S 1 output high or low, if the flip-flop begins working with S 1 low, i.e. 0 V, it means that the electronic circuit is powered at 1 V to 1.5 V before the 5 V level is reached. This results in a relatively high current consumption of several mA. Because the resistor R 29 limits the input current to less than 0.3 mA, the internal voltage cannot reach 5 V and the IC 3 a /IC 3 b flip-flop cannot be reset and the circuit stays in a non-working high current consumption mode. This situation is prevented by the R 29 , C 11 combination which effectively acts as a “CPU watchdog” by resetting the IC 3 a and IC 3 b flip-flop after 500 s if the flip-flop remains in the state with the S 1 output in a 0 V state. This stops the power supply to the electronics and removes the electronics from the non-working high current consumption mode. The internal power supply can therefore reach +5 V required to power the circuit under normal operating conditions. Under normal operating conditions the S 1 output remains low for 45 s and the 500 s reset period does not disturb the normal functionality of the electronics.
The synchronization signal Si is taken from the output of gate 72 . The output of gate 70 (IC 3 a ) is fed to a sample and hold circuit 73 (IC 2 D) where it will be seen that the output at pin C, as shown in FIG. 7 b , is the inverse of the synchronization signal S 1 . The output of sample and hold 72 is fed to pin 89 of circuit 90 to supply power to the analog circuits only during the 40 s period of the +5 V pulse. This means that all of the signal processing as shown in FIGS. 7 c – 7 j takes place within this 40 s period, thereby minimizing electrical power consumption.
NOR gates 74 , 76 form an oscillator (see signal CLK in FIG. 7 c ) with an oscillator period of 5 s set by the combination R 33 , C 8 . The capacitor C 8 has a thermally stable dielectric to avoid frequency variations during operation. The oscillator supplies the clock signal to the IC 1 counter which provides:
(a) at pin D 3 , a pulse sampling the level of ambient light; (b) at pin D 4 , a pulse indicating illumination of the LED as well as a pulse sampling the level of the signal (ambient and LED signals); (c) at pin D 7 and pin D 8 , pulses for signals amplified by the operational amplifier 1 C 4 ; (d) at pin D 9 , the pulse is deleted from the memory (counter IC 5 ) after the start of measurement.
These logic signals are depicted as signals a, b, d and e with respective pulse widths t a , t b , t d and t e as shown in FIG. 7 c of the drawings.
The LED emitting stage, generally indicated by reference numeral 80 , will now be described.
A pulse of light is emitted by LED 24 which is connected between the supply and the collector of transistor Q 5 . The current through the LED is measured by the drop in voltage across resistances R 22 , R 23 in parallel, and is shown as signal S 3 in FIG. 7 e . This controls the power emitted by Q 4 in the following manner. When the clock pulse rises at the output “D 4 ” of counter IC 1 at time t b , the current at the base of the transistor Q 5 rises to about 4 mA across resistor R 20 . The transistor Q 5 causes the LED shown in waveform S 3 to saturate until the current across the LED is sufficient to cause transistor Q 4 to conduct, as it receives part of the current supply from Q 5 . The combination Q 4 , Q 5 creates a feedback mechanism and the combination self-stabilizes for a LED current between 0–100 mA, the value depending on the control signal as shown in waveform S 6 in FIG. 7 i being supplied to transistor Q 4 . The 470 pF capacitor C 4 delays the conduction of transistor Q 5 until the switching of the general clock to avoid a current peak being produced before transistor Q 4 is enabled. The R 24 ,C 5 supply combination prevents the LED current causing a glitch in the supply voltage which could affect the operation of the photo-detector stage. The LED supply stage only operates at “high current”; the current at the base of resistor Q 5 is about 4 mA and the current at the base of resistor Q 4 , which is the current which controls supply of power to the LED, rises to 0.1 mA when the system is used in full visibility. Full visibility is the maximum level of ambient light. This is why the control current is provided only during the time the LED is illuminated.
The photo-detection and pre-amplification stage, generally indicated by reference numeral 82 , is provided by the photo-transistor 32 shown coupled to the emitter of transistor Q 2 which reduces the effect of high frequency signals on the capacitance of the base emitter of Q 1 . The collector voltage of Q 2 is also coupled to the collector of photo-transistor Q 1 to provide a low impedance at the stage output which is shown by pre-amplified optical signal S 2 shown in FIG. 7 d . Resistors R 2 and R 3 form a voltage divider for transistor Q 1 and the voltage is supplied across 100 kΩ resistor R 4 to the photo-transistor Q 1 . This sets the sensitivity of the pre-amplifier to −300 mV per photo-current microamp on the base of the photo-transistor Q 1 . The pre-amplifier stage 82 thereby provides a negative voltage pulse when it receives a pulse of light. This stage consumes 600 A and has a rise time about 2 s. It is supplied throughout the cycle of the general clock which is about 40 s ( FIG. 7 c ) for a frequency of 1 KHz.
The operating point of the stage 82 with no photo-current is around three times V be of Q 1 , i.e. 1.8 V at output, thereby fixing the collector current of Q 1 and Q 2 at around 100 A. The divider bridge R5R6 fixes the base potential of Q 2 at 1 V. No decoupling is present to give the pre-amplifier a very short availability time. The output signal is available after 5 to 10 s from S 2 .
The output of the pre-amplification stage is fed to sample and hold circuits 86 , 88 via resistance R 7 and prevents the first stage being subjected to capacitance which can cause instability. First sample and hold circuit 86 operates during the clock cycle t a in order to sample the level of ambient light before illumination of the LED. The second sample and hold circuit 88 operates during illumination of the LED during time t b in order to sample the signal level. The latter sampled signal, being lower than the ambient signal, is fed to the inverting input of the differential amplifier, generally indicated by reference numeral 90 , formed by three amplifiers of 1 C 4 (IC 4 A, IC 4 B, IC 4 D). IC 4 contains four operational amplifiers, generally indicated by reference numeral 92 , 94 , 96 , 98 . The differential amplifier has a gain of 10 . The operational amplifiers 92 , 94 , 96 , 98 selected are classic type LM324 for low cost, low power consumption (about 600 A) and a low operating voltage of about 4 V. Its gain and slew rate are sufficient to provide stable output after 30 s. Like the photo-detection stage, the operational amplifier is only supplied for 40 s each time a measurement is taken. The amplifier output signal is shown as signal S 4 in FIG. 7 f of the drawings.
The output signal from the differential amplifier, signal S 4 , is routed through blocking diode D 2 . The output voltage is retained by capacitance C 3 and is the voltage used to control the emission of the light pulse from LED 24 . The voltage retained by C 3 can be set by adjusting the time constant set by the combination R 18 , C 3 and by the percentage of time signal S 4 is present. The discharging time constant is defined by the combination R 19 , C 3 and by the duty cycle (t b ) of closure of switch IC 2 C. Time constants can be calculated for operating at a thousand measurements per second as follows: rising time constant: R 18 =2.7 K, C 3 =4.7 pF and the signal S 4 about 20 s, giving a result of about 0.88 seconds. The discharging time constant, R 19 =1K, C 3 =4.7 pF and the switch opening time is about 5 s which gives a result of about 0.94 seconds. Signal S 6 in FIG. 7 i depicts the voltage for controlling the LED supply.
The fourth amplifier of IC 4 96 compares the voltage corresponding to the level of ambient light with a fixed threshold of 500 mV. When the pre-amplifier is illuminated by a large light signal (for example, bright sunlight), the signal is below the 500 mV threshold and the output voltage of the operational amplifier 96 rises to saturation as shown in signal S 5 in FIG. 7 h.
In use, saturation is detected by the illumination of the photo-transistor, i.e. when the LED illuminates and, the signal S 5 rises to 3.8 V which is the saturation voltage of amplifier IC 4 C. The current through R 34 saturates transistor Q 6 from the time t b until the time t e . Likewise, when the pulse from the LED 24 is correctly received, the output of differential amplifier 90 rises to around 1.4 V and the current through resistor R 14 switches on transistor Q 6 . From the time t b until the time t e the collector of Q 6 is pulled towards the supply potential by R 15 and R 16 during time t d and t e . If one of the two conditions above (or if both simultaneously) are present, the transistor Q 6 will become saturated and the potential of the collector will not rise, thus transistor Q 7 will remain off. Q 7 is the transistor which blocks or allows the pulses to reset the counter 1 C 5 100 . On the other hand, if the photo-transistor 32 does not receive pulses of light, or is not saturated by ambient light, transistor Q 6 remains off and Q 7 will be saturated during time t e .
In addition, the counter IC 5 100 processes the output signals from amplifier 90 in accordance with the timing signals. If transistor Q 7 remains off, the counter IC 5 will be reset to zero at the end of each measurement during time t e (signal S 7 in FIG. 7 j ). If transistor Q 7 switches on, as indicated above, each pulse for resetting the counter to zero will not be delivered but the counter receives a clock pulse for each measurement during time t d , therefore, the counter counts as long as the signal is interrupted and the counter is reset to zero when the interruption ceases. If three successive pulses due to an interruption are counted, the counter switches off its active output until the removal of the optical barrier. The number of successive pulses measured during interruption of the signal by the system can be set between 1 and 9, although 3 has been found to be particularly convenient since at a frequency of 1 KHz this means an output is provided in 3 mS.
After detecting three successive pulses due to interruption of the LED signal, the output of the counter is fed to a MOS transistor 60 via the RC combination formed by R 25 and C 6 to provide a pulse of around 100 mseconds. Output as provided by the drain of Q 8 through current limiting resistor R 26 . Protection against high voltage and polarity inversion is provided by Zener diode D 4 .
The aforementioned circuit has the principal advantage of being low cost, uses standard components and has very low current and power consumption with an average current consumption of about 0.2 mA because self-biasing circuitry is used. Regulation of the circuit supply is used to achieve a response time which allows high frequency illumination of the LED and high frequency operation of the amplifier. The supply voltage can vary between typically 9 and 16 V and the LED needs to be energized with pulses of 5 s duration to provide satisfactory functioning.
In this way it will be seen that the circuitry provided minimizes power consumption because power is only supplied to the circuitry for the duration of the period of the pulses of the synchronization signal which is particularly advantageous in a vehicle or any other application where minimizing electrical power consumption is important. The use of pulses to control illumination of the LED and the detection of an absence of those pulses for a predetermined number of cycles is advantageous.
It will be appreciated that various modifications may be made to the apparatus described above without departing from the scope of the invention. An alternative embodiment of sensor device is shown in FIG. 8 of the drawings which is preferred for use with vehicles. In this case the light source 110 and detector 114 are located in a post 115 disposed at one end of the handle 14 . In this case a reflector 123 (shown in broken outline) is located at the opposite end of the handle 14 . Thus, it will be seen that the incident beam 126 and reflected beam 127 are parallel to the handle 14 and to the door skin 118 . This embodiment has the advantage that an additional hole in the door skin 118 , such as that shown in FIGS. 1 and 2 , is avoided because the post can use the same hole as the handle 14 . The reflector 123 is located to minimize the possibility of dirt being deposited, whether by a user or otherwise, on the mirror reflector 123 . Thus, a lens protector is also unnecessary in this embodiment. The user can modify the optical beam characteristic by placing his hand anywhere on the door providing an ergonomic advantage. This arrangement is simpler and is easier and less expensive to install.
Further, alternative embodiments are shown in FIGS. 9 a and 9 b of the drawings, which depict a car door handle assembly similar to that shown in FIGS. 1 and 2 in which LED 210 generates an incident beam 212 which is detected directly by a photo-transistor 214 without the use of a mirror. When the user inserts his hand between the LED 210 and the photo-transistor 214 it breaks or modifies the beam 212 in the same way as described above. The light emitting diodes and photo-transistors can be positioned as appropriate to facilitate interruption of a beam by a user. Thus, FIG. 9 b shows the beam parallel to the door skin 18 similar to that shown in FIG. 8 . These alternative arrangements can be provided to operate with the same or similar circuit to that described above.
A further embodiment of the invention is shown in FIG. 10 which is similar to the arrangement shown in FIG. 8 . In this embodiment sensor enclosure 228 is mounted in door bracket 229 , and a post or light-pipe 230 and also may be configured to carry a light source and a detectors, which can be arranged in the same way as depicted in FIG. 8 , that is they are disposed adjacent each other, the same distance along the post axis. The enclosure 228 also has mechanical back-up and locking switches 235 , 237 respectively. There is no reflector in this embodiment and the sensor circuit operates by detecting light reflected from a user's hand when inserted between the handle 236 and the door skin 238 . The circuit is substantially identical to that of FIG. 6 but as long as no reflected pulses are received, the counter in the receiving circuitry 58 is continually set to zero and the output circuitry does not generate an output pulse. The counter IC 5 100 is set up so that if three successive pulses of light are detected following reflection from a user's hand, the counter generates an output signal which is fed to the MOS transmitter as described above with reference to FIG. 6 . Thus, the circuit only produces an output when the beam is reflected by a user, and in combination with the user's ID signal, an unlocking signal is sent to the door so that when the user pulls on the handle the door is already unlocked. The power supply to the circuit is also only supplied during the period of the synchronization circuit to minimize power consumption and, as before, all measurements and signal processing take place within this 40 s period.
This embodiment has the advantage of minimizing cost: a reflector is not required and the post 230 uses the same aperture 240 in the door as the handle facilitating assembly. Because a reflector is not required, problems associated with the reflector such as keeping it clean and amplifying power are avoided.
Reference is also made to a further embodiment of the invention which is similar to the arrangement shown in FIG. 1 but without the reflector 23 . In this embodiment the signal is reflected back to the detector 16 by the user's hand. The sensor circuit operates in the same way as described with reference to FIG. 10 ; counting a predetermined number of pulses present results in an output signal which is fed to a MOS transistor for generating a control signal to unlock the door as described above.
Various other modifications may be made to the apparatus and circuitry hereinabove described without departing from the scope of the invention. Certain applications and minimizing of power consumption may not be necessary, for example in buildings and the like where mains power supply is available and the power consumption required by the sensor system may be regarded as minimal. In such a case the IR optical signal could be provided by a continuous signal and actuation of the unlocking mechanism could be achieved by detecting the absence of the continuous signal for a predetermined period or by counting a number of pulses as described above. The LED and photo-transistor may be located separately from the handle. For example, a slot could be provided in a door or entry to a building and a plastic card, similar to a credit card of the like, could be swiped between the slot to interrupt the beam and the output of the signal processing circuitry could be used to unlock a mechanism to allow a user to open a door which is remote from a sensing mechanism.
The sensor device has a number of advantages which allow its use in a variety of applications, such as in vehicles, buildings and the like. The use of a partially or totally modified or interrupted beam to detect the presence and absence of an object has a variety of applications. For example, it may be used as a rain sensor and for detecting and counting the passage of objects interrupting the beam. The structure has a number of advantages which facilitate widespread use, such as low power consumption during use, the use of up to 100 mA drive current provided to the IR LED to generate a high power optical pulse to minimize the effect of dirt and the like on the lenses and reflectors, where used, fast frequency response compatible with high frequency pulses, a wide operating temperature range and good noise immunity to ambient light changes and electromagnetic interference. Synchronization of the detection of the light impulses provides good immunity against parasitic electrical signals and radio signals and the use of a counter to detect predetermined period of interruption minimizes the effect of spurious signals causing malfunctioning of the circuitry.
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A keyless access sensor system for use with a keyless access control mechanism (KACM) is described for controlling the operation of a locking device. The KACM receives a signal from a sensor device for keyless access to create a first output signal before the user has begun any action on the handle in order to open the door. The first output signal is sent to a general processor, which initiates a recognition process and, after recognition of the authorized user the processor then generates an unlocking signal which unlocks the locking device before the authorized user will have fully accomplished the action of opening the door. Thus the authorized user is allowed to open the door without any specific un-ergonomic and time-consuming additional action to the simple action of actuating the handle to open the door. The second signal is generated by a device, such as a fob, card or the like, carrying a unique digital or analog identification in response to RF or IR interrogation from the general processor after it receives the output signal from the sensor device for keyless access.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of International Application No. PCT/US2014/035042 filed Apr. 22, 2014 which claims the benefit of U.S. Provisional Patent Application No. 61/814,653 filed Apr. 22, 2013.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of semi-polar III-nitride films and materials and method for making the same.
2. Prior Art
Group III-nitrides, which include but are not limited to Al x In y Ga 1-x-y N compositions in which 0≦x, y≦1, are of considerable interest in many fields, such as the fabrication of high brightness light emitting diodes (LEDs), laser diodes, and power electronics. Virtually all group III-nitrides grown today are produced such that the maximum surface area available for device fabrication lies on the (00.1) c-plane, wherein the notation (hk.l) is a shorthand form of Miller-Bravais crystallographic notation to identify crystal planes in hexagonal crystals. The “.” Represents the i index in (hkil) four-index notation, which is redundant as h+k+i=0. One skilled in the art further understands that (hkil) notation using parentheses refers to a specific crystal plane while notation using curly brackets such as {hkil} refers to a family of related crystallographic planes. For the purposes of this invention, { } and ( ) notation will be understood to be interchangeable as the invention typically applies to all specific planes that belong to any family of planes.
Conventional c-plane-oriented nitrides can be referred to as “polar” nitrides because of the substantial piezoelectric and spontaneous polarization fields that exist parallel to the c-axis and therefore perpendicular to the c-plane. Such polarization fields restrict performance of polar group III-nitride devices by causing color shifting, limiting radiative recombination efficiency, and reducing high-current density efficiency.
An alternate set of group III-nitride crystal orientations are referred to as “semi-polar.” Semi-polar nitrides are nitride crystal planes having at least two non-zero h, k, or i indices and a non-zero l index in Miller-Bravais notation. Some common semi-polar planes include, but are not limited to, the {10.1}, {10.2}, {10.3}, {20.1}, {30.1}, and {11.2} planes.
Group III-nitrides are commonly fabricated by several techniques, including but not limited to metalorganic chemical vapor deposition (MOCVD or OMVPE), molecular beam epitaxy (MBE), and hydride vapor phase epitaxy (HVPE). The overwhelming majority of group III-nitride development has been focused on polar c-plane oriented material. Semi-polar group-III nitride planes, however, have historically proven difficult to grow by any technique using comparable parameters to polar nitrides. Indeed, one skilled in the art will recognize that growth of a semi-polar group-III nitride film, template, or free-standing layer using production parameters optimized for polar nitrides generally yields low-quality, rough, and defective material that is virtually unusable for fabrication of optoelectronic and electronic devices.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a simple embodiment of the present invention having two pairs of Periodic Epi-Structure Layers grown upon a graded or stepped AlGaN layer.
FIG. 2 illustrates an embodiment of the present invention wherein the Graded Al x Ga 1-x N Layer has been eliminated and defect reduction is achieved by way of the use of Periodic Epi-Structure inclusion.
FIG. 3 illustrates an embodiment of the present invention wherein the Periodic Epi-Structure has been eliminated and defect reduction is achieved by way of the use of a graded AlGaN layer.
FIG. 4 is a Nomarski optical contrast micrograph showing an approximately 15 of (11.2) GaN grown upon a Al 0.35 Ga 0.65 N intermediate layer grown upon an AlN nucleation layer on a m-plane sapphire substrate without the benefit of the present invention.
FIG. 5 is a Nomarski optical contrast micrograph showing a GaN film grown upon a 10-period Periodic Epi-Structure consisting of (a) layers consisting Al 0.35 Ga 0.65 N and (b) layers consisting of GaN. The Periodic Epi-Structure was grown on a Graded Al x Ga 1-x N layer that transitioned from AlN to GaN in five steps in accordance with an embodiment of the invention.
FIG. 6 is a Nomarski optical contrast micrograph showing a GaN film grown upon a 10-period Periodic Epi-Structure consisting of (a) layers consisting Al 0.85 Ga 0.15 N and (b) layers consisting of GaN. The Periodic Epi-Structure was grown on a Graded Al x Ga 1-x N layer that transitioned from AlN to GaN in five steps in accordance with an embodiment of the invention.
FIG. 7 is a Nomarski optical contrast micrograph showing a GaN film grown upon a 10-period Periodic Epi-Structure consisting of Al 0.85 Ga 0.15 N and (b) layers consisting of GaN in accordance with an embodiment of the invention. The Periodic Epi-Structure was grown on a Graded Al x Ga 1-x N layer that transitioned from AlN to GaN in five steps. The terminal GaN layer grown at a reduced growth rate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a means of significantly reducing defect densities, reducing surface roughness, and improving functionality of semi-polar group III-nitrides. The invention utilizes a novel variant of HVPE to grow nanometer-scale periodic epi-structures on semi-polar III-nitride planes. The invention further includes the use of stepped and/or graded AlGaN layers to improve phase purity and reduce macroscopic defect densities.
Key novel elements of the invention include one or more of the following:
1. Nanometer-scale control of semi-polar AlGaN and GaN growth rates with HVPE, a technique that is known for much higher growth rates
2. Incorporation of stepped or graded AlGaN layers as a transition from optional AlN nucleation layers on the m-plane Al 2 O 3 substrates to GaN at the free surface. In one embodiment, the film layer is transitioned from AlN to GaN in five composition steps
3. Growth of nanometer-scale periodic structures that feature alternating thin layers of AlGaN and GaN of different compositions
4. Application of the invention specifically to the growth of high-quality semi-polar group III-nitride films, templates, free-standing substrates, and bulk materials
5. Ability to grow the nanometer-scale graded AlGaN layers and periodic epi-structures in the same growth run as thin and thick AlGaN and GaN films, enabling low-cost template production compared to methods that rely on MBE or MOCVD for group III-nitride growth
6. Achievement of reduced surface roughness, reduced macroscopic defect density, and/or reduced micro-structural defect densities compared to semi-polar group III-nitrides as described in the prior art
The invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings in which like reference numerals refer to similar elements. References in the following detailed description of the present invention to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristics described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in this detailed description are not necessarily all referring to the same embodiment. The following figures illustrate several embodiments of the invention.
FIG. 1 illustrates a template structure 100 that includes the invention. An optional nucleation layer 120 is deposited on a suitable substrate 110 . A Graded AlGaN region 130 is deposited on the nucleation layer, upon which a nanometer-scale periodic epi-structure 140 is grown. A terminal group III-nitride layer such as GaN is grown upon the periodic epi-structure, represented by block 150 .
Referring to FIG. 1 , the substrate 110 may be any substrate that is capable of supporting group III-nitride growth, either heteroepitaxially or homoepitaxially. Examples of suitable substrate materials include, but are not limited to, sapphire, silicon, lithium aluminate, spinel, silicon carbide, gallium nitride, aluminum nitride, and silica glass. The substrate orientation can be any orientation that supports group III-nitride epitaxial growth, including but not limited to the sapphire c-plane, m-plane, r-plane, or n-plane; the silicon {100}, {110} or {111} planes; the lithium aluminate {100} plane; the silicon carbide {00.1}, {10.0}, {11.0}, {11.1}, {11.2}, {10.1}, {10.2}, {10.3}, and {20.1} planes. One skilled in the art will recognize that other substrate materials and orientations not listed here may be utilized in the practice of the invention.
The nucleation layer 120 may be any group III-nitride composition, may be deposited at any temperature ranging from 400 to 1300 degrees Celsius, and may be of any thickness from 0.1 nm to 1000 μm. The nucleation layer may further be the result of a deposition process, such as the deposition of AlN on a sapphire substrate; or may be the result of a modification of the substrate top surface, such as may be achieved by nitridizing a sapphire top surface by flowing ammonia over sapphire during annealing at high temperature, converting a one or more mono-layers of Al2O3 into AlN. The nucleation layer may further be omitted completely from the structure if so desired.
The Graded AlGaN region 130 is deposited on the nucleation layer. The Graded Al x Ga 1-x N region involves a transition from a initial group III-nitride composition, such as Al 1.0 Ga 0.0 N to a terminal group III-nitride composition, such as Al 0.0 Ga 1.0 N, over a total thickness ranging from approximate 5 nm to approximately 10 μm. The transition may be executed continuously, varying the composition as a function of growth time with no distinct layer structure. For example, in one embodiment the Graded AlGaN region involves a transition from AlN to GaN with a linear composition change as a function of thickness over a region thickness of 200 nm.
In an alternate embodiment, the Graded Al x Ga 1-x N region may be executed in a series of steps from an initial composition to a terminal composition. For example, in this alternate embodiment the Graded Al x Ga 1-x N region consists of a transition from AlN to GaN including six distinct layers having compositions of Al 1.00 Ga 0.00 N, Al 0.80 Ga 0.20 N, Al 0.60 Ga 0.40 N, Al 0.40 Ga 0.60 N, Al 0.20 Ga 0.80 N, and Al 0.00 Ga 1.00 N, respectively.
In another embodiment, a portion of the Graded Al x Ga 1-x N region is compositionally varied continuously while another portion is varied stepwise. The thickness of each gradation need not be constant throughout the Graded Al x Ga 1-x N layer. One skilled in the art will recognize that the specific number of gradations in and the total thickness of the Graded Al x Ga 1-x N region may be varied without deviating from the scope of the present invention.
The Periodic Epi-Structure 140 consists of pairs of group III-nitride layers having dissimilar composition that are grown upon one another. Referring to FIG. 1 , one of the layers has been denoted Layer (a) and the other denoted as Layer (b) in block 140 . It is essential that the (a) and (b) layers consist of dissimilar group III-nitride compositions from one another. For example, in one embodiment Layer (a) is represents Al 0.80 Ga 0.20 N, while Layer (b) is Al 0.00 Ga 1.00 N. In the simplest implementation of the invention, all (a) layers in the Periodic Epi-Structure would consist of similar compositions to all other (a) layers, while all (b) layers in the Periodic Epi-Structure would consist of similar compositions to all other (b) layers. However, in some embodiments it is desirable to vary the composition of either the (a) layers or (b) layers (or both) through the thickness of the Periodic Epi-Structure. Such variation is compatible with the invention provided that each layer consists of a compositionally distinct group III-nitride from the immediately adjacent layers.
In the simple embodiment illustrated in FIG. 1 , two pairs of Periodic Epi-Structure Layers 140 are illustrated. The number of pairs of Periodic Epi-Structure Layers used in practice will vary from approximately two pairs to approximately 200 pairs.
The thickness of the (a) and (b) layers in the Periodic Epi-Structure will each typically range from approximately 1 nm to approximately 100 nm. There is no requirement that identical thicknesses be used for all (a) layers and all (b) layers, respectively. In one embodiment, the thickness of the (a) layers is approximately 5 nm and the thickness of the (b) layers is approximately 20 nm. The thickness of the layers can be varied throughout the thickness of the Periodic Epi-Structure as well. For example, it may be desirable to utilize a structure in which the layer thicknesses are approximately 5 nm each for five pairs, followed by thicknesses of 10 nm each for five pairs. One skilled in the art will recognize that many variations of layer thicknesses can be utilized successfully in the practice of the invention.
The top layer represented by block 150 represents the terminal composition of the thin film or template that is grown utilizing the invention. Typically, this top layer will consist of GaN, but in practice it can consist of any group III-nitride alloy composition. This layer can be grown at different growth rates and can also be doped with modifying atoms or ions, including but not limited to Si, C, O, Mg, and Zn.
The thickness of the top layer may range from 1 nm in the case of thin templates to 50 mm in the case of bulk nitride materials grown for use as free-standing substrates. Typically, the top layer thickness will be approximately five to ten micrometers for group III-nitride template fabrication. Similarly, typically thicknesses for free-standing film production are on the order of 250-1000 μm. One skilled in the art will recognize that many ranges of thicknesses are compatible with the practice of the invention.
The invention can also be practiced with the exclusion of the Graded Al x Ga 1-x N Layer, as illustrated in FIG. 2 . In the embodiment illustrated by block 101 , the Periodic Epi-Structure 140 is grown upon the Nucleation Layer 120 .
The invention can also be practiced with the exclusion of the Periodic Epi-Structure 140 , as illustrated in FIG. 3 . In the embodiment illustrated in block 102 , the terminal GaN Layer 150 is grown upon the Graded Al x Ga 1-x N layer 130 .
One skilled in the art will further recognize that the order of the blocks as illustrated in FIGS. 1-3 can be rearranged without fundamentally deviating from the scope of the invention. For example, the Graded Al x Ga 1-x N Layer could be grown upon the Periodic Epi-Structure instead of being grown in the order described in FIG. 1 . It should also be emphasized that additional layers not described herein could be inserted into the structure. For example, in one embodiment a GaN layer is grown upon the nucleation layer, upon which the Graded Al x Ga 1-x N layer is grown. Such additions of supplemental layers are consistent with the scope and practice of the invention.
FIGS. 4-7 provide Nomarski optical contrast micrographs illustrating improved surface morphology of {11.2} GaN and Al x Ga 1-x N films incorporating the present invention. In FIG. 4 , an Al x Ga 1-x N surface grown without the invention is shown. This film consisted of approximately 15 μm of (11.2) GaN grown upon a Al 0.35 Ga 0.65 N intermediate layer grown upon an AlN nucleation layer on a m-plane sapphire substrate.
FIG. 5 shows a Nomarski optical contrast micrograph of a GaN film grown upon a 10-period Periodic Epi-Structure consisting of (a) layers consisting of Al 0.35 Ga 0.65 N and (b) layers consisting of GaN. The Periodic Epi-Structure was grown on a Graded Al x Ga 1-x N layer that transitioned from AlN to GaN in five steps. A comparison of surface roughness between FIG. 5 and FIG. 4 clearly shows the superior quality of the surface in FIG. 5 .
FIG. 6 shows a Nomarski optical contrast micrograph of a GaN film grown upon a 10-period Periodic Epi-Structure consisting of (a) layers consisting Al 0.85 Ga 0.15 N and (b) layers consisting of GaN. The Periodic Epi-Structure was grown on a Graded Al x Ga 1-x N layer that transitioned from AlN to GaN in five steps. A comparison of surface roughness between FIG. 6 and FIG. 4 clearly shows the superior quality of the surface in FIG. 6 .
FIG. 7 shows a Nomarski optical contrast micrograph of a GaN film grown upon a 10-period Periodic Epi-Structure consisting of (a) layers consisting Al 0.85 Ga 0.15 N and (b) layers consisting of GaN. The Periodic Epi-Structure was grown on a Graded Al x Ga 1-x N layer that transitioned from AlN to GaN in five steps. In this epi-growth example the terminal GaN layer was grown at a reduced growth rate, yielding further reduction in surface roughness. A comparison of surface roughness between FIG. 7 and FIG. 4 clearly shows the superior quality of the surface in FIG. 7 .
The incorporation of the present invention into the growth of semi-polar group III-nitrides can reduce terminal layer surface roughness by 75% or more compared to semi-polar group III-nitride films grown without the invention. The invention further improves micro-structural quality of the terminal group III-nitride layers by blocking propagation of micro-structural defects and relieving strain related to lattice mismatch and thermal expansion mismatch.
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A method has been developed to overcome deficiencies in the prior art in the properties and fabrication of semi-polar group III-nitride templates, films, and materials. A novel variant of hydride vapor phase epitaxy has been developed that provides for controlled growth of nanometer-scale periodic structures. The growth method has been utilized to grow multi-period stacks of alternating AlGaN layers of distinct compositions. The application of such periodic structures to semi-polar III-nitrides yielded superior structural and morphological properties of the material, including reduced threading dislocation density and surface roughness at the free surface of the as-grown material. Such enhancements enable to fabrication of superior quality semi-polar III-nitride electronic and optoelectronic devices, including but not limited to transistors, light emitting diodes, and laser diodes.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to the fields of pharmaceutical chemistry. More particularly, the present invention relates to a novel method for preparing and purifying 4-(6-Amino-purin-9-yl)-2(S)-hydroxy-butyric acid methyl ester (hereinafter, referred to as DZ2002).
BACKGROUND OF THE INVENTION
[0002] DZ2002 is a reversible inhibitor of S-Adenosyl-L-homocysteine hydrolase (SAHH). It has been demonstrated that DZ2002 selectively suppresses macrophage function and activates B cells function, inhibits cell immune and humoral immune responses, and has a wide margin between the toxic and therapeutic doses with a high therapeutic index (Chong-Sheng Yuan, USP: 2005/0182075, 2005; Yun-Feng Fu, Jun-Xia Wang, Jian-Ping Zuo etc., The Journal of Pharmacology and Experimental Therapeutics, 118, 1229˜1237; Brian R. Lawson, Yulia Manenkova, Chong Yuan etc., The Journal of Immunology, 178, 5366˜5374, 2007).
[0003] A known method for preparing DZ2002 started from (S)-(−)-α-hydroxybutyrolactone, after the hydroxyl group had been protected with a silyl group, the lactone was treated with tetraisopropyl titanate to open the lactone ring, followed by being converted to a corresponding p-toluenesulfonate. Then it was nucleophilically substituted with adenine and deprotected by removal of the silyl protective group to obtain DZ2002. The details are shown in Scheme 1. In the preparation method, (S)-(−)-α-hydroxybutyrolactone is expensive, the ring-opening reaction using tetraisopropyl titanate has a low yield with a complicated post-treatment, and the chiral center tends to be racemized during the reaction. In addition, DZ2002 is purified by column chromatography, which is time-consuming with a low productivity.
[0000]
SUMMARY OF THE INVENTION
[0004] The present invention aims at developing an effective method for preparing and purifying DZ2002 on a large scale, which utilizes L-malic acid as a starting material. The present invention has advantages in easily available materials, low cost, simple operation process, high productivity, easily being scaled-up, as well as high retention of the chiral center during the reaction.
[0005] The object of the present invention was achieved by a process illustrated in Scheme 2.
[0000]
[0006] The present invention provides a method for preparing 4-(6-Amino-purin-9-yl)-2(S)-hydroxy-butyric acid methyl ester, comprising the following steps.
[0007] (1) A ring-closing reaction was carried out by a nucleophilic substitution between L-malic acid and a protective agent, a carbonyl compound having a structure of R 1 COR 2 or a diol-carbonyl condensation compound thereof, to selectively give an intermediate I whose 1-carboxyl and 2-hydroxyl groups were both protected simultaneously, wherein R 1 and R 2 are each independently H, methyl, ethyl, n-propyl, n-butyl, phenyl, p-methoxyphenyl or the like. The carbonyl compound is preferably acetone, and the diol-carbonyl condensation compound is preferably acetone dimethyl acetal. In this case, R 1 ═R 2 =methyl.
[0008] The intermediate I, whose 1-carboxyl and 2-hydroxyl groups are both protected selectively, may be easily obtained by reacting L-malic acid with the protective agent in an appropriate solvent in the presence of a weak acid as a catalyst. With respect to the kind of the protective group and the corresponding incorporation process thereof, reference is made to “ Protective groups in organic synthesis ” (The organic chemistry teaching and researching group of East China University of Science and Technology (translated), East China University of Science and Technology Press, 2004).
[0009] (2) The intermediate I obtained from step (1) was reduced to an intermediate alcohol II by a reducing agent, wherein the 4-carboxyl group of the intermediate I was reduced to the corresponding hydroxyl group by a reducing agent such as a borane agent or a metal hydride to give the intermediate alcohol II. The borane agent may be borane, borane-pyridine complex, borane-dimethylthioether complex, borane-tetrahydrofuran complex, borane-ammonia complex or the like. The metal hydride may be LiAlH 4 , NaBH 4 , KBH 4 or NaBH 3 CN. In the case of when the reducing agent is a metal hydride, it may be used alone or in combination with a reagent selected from the group consisting of AlCl 3 , NiCl 2 , CeCl 3 , ZnCl 2 , LiCl, I 2 and the like. The reducing agent is preferably a borane or a complex thereof, which may be produced in situ, or a commercially available agent, and more preferably, a commercial borane-dimethylthioether complex.
[0010] (3) The intermediate alcohol II obtained from step (2) may be esterified by an acyl chloride selected from the group consisting of p-toluenesulfochloride, mesyl chloride, trifluoro-acetyl chloride, trichloro-acetyl chloride and acetyl chloride in the presence of a base to give an intermediate III, wherein X is one selected from the group consisting of mesyloxyl, p-toluenesulfonyloxyl, trifluoroacetyloxyl, trichloroacetyloxyl and acetyloxyl. Alternatively, the intermediate alcohol II may be halogenated by a halogenating agent selected from the group consisting of phosphorus tribromide, phosphorus pentabromide, carbon tetrabromide/triphenylphosphine and iodine/triphenylphosphine to give an intermediate III, wherein X is Br or I.
[0011] More specifically, the hydroxyl of intermediate alcohol II, which was obtained by reduction, was further transformed to a corresponding group that is easy to be removed to give the intermediate III, wherein X is either a substituent such as Br, I and the like, or a corresponding activated ester group such as mesyloxyl, p-toluenesulfonyloxyl, trifluoroacetyloxyl, trichloroacetyloxyl, acetyloxyl and the like, preferably mesyloxyl or p-toluenesulfonyloxyl. When the hydroxyl of the intermediate alcohol II was converted to an activated ester group, the used base is one organic base selected from the group consisting of triethylamine, diisopropylethylamine, pyridine and the like.
[0012] (4) The intermediate III obtained from step (3) was nucleophilically substituted by adenine in an appropriate solvent at a suitable temperature in the presence of a base and a phase transfer catalyst to give an intermediate IV.
[0013] More specifically, the substitution may be carried out at a temperature in the range of 30° C. to 120° C., preferably 40° C. to 60° C. The phase transfer catalyst may be tetrabutylammonium bromide, tetrabutylammonium chloride, tetrabutylammonium iodide, 18-crown-6, polyethylene glycol or the like, preferably 18-crown-6. The base may be an inorganic base such as sodium hydride, K 2 CO 3 , Na 2 CO 3 , LiCO 3 , NaOH, KOH, LiOH and the like, or an organic base such as triethylamine, diisopropylethylamine, pyridine, methylpyridine, n-butyllithium, sec-butyllithium, lithium diisopropylamine, lithium hexamethyldisilazide, sodium hexamethyldisilazide, potassium hexamethyldisilazide or the like, preferably sodium hydride, K 2 CO 3 or Na 2 CO 3 . The solvent may be one selected from a group consisting of a strongly polar non-protonic solvent such as formamide, DMF, DMA, sulfolane, DMSO, NMP, HMPA(hexamethyl phosphoric triamide) and the like; a ketone solvent such as acetone, butanone and the like; an aromatic solvent such as benzene, toluene and the like; an ester solvent such as ethyl acetate, butyl acetate and the like; a chlorohydrocarbon solvent such as dichloromethane, dichloroethane and the like; and a ether solvent such as diisopropyl ether, tetrahydrofuran, dioxane and the like, preferably formamide, DMF, DMA, NMP or sulfolane.
[0014] (5) The intermediate IV obtained from step (4) was deprotected and methyl-esterified simultaneously in a methanol system in the presence of an acid or a base to give a crude DZ2002.
[0015] The transformation in this step was carried out in a HCl/methanol mixture or sodium alkoxide/methanol mixture, preferably in HCl/methanol mixture. With respect to the process for deprotection, reference is made to “ Protective groups in organic synthesis ” (The organic chemistry teaching and research group of East China University of Science and Technology(translated), East China University of Science and Technology Press, 2004).
[0016] In the preparation method according to the present invention, the steps (3) and (4) may be replaced by the following step, that is, the intermediate alcohol II, which was obtained by the selective reduction of step (2), may be directly reacted with adenine through Mitsunobu reaction in the presence of a phosphine agent and a reagent such as diethyl azodiformate (DEAD), diisopropyl azodiformate (DIAD) or the like to give an intermediate IV, the product of the nucleophilic substitution, wherein the phosphine agent is triphenylphosphine or trialkylphosphine, wherein the alkyl is a short chain C1-C4 alkyl.
[0017] The resultant crude DZ2002 from the above methods may be purified by recrystallization. The recrystallization may be performed using an alcohol solvent such as methanol, ethanol, isopropanol and the like, or simply using water, or using a mixture of alcohol and water. It is preferable to use water as the solvent for recrystallization.
[0018] Racemic DZ2002 can also be synthesized through the present method using a racemic malic acid as a starting material. The racemoid is esterified by a chiral acid such as Mosher agent to give the corresponding ester. The diastereoisomers may be separated through a method such as recrystallization due to their difference in physical properties such as solubility, followed by hydrolysis to give DZ2002. Therefore, the present invention also includes such method.
[0019] The present invention has the following significant advantages over the preparation methods of the prior art:
[0020] 1. In the prior art, (5)-(−)-α-hydroxybutyrolactone was used as a starting material, which is expensive (1788 RMB/g, Aldrich, 2007-2008), while the present invention starts with L-malic acid, which is cheap (30 RMB/kg) and easily available, thus greatly reducing the cost;
[0021] 2. In the preparation method according to the present invention, the racemization does not tend to occur since the chiral center was protected by ring-formation during the reaction, and thus the product quality is much better than that of the prior art. For example, the product of the prior art has a specific rotation of +12.5° as measured, while DZ2002 prepared by the method of the present invention has a specific rotation which can be generally controlled in the range of +18° to +20°.
[0022] 3. The method of the present invention has a high productivity and is easily scaled up, since the crude DZ2002 may be purified through recrystallization.
DETAILED DESCRIPTION
BEST MODE FOR CARRYING OUT THE INVENTION
[0023] The present invention will be further illustrated by the following examples, which may not be construed to restrict the scope of the present invention.
[0024] I. Selective Protection of L-Malic Acid
EXAMPLE 1
[0025]
[0026] To a suspension of L-malic acid (4.0 g, 30.0 mmol) (SHANG HAI BANGCHENG CHEMICAL Co. Ltd.) in dry acetone (100 ml), p-toluenesulfonic acid (60.0 mg, 0.33 mmol) was added. The mixture was heated to reflux for 6 h to gradually become clear. After the solvent was removed through concentration, the resultant residue was diluted with water (100 ml) and sufficiently extracted with dichloromethane. The combined organic phase was washed with saturated saline, dried and concentrated to obtain a nearly colorless transparent oil, which was then recrystallized from dichloromethane/n-hexane (1/5, v/v), dried in vacuo to afford compound I-1 (2.0 g) as a white crystal with a yield of 50.0%.
EXAMPLE 2
[0027]
[0028] To a suspension of L-malic acid (4.0 g, 30.0 mmol) in dry benzene (80 ml), were added fresh phenyl aldehyde (3.2 g, 30 mmol) and pyridinium p-toluenesulfonate (151.0 mg, 0.6 mmol). After heated to reflux and water-segregated for 3 h, the mixture became clear. After the solvent was removed through concentration, the resultant residue was diluted with water (100 ml) and sufficiently extracted with dichloromethane. The combined organic phase was washed with saturated saline, dried and concentrated to afford compound I-2 (4.3 g) as a nearly colorless transparent oil with a yield of 65.3%, which will be used directly in the next step without purification.
EXAMPLE 3
[0029]
[0030] To a suspension of L-malic acid (10.0 g, 74.6 mmol) in fresh 2,2-dimethoxypropane (100 ml), p-toluenesulfonic acid (0.20 g, 1.04 mmol) was added. After reacted at room temperature for 3 h, the mixture became clear. After the solvent was removed through concentrating, the resultant residue was diluted with water (150 ml) and sufficiently extracted with dichloromethane. The combined organic phase was washed with saturated saline, dried and concentrated to obtain a nearly colorless transparent oil, which was then slowly solidified to afford compound I-1 (4.8 g) as a white crystal with a yield of 37.0%.
EXAMPLE 4
[0031]
[0032] To a suspension of L-malic acid (6.7 g, 50.0 mmol) in fresh ethyl ether (100 ml), redistilled propylaldehyde (3.2 g, 55.0 mmol) was added under ice bath. Redistilled boron trifluoride etherate (19.0 ml, 150.0 mmol) was then added dropwise for 30 min, followed by keeping the temperature for 3 h. After diluted with water (100 ml), the mixture was sufficiently extracted with ethyl ether. The combined organic phase was washed with saturated saline, dried and concentrated to afford compound I-3 (6.8 g) as a nearly colorless transparent oil with a yield of 78.1%, which will be used directly in the next step without purification.
[0033] II. Selective Reduction of the Protected L-Malic Aid, Intermediate I, to Alcohol II (Illustrated with the Case that R 1 ═R 2 =Methyl, i.e., Compound I-1, which may not be Construed to Restrict the Invention)
[0000]
EXAMPLE 1
[0034] To a solution of the compound I-1 (24.4 g, 0.14 mol) obtained from the last step in fresh tetrahydrofuran (150 ml), was dropwise added a solution (2M, 77.0 ml, 0.15 mol) of borane-methyl sulfide complex in tetrahydrofuran for 1.5 h under ice bath. After the addition, the mixture was stirred at that temperature for 2 h and then at room temperature for 12 h. Methanol (77.0 ml) was slowly and dropwise added into the mixture to destroy the residual borane. After the addition, the mixture was stirred at room temperature for 30 min, and then concentrated. The resultant residue was purified through silica-gel column chromatography eluting with n-hexane/ethyl acetate (2/1, v/v) to afford alcohol II-1 with a yield of 74.1-86.6%.
EXAMPLE 2
[0035] To a suspension of sodium borohydride (6.4 g, 0.17 mol) in tetrahydrofuran (50 ml), was dropwise added a solution of the resultant compound I-1 (24.4 g, 0.14 mol) from the last step in fresh tetrahydrofuran (50 ml) for 1 h under room temperature. After the addition, a solution of iodine (21.6 g, 0.085 mol) in tetrahydrofuran (50 ml) was dropwise added to the above mixture for 1 h, followed by stirring for 2 h at room temperature. After methanol (50 ml) was slowly and dropwise added into the reaction system, the mixture was stirred at room temperature for 30 min, and then concentrated. The resultant residue was purified through silica-gel column chromatography eluting with n-hexane/ethyl acetate (2/1, v/v) to afford alcohol II-1 with a yield of 62.1-75.0%.
EXAMPLE 3
[0036] To a suspension of sodium borohydride (7.2 g, 0.19 mol) in tetrahydrofuran (100 ml), was dropwise added a fresh boron trifluoride etherate (26.8 g, 0.19 mol) for 1.5 h under ice bath, generating a large amount of gas and white turbidness. After removing the ice bath, the mixture was stirred at room temperature for 1 h. A solution of the compound I-1 (24.4 g, 0.14 mol) obtained from the last step in tetrahydrofuran (50 ml) was dropwise added for 1.5 h under ice bath, followed by stirring for 12 h at room temperature. After methanol (70 ml) was slowly and dropwise added into the reaction system, the mixture was stirred at room temperature for 30 min, and then concentrated. The resultant residue was purified through silica-gel column chromatography eluting with n-hexane/ethyl acetate (2/1, v/v) to afford alcohol II-1 with a yield of 55.0-65.3%.
EXAMPLE 4
[0037] To a suspension of sodium borohydride (7.2 g, 0.19 mol) and fresh dimethyl sulfide (11.8 g, 0.19 mol) in tetrahydrofuran (100 ml), was dropwise added a fresh boron trifluoride esterate (26.8 g, 0.19 mol) for 1.5 h under ice bath, generating a large amount of gas and white turbidness. After removing the ice bath, the mixture was stirred at room temperature for 1 h. A solution of the compound I-1 (24.4 g, 0.14 mol) obtained from the last step in tetrahydrofuran (50 ml) was dropwise added for 1.5 h under ice bath, followed by stirring for 12 h at room temperature. After methanol (70 ml) was slowly and dropwise added into the reaction system, the mixture was stirred at room temperature for 30 min, and then concentrated. The resultant residue was purified through silica-gel column chromatography eluting with n-hexane/ethyl acetate (2/1, v/v) to afford alcohol II-1 with a yield of 71.2-85.6%.
EXAMPLE 5
[0038] To a suspension of sodium borohydride (7.2 g, 0.19 mol) and fresh dimethyl sulfide (11.8 g, 0.19 mol) in tetrahydrofuran (100 ml), was dropwise added a solution of fresh trimethylsilyl chloride (20.6 g, 0.19 mol) in tetrahydrofuran (50 ml) for 1.5 h under ice bath, generating a large amount of gas and white turbidness. After removing the ice bath, the mixture was stirred at room temperature for 1 h. A solution of the compound I-1 (24.4 g, 0.14 mol) obtained from the last step in tetrahydrofuran (50 ml) was dropwise added for 1.5 h under ice bath, followed by stirring for 12 h at room temperature. After methanol (70 ml) was slowly and dropwise added into the reaction system, the mixture was stirred at room temperature for 30 min, and then concentrated. The resultant residue was purified through silica-gel column chromatography eluting with n-hexane/ethyl acetate (2/1, v/v) to afford alcohol II-1 with a yield of 78.2-83.5%.
[0039] III. Transformation of the Intermediate Alcohol II to Intermediate III (Illustrated by Alcohol II-1, which may not be Construed to Restrict the Invention)
EXAMPLE 1
[0040]
[0041] To a solution of the alcohol II-1 (52.8 g, 0.33 mol) obtained from the last step in fresh pyridine (250 ml), p-toluenesulfonyl chloride (62.7 g, 0.33 mol) was batchwise added under ice bath, followed by stirring at room temperature for 5 h. After the solvent was recovered under reduced pressure, the resultant residue was diluted with ethyl acetate (400 ml), washed with HCl solution (5%), saturated sodium bicarbonate solution and saline respectively, dried and concentrated. The resultant residue was purified through silica-gel column chromatography eluting with n-hexane/ethyl acetate (10/1, v/v) to afford intermediate III-1 with a yield of 59.8-67.6%.
EXAMPLE 2
[0042]
[0043] To a solution of the alcohol II-1 (32.0 g, 0.20 mol) obtained from the last step and N,N-diisopropylethylamine (51.6 g, 0.40 mol) in fresh dichloromethane (200 ml), fresh mesyl chloride (22.8 g, 0.20 mol) was dropwise added for 30 min under ice bath, followed by stirring at room temperature for 3 h. After the solvent was recovered under reduced pressure, the resultant residue was diluted with ethyl acetate (400 ml), washed with HCl solution (5%), saturated sodium bicarbonate solution and saline respectively, dried and concentrated. The resultant residue was purified through silica-gel column chromatography eluting with n-hexane/ethyl acetate (10/1, v/v) to afford intermediate 111-2 with a yield of 71.2-77.7%.
EXAMPLE 3
[0044]
[0045] To a solution of iodine (57.2 g, 0.23 mol) in dichloromethane (300 ml), triphenylphosphine (59.0 g, 0.23 mol) was batchwise added at room temperature. After stirring for 15 min, imidazole (25.5 g, 0.38 mol) was added thereto, and the stirring continued for 15 min. A solution of the alcohol II-1 (24.0 g, 0.15 mol) in dichloromethane (100 ml) was then dropwise added into the above reaction system, and the mixture was stirred at room temperature for 12 h. After the mixture was concentrated, the residue was sufficiently extracted with methyl tert-butyl ether, followed by concentrating the extract. The residue was purified through silica-gel column chromatography eluting with n-hexane/ethyl acetate (10/1, v/v) to afford intermediate III-3 with a yield of 65.6-78.3%.
EXAMPLE 4
[0046]
[0047] To a solution of the alcohol II-1 (25.6 g, 0.16 mol) obtained from the last step in fresh dichloromethane (250 ml), carbon tetrabromide (68.2, 0.21 mol) was added batchwise. A solution of triphenylphosphine (55.0 g, 0.21 mol) in dichloromethane (200 ml) was then charged dropwise into the reaction system for 1 h under ice bath, followed by stirring at room temperature for 12 h. After the mixture was concentrated, the residue was sufficiently extracted with methyl tert-butyl ether, followed by concentrating the extract. The residue was purified through silica-gel column chromatography eluting with n-hexane/ethyl acetate (10/1, v/v) to afford the corresponding intermediate III-4 with a yield of 60.2-73.3%.
[0048] IV. Nucleophilic Substitution Between Adenine and Intermediate III (Illustrated by Compound III-1, which may not be Construed to Restrict the Invention)
[0000]
EXAMPLE 1
[0049] To a solution of adenine (47.0 g, 0.35 mol) and 18-crown-6 (1.2 g, 4.5 mmol) in fresh DMF (250 ml), sodium hydride (60%, 14.0 g, 0.35 mol) was batchwise added at room temperature. After the addition, the mixture was stirred at 60° C. for 2 h. A solution of the compound III-1 (53.4 g, 0.17 mol) obtained from the last step in fresh DMF (50 ml) was dropwise charged into the above mixture at 60° C., and the temperature was kept for 12 h. Under ice bath, the mixture was diluted with water (300 ml), and extracted sufficiently with ethyl acetate. The combined organic phase was washed with saturated saline, dried and concentrated. The resultant residue was purified through silica-gel column chromatography eluting with chloroform/methanol (20:1, v/v, then 10:1, v/v) to afford an intermediate IV-1 with a yield of 29.2-35.3%.
EXAMPLE 2
[0050] To a solution of adenine (47.0 g, 0.35 mol) and 18-crown-6 (1.2 g, 4.5 mmol) in fresh formamide (250 ml), sodium hydride (60%, 14.0 g, 0.35 mol) was batchwise added at room temperature. After the addition, the mixture was stirred at 50° C. for 2 h. A solution of the compound III-1 (53.4 g, 0.17 mol) obtained from the last step in fresh dioxane (50 ml) was dropwise charged into the above mixture at 50° C., and the temperature was kept for 12 h. After the solvent was removed under reduced pressure, the resultant residue was purified through silica-gel column chromatography eluting with chloroform/methanol (20:1, v/v, then 10:1, v/v) to afford the corresponding intermediate IV-1 with a yield of 55.3-59.4%.
EXAMPLE 3
[0051] Adenine (39.2 g, 0.29 mol), intermediate III-1 (44.0 g, 0.14 mol), anhydrous potassium carbonate (60.0 g, 0.44 mol) and 18-crown-6 (1.0 g, 3.8 mmol) were suspended in fresh DMF (220 ml), and the mixture was stirred at 50° C. for 12 h. After the solvent was removed under reduced pressure, the resultant residue was directly purified through silica-gel column chromatography eluting with chloroform/methanol (20:1, v/v, then 10:1, v/v) to afford the intermediate IV-1 with a yield of 44.3-55.0%.
EXAMPLE 4
[0052] Adenine (39.2 g, 0.29 mol), intermediate III-1 (44.0 g, 0.14 mol), anhydrous potassium carbonate (60.0 g, 0.44 mol) and 18-crown-6 (1.0 g, 3.8 mmol) were suspended in fresh DMF (220 ml), and the mixture was stirred at 50° C. for 12 h. Under ice bath, the mixture was diluted with water (300 ml), and extracted sufficiently with ethyl acetate. The combined organic phase was washed with saturated saline, dried and concentrated. The resultant residue was directly purified through silica-gel column chromatography eluting with chloroform/methanol (20:1, v/v, then 10:1, v/v) to afford the corresponding intermediate IV-1 with a yield of 40.1-51.0%.
[0053] V. Preparation of Intermediate IV-1 through Mitsunobu Reaction (Illustrated by Compound II-1, which may not be Construed to Restrict the Invention)
[0000]
EXAMPLE
[0054] To a solution of adenine (7.8 g, 0.058 mol), intermediate II-1 (4.5 g, 0.028 mol) and triphenylphosphine (8.8 g, 0.034 mol) in fresh DMF (50 ml), diethyl azodiformate (DEAD) (5.8 g, 0.034 mol) was charged dropwise at room temperature. After the addition, the mixture was stirred at room temperature for 12 h. Under ice bath, the mixture was diluted with water (50 ml), and extracted sufficiently with ethyl acetate. The combined organic phase was washed with saturated saline, dried and concentrated. The resultant residue was directly purified through silica-gel column chromatography eluting with chloroform/methanol (20:1, v/v, then 10:1, v/v) to afford the intermediate IV-1 with a yield of 38.0-47.2%.
[0055] VI Synthesis of Crude DZ2002 (Illustrated with the case that R 1 ═R 2 =Methyl, which may not be Construed to Restrict the Invention)
[0000]
EXAMPLE 1
[0056] To a solution of the intermediate IV-1 (18.0 g, 0.065 mol) in 540 ml of methanol, a HCl/methanol solution (0.1 mol) was added dropwise for 30 min under stirring and ice bath. After the addition, the ice bath was removed, and the mixture was stirred at room temperature for 5 h. The completeness of the reaction was identified by TLC (chloroform/methanol=10/1, v/v). After the addition of an appropriate amount of silica-gel, the reaction mixture was concentrated under reduced pressure. The obtained solid was transferred to a silica-gel column in a manner of dry sample and eluted with chloroform/methanol (10/v, v/v, then 5:1, v/v). The eluent containing DZ2002 was concentrated to afford the crude DZ2002 as a light yellow solid with a yield of 51.8-72.5%.
EXAMPLE 2
[0057] To a solution of the intermediate IV-1 (18.0 g, 0.065 mol) in 540 ml of methanol, solid sodium methoxide (7 g, 0.13 mol) was added batchwise for 30 min under stirring and ice bath. After the addition, the ice bath was removed, and the mixture was stirred at room temperature for 3 h. The completeness of the reaction was identified by TLC (chloroform/methanol=10/1, v/v) and the post-treatment was the same as that of the above Example 1. Yield: 40.2-68.7%.
[0058] VII. Recrystallization of the Crude DZ2002
EXAMPLE 1
[0059] The above crude DZ2002 (10 g) was suspended in anhydrous methanol (50 ml) and heated to dissolve completely, followed by addition of activated carbon (1 g). After the heating and stirring continued for 30 min, the mixture was hot-filtered and the solid was washed with a small amount of hot methanol. The obtained filtrate was concentrated under reduced pressure, and a solid was precipitated gradually during the concentration. When the volume of methanol was reduced to ⅓ of the original, anhydrous ethyl ether (50 ml) was charged into the concentrate. After stirred at room temperature for 30 min, the mixture was filtered, and the obtained solid was washed with anhydrous ethyl ether and dried in vacuo to afford a nearly white crystal (8.2 g). 1 HNMR(DMSO-d 6 ): 1.97-2.09(1H, m), 2.17-2.26(1H, m), 3.57(3H, s), 3.96-4.03(1H, m), 4.20-4.25(2H, t), 5.68-5.70(1H, d), 7.16(2H, s), 8.05(1H, s), 8.12(1H, s). LC purity: no less than 99.5%; Single impurity: no more than 0.2%; Specific rotation: +18°-+20° ; Melting point: 162-164° C.
EXAMPLE 2
[0060] The above crude DZ2002 (10 g) was suspended in a methanol/water solution (50%, v/v)(50 ml) and heated to dissolve completely, followed by addition of activated carbon (1 g). After the heating and stirring continued for 30 min, the mixture was hot-filtered and the solid was washed with a small amount of hot methanol. The obtained filtrate was disposed in a refrigerator at 4° C., and stored overnight after a small amount of DZ2002 seeds were added therein. After the mixture was filtered, the obtained solid was washed with a small amount of cold anhydrous methanol and dried in vacuo to afford a nearly white crystal (7.3 g) with specific parameters in accordance with the above.
EXAMPLE 3
[0061] The above crude DZ2002 (10 g) was suspended in a water (50 m1) and heated to dissolve completely, followed by addition of activated carbon (1 g). After the heating and stirring continued for 30 min, the mixture was hot-filtered and the solid was washed with a small amount of hot water. The obtained filtrate was disposed in a refrigerator at 4° C., and stored overnight after a small amount of DZ2002 seeds were added therein. After the mixture was filtered, the obtained solid was washed with a small amount of cold water and dried in vacuo to afford a nearly white crystal (6.8 g) with specific parameters in accordance with the above.
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The present invention discloses a novel method for preparing and purifying 4-(6-Amino-purin-9-yl)-2(S)-hydroxy-butyric acid methyl ester. The preparation started from cheap and easily available L-malic acid, which was transformed to intermediate I after simultaneous protection of the groups of 1-carboxyl and 2-hydroxyl. The intermediate I was selectively reduced to intermediate alcohol II, whose hydroxyl group was further transformed to an easily leaving group to afford intermediate III. The intermediate III was nucleophilically substituted with adenine to afford intermediate IV. The intermediate IV was deprotected and methyl-esterified simultaneously in methanol in the presence of an acid or a base to afford crude 4-(6-Amino-purin-9-yl)-2(S)-hydroxy-butyric acid methyl ester, which was purified by recrystallization to afford the purified product. Comparing with the prior preparation methods, the present method has advantages in low cost, mild conditions, high retention of the chiral center during the reaction, high productivity, great improvement in the quality and yield of the product and great decrease in cost, and thus is suitable for the production on a large scale.
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FIELD OF THE INVENTION
This invention generally relates to duplicating machines and, more particularly, to ink fountain assemblies for use in duplicating machines.
BACKGROUND OF THE INVENTION
Printing machines, such as rotary offset lithographic duplicating machines, rotary printing presses, or the like, normally include a printing couple which includes a number of cylinders and/or rollers such as impression cylinders, master cylinders, blanket cylinders, ductor rollers, regulator rollers, and the like. An ink fountain is disposed on the machine, usually at the rear thereof, for feeding ink to the various rollers of the printing couple which transfers images to copy sheets.
Conventional ink fountain assemblies normally take the form of a fountain trough defined by an elongated blade extending along one side and an ink fountain roller extending along the opposite side of the trough. The ink fountain roller transfers the ink to the other rollers of the printing couple. The blade is adjustable by a plurality of thumb screws spaced longitudinally of the blade to vary a "gap" between an edge of the blade and the ink fountain roller in order to maintain consistency in the amount of ink applied to the roller uniformly along the length of the roller and to adjust the ink fountain "setting" for any given printing job. The thumb screws are individually rotatably adjustable, i.e. independently of each other, and usually have an inner distal end which moves against the underside of the blade to move the blade toward and away from the roller and, thereby, vary the gap.
The normal procedure of setting an ink fountain, i.e., the flow of ink through the gap, is a trial and error method. Specifically, a job copy is inspected and all of the adjustable thumb screws are set by sheer estimation. A number of trial copies are run on the machine and the results are observed. The thumb screws are adjusted for too little or too much ink being fed through the gap in the area of each screw. Another trial run is performed, and the procedure is repeated until an acceptable copy is made, taking into consideration proper ink coverage, color density, resolution, ink film thickness and ink drying time. Densitometers or other instruments may be used during the procedure. In actual practice, a very experienced machine operator becomes very proficient with these procedures. However, less experienced operators cause cost effectiveness problems, and beginner or trainee operators often have extraordinary problems in attaining acceptable copies.
The above scenario results in further inefficiency problems, even with an experienced machine operator, because of the inability of efficiently duplicating a precise ink fountain "setting" once the setting is changed either intentionally or inadvertently. For instance, a printing run or job of 10,000 sheets may be on order. Once the job is finished, another job is started, with the thumb screws adjusted to a completely different fountain setting. Thereafter, whether a day later or months later, if an order for the previous job must be repeated, there is no way to duplicate the paper ink fountain setting without again following the usual trial and error procedure. Such periodic or repeat orders are quite common in the print shop business.
In addition, should any one or more of the thumb screws be rotated out of their proper position of adjustment, either accidentally or through tampering, there is no way to detect that the thumb screws are out of adjustment.
The above problems easily can be visualized when considering that the thumb screws simply have knurled heads for manually adjustably rotating the screws. In some instances the screws have diametral slots in the outer face of the heads for receiving a tool, such as a screwdriver, for rotatably adjusting the screws. In any event, one thumb screw usually is rotated, in its proper position of adjustment, to a different angle than its adjacent or other screws. Therefore, even if the heads have a tool-receiving slot, the slots may appear in all kinds of angular orientations. There is no way to repeat at a later time all of the respective angular positions of the screws, and there is no way to detect whether or not any of the screws have been unintentionally rotated away from the positions in which they were initially rotated to proper adjustment.
There are various known, sophisticated scanning mechanisms used in high priced presses for setting ink fountain screws by servo-motors or similar devices and which can be repeatable. The mechanisms are computerized and feed back signals from the scanners to the ink fountain screws. However, such mechanisms can cost almost as much as an entire print shop machine.
This invention is directed to solving the above problems by providing a unique system including a visual calibrated system of setting an ink fountain and including indicating means removably mountable on each thumb screw for facilitating repeat setting of the ink fountain and for detecting any movement of the thumb screws away from their proper positions of adjustment.
SUMMARY OF THE INVENTION
An object, therefore, of the invention is to provide a novel system for setting and calibrating the thumb screws of an ink fountain assembly.
In the exemplary embodiment of the invention, an ink fountain assembly is disclosed for use in duplicating machines, such as rotary offset lithographic machines. The ink fountain includes a fountain trough having an elongated blade and an ink fountain roller defining a gap therebetween through which ink is fed to other rollers of the machine. A plurality of independently adjustable thumbscrews are provided for varying the gap and the ink flow therethrough. Generally, positional indicating means are readily mountable on the thumb screws once the thumb screws are in proper positions of adjustment for visually calibrating the ink fountain setting.
As disclosed herein, the positional indicating means are in the form of a plurality of caps positionable over the thumb screws, as by a press fit. The caps can be fit over the thumb screws in any angular position relative thereto. The invention contemplates that the caps have indicating means thereon. A calibration plate is positioned behind the caps with a calibration dial in the form of a graduated scale about each cap. Once all of the thumb screws are set to attain an even flow of ink through the gap along the entire ink fountain blade, which can be termed a "base line" setting, the caps then are positioned over the thumb screws with all the indicators in a common direction. The caps then are used to further adjust the thumb screws to a particular fountain setting for a particular job. Once set, a job record can be made for that job by recording the positions of the indicators on the caps in relation to their respective calibrations on the dials. Any job easily can be precisely repeated, regardless of subsequent ink fountain settings, by referring to the job record.
Other features of the invention include the provision of means for locking the caps to the respective thumb screws, as well as means for preventing rotation of the thumb screws more than 360 degrees after the caps are positioned thereon. These features can be provided by a common means in the form of a set screw which projects radially outwardly from the side of each cap. The set screws lock the caps to the thumb screws and, in combination with abutment means on the ink fountain assembly, provide stop means to prevent excessive rotation of the thumb screws and caps.
Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of this invention which are believed to be novel are set forth with particularity in the appended claims. The invention, together with its objects and the advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the figures and in which:
FIG. 1 is a perspective view of a typical ink fountain assembly but incorporating the calibrated adjusting system of the invention;
FIG. 2 is a fragmented front elevational view, on an enlarged scale, of the assembly of FIG. 1;
FIG. 3 is a vertical section, on an enlarged scale, taken generally along line 3--3 of FIG. 2; and
FIG. 4 is a vertical section taken generally along the line 4--4 of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in greater detail, and first to FIG. 1, a typical ink fountain assembly, generally designated 10, is shown to include a fountain trough, generally designated 12, defined by an elongated blade 14 extending along one side of the trough and an ink fountain roller 16 extending along the other side of the trough. The blade and roller are mounted on a frame 18 which includes a pair of side plate portions 20. As is conventional, the blade is secured to the frame by a plurality of threaded fasteners (not shown). One form of ink fountain assembly is shown in U.S. Pat. No. 4,553,477 to Witczak, dated Nov. 19, 1985 and assigned to the assignee of this invention, and which is incorporated herein by reference.
FIG. 2 shows a section through the ink fountain assembly to better illustrate that an edge 22 of blade 14 defines a gap, generally designated 24, between the blade and ink fountain roller 16 through which ink is fed onto the surface of roller 16 which transfers the ink to other rollers of the printing or duplicating machine which eventually transfer images to copy sheets. As is known, a plurality of thumb screws 26 are threaded through frame 18, with distal ends 28 of the thumb screws angularly abutting against the underside of blade 14. By adjusting the thumb screws, gap 24 between blade 14 and roller 16 can be varied along the length of the roller to maintain a consistent thickness of ink applied to the roller uniformly along the blade.
As is conventional, and still referring to FIG. 2, each thumb screw 36 has an enlarged knurled head 30 exposed at the front of frame 18 for grasping and rotating by an operator of the machine, as between his thumb and index finger. Although only one thumb screw is shown in FIG. 2, as is known, the thumb screws are spaced longitudinally along the underside of blade 14 lengthwise of the ink fountain assembly. Often, the thumb screws also may have a slot in the outer face thereof (not shown in the drawing) for receiving a tool, such as a screwdriver, to facilitate rotatably adjusting the thumb screws.
A problem with ink fountain assemblies as described above is that once the thumb screws all are rotatably adjusted to proper positions of adjustment to establish the desired gap 24 lengthwise along blade 14 and roller 16 for any given job as described above, that ink fountain "setting" is unique to that job and cannot later be repeated without completely going through the setting or adjusting procedure again. In addition, there is no way for the operator to detect whether or not any one or more of the thumb screws have been rotated subsequent to proper adjustment. This easily can be understood when it is recognized that the thumb screws simply have a knurled head on the outer distal end thereof. Even if the thumb screws have a diametral slot for receiving a tool, the slots are in a myriad of angular orientations depending upon their proper individual adjustable setting. Any improper rotation of any screw will give no indication whatsoever. Generally, this invention is directed to solving these problems by providing a novel visual calibration system including indicating means readily mountable on each thumb screw and an associated calibration dial for each indicating means.
More particularly, in the exemplary embodiment of the invention, a plurality of caps 34 have inner socket portions 36 (FIG. 2) for press fitting over heads 30 of thumb screws 26. Sockets 36 are cylindrical in shape for mating with the exterior round shape of heads 30 so that the caps can be readily positioned onto the heads in any angular position relative thereto. Each cap has a narrow outer distal end portion 38 for grasping between the thumb and index finger of an operator. As seen in FIG. 2, means in the form of set screws 40 are threaded through sockets 38 of caps 34 for locking the caps to heads 30 of the thumb screws.
An elongated face plate 42 is clamped to frame 18, as by screws or bolts 44 (FIG. 3). As seen in FIG. 2, face plate 42 extends upwardly beyond set screws 40 a given distance. This distance can be designed to be greater than the conventional Allen wrench which must be used in order to rotate the set screws and change the relative positions between the caps and their respective set screws. It also can be seen in FIG. 2 that face plate 42 has apertures 46 which are large enough to fit over caps 34 but smaller than socket portions 36 of the caps so that the caps cannot be removed without removing the face plate. For purposes described hereinafter, an abutment/clamp plate 47 is secured to the back side of face plate 42 by spring-loaded bolt 49. The clamp plate extends downwardly from the lower edge of the face plate to define an exposed lip, as seen in FIGS. 1 and 3.
FIG. 1 shows that each cap 34 has a straight line indicator 48 on the side thereof, and FIGS. 1 and 3, show that face plate 42 has numerical calibrations 50 imprinted on the front face of the plate. Each calibration 50 is in the form of a dial, particularly a graduated numerical scale over a 180° arc from numbers "8" down to "0". Of course, other scales or calibrations can be used.
With the system of the invention, the ink fountain setting procedure is to first adjust the ink fountain screws 26 so that there is an even flow of ink being fed to the ink rollers and to obtain proper print density of ink. The latter can be determined by using a color chart and a densitometer. Preferably, the color density should be within ±0.04 of the digital densitometer reading throughout the copy area. A sufficient number of copy sheets should be run to insure that the ink and moisture have leveled out and the ink density is constant. The operator now has attained a "base line setting" for the ink fountain.
Once the base line setting is attained, face plate 42 is positioned over knurled heads 30 of the thumb screws and fixed in place by bolts 44. Caps 34 are positioned over heads 30 with their indicator lines 48 in line with the respective numerals "8" on the graduated scales, as shown in FIG. 1, and are locked in those positions by set screws 40. The system now has a base line setting for the ink fountain, and a visual, calibrated, quick reference of this ink flow setting is provided for all types of copy layouts and/or jobs. FIG. 1 shows all of the caps in a common horizontal line representing the base line setting.
The operator now takes his job. copy and clamps it between face plate 42 and clamp plate 47 so that the copy is centered on the ink fountain and hangs downwardly below the caps 34. Springs 52 on the spring-loaded bolts 49 yield to allow clamp plate 47 to "open" away (rearwardly) from face plate 42 for insertion of the copy, and the springs are effective to clamp the copy between the plates.
The operator now can adjust the thumb screws by grasping and rotating caps 34 away from the "8" position, with the "0" position completely cutting off ink flow in that area of the fountain blade corresponding to the respective thumb screw, in order to set the ink fountain to print according to the copy, following normal procedures.
FIG. 3 shows the caps in different adjusted angular positions. The two left-hand caps have been rotated a full 180 degrees so that their indicator lines 48 (FIG. 1) are on "0" of the graduated scales. This may be to cut off ink flow at the left-hand margin of the sheet, for instance. Once set, the operator has a visual, complete calibration of the proper ink fountain setting for that job. Job record sheets can be provided and the positions of all the set screws relative to their graduated dials can be recorded for future, repeat performance of the same job.
Lastly, a further feature of the invention is the provision of means for preventing rotation of the thumb screws more than 360 degrees after the caps are positioned thereon. In other words, it would do little good to place caps over the thumb screws if the caps could be rotated a full 360 degrees, i.e., to bring indicator lines 48 back to their same positions which would give a false indication of proper adjustment. This means is provided by clamp plate 48 (FIGS. 2 and 4) also comprising an abutment plate. This abutment plate is in the path of rotational movement of set screws 40 such that a stop means is provided as shown in FIG. 4. Should any cap or thumb screw be rotated away from its proper position of adjustment, as indicated by double-headed circular arrow "A" in FIG. 4, its respective set screw 40 will engage abutment plate 48 as a stop means.
It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.
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An ink fountain assembly for use in duplicating machines, such as rotary offset lithographic machines. A fountain trough is defined by an elongated blade extending along one side of the trough and an ink fountain roller extending along the other side of the trough defining a gap therebetween. A plurality of independently adjustable thumb screws are provided for varying the gap and the ink flow therethrough. A plurality of caps are positionable over the thumb screws in any angular position relative thereto. The caps have indicators to facilitate calibrating the positions of adjustment of the thumb screws.
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BACKGROUND
[0001] The invention is related to the field of remotely hosted computing, commonly referred to in the information technology industry as “cloud computing”.
SUMMARY
[0002] A primary cloud computing system (CCS) provides a cloud-hosted desktop, in some embodiments employing software known by the name Citrix XenApp™ or Citrix XenDesktop™ A cloud-hosted desktop typically includes off-the-shelf application programs like Microsoft Office®, Adobe Reader® etc. However, there may be other application programs that are not offered by the primary CCS. There may be a variety of reasons as follows:
[0003] 1. The application program may be a specialized line-of-business application program that a service provider operating the primary CCS doesn't want to provide (e.g., it may be very specialized and used by few customers).
[0004] 2. The customer wants to host the application program in their own datacenter for some reason, such as security/compliance.
[0005] 3. The application program is only available from a separate source, such as an organization that developed the application program and offers it as a service. In this case, the application may be delivered by a separate CCS (may be referred to as a secondary CCS).
[0006] Thus in some situations, a desktop is being delivered from one cloud, and application programs are being delivered from other clouds (i.e., an in-premise cloud, or a cloud operated by an Internet service provider (ISV cloud). When the user is accessing the cloud-hosted desktop, the user needs a way to access such separately delivered (or “separately hosted”) application programs, preferably in a manner seamlessly integrated into the cloud-hosted desktop. This way the user can access a wider variety of computing resources from one hosted desktop provided by a primary CCS, even resources that are made available to the user by a different computing system such as a secondary CCS. The user is not burdened with maintaining and switching between different interfaces to different systems to access desired resources.
[0007] In general, the present disclosure is directed to techniques for integrating application programs being delivered from one or more cloud computing systems (“clouds” or “CCSs”) into a desktop being delivered/hosted by another cloud. Two separate aspects are described. One is the integration of controls for directly launching a separately hosted application program from a desktop hosted by a primary CCS, such as by selection of an entry in a start menu or activation of a “shortcut” icon that points to the application program. Another aspect is the desire to indirectly launch such a separately hosted application program based on a user opening or accessing content (e.g. data file) that is specifically associated with the separately hosted application program but residing more locally, such as in the hosted desktop. In this aspect, the challenge includes seamlessly redirecting the content to the other cloud without requiring any direct network connectivity between the clouds. As an example, a user may receive a file as an attachment in an e-mail program running in the cloud-hosted desktop, while the application program needed to open the content is hosted in a separate cloud. This kind of task is enabled by the presently disclosed techniques.
[0008] Generally, the disclosed techniques provide a way to integrate application programs from multiple clouds (public or private) without certain performance and other issues associated with known approaches and providing a seamless user experience.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The foregoing and other objects, features and advantages will be apparent from the following description of particular embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of various embodiments of the invention.
[0010] FIG. 1 is a block diagram of a heterogeneous cloud computing system having separate cloud computing systems providing application services to a client computer;
[0011] FIG. 2 is a block diagram showing more detail of components of the cloud computing system;
[0012] FIGS. 3 and 4 are depictions of window-type graphical user interface displays;
[0013] FIGS. 5-8 are flow diagrams depicting system functionality.
DETAILED DESCRIPTION
[0014] The entire disclosure of U.S. Provisional Application 61/551,390 filed Oct. 25, 2011 is incorporated by reference herein.
[0015] FIG. 1 shows a computing environment including a primary cloud computing system (primary CCS) 10 and a secondary cloud computing system (secondary CCS) 12 , along with a client computer (CLT) 14 operating in an organization computing system 16 . As shown, the primary CCS 10 has a functional connection 13 to the client computer 14 over which the primary CCS 10 provides computing services including a hosted desktop user interface (“hosted desktop”) and (optionally) one or more primary-hosted application programs (“apps”) to the client computer 14 . The secondary CCS 12 has a functional connection 15 to the client computer 14 over which it provides computing services including one or more secondary-hosted application programs to the client computer 14 . The application programs from the primary CCS 10 and secondary CCS 12 are provided as application services, meaning that they are executed at the respective system 10 , 12 on behalf of and under control of the client computer 14 , typically including user input/output via one or more windows or similar user interfaces displayed at the client computer 14 .
[0016] The primary CCS 10 , secondary CCS 12 , and organization computing system 14 are all generally realized as networked computer systems having computers and other hardware resources interconnected by computer network connections. In a typical case the computers include so-called “server” computers each having memory, computer program instruction processing circuitry, and input/output circuitry for interfacing the server computer to one or more networks, to local storage devices, and to other peripheral devices or systems. Other hardware resources can include network-attached storage systems and other specialized systems and components. The computers execute computer program instructions that cause the computers to perform methods or functions as generally known in the art. The description herein is primarily at a functional level, and it will be understood that the functions are realized by the computers and other hardware resources executing corresponding sets of computer instructions referred to as “programs”, “routines”, etc. as generally known.
[0017] The organization computing system 16 may be organized in a conventional manner to include both user-associated “client” computers as well as sets of server computers, which may be physically located in one or more datacenters for example. The primary and secondary cloud computing systems 10 , 12 are distinguished as such by virtue of their ability to provide computing services to external clients (such as client 14 ) without exposing underlying low-level details about the specific hardware or software structure and organization. A client 14 can be configured with minimal information to enable it to obtain a desired service from either the primary or secondary CCS 10 , 12 , leaving the details of much of the underlying structure and functionality to software tailored for the purpose. As an example, from a user perspective a hosted desktop may be accessed by clicking on an icon, and it appears and functions in the same way as a local desktop presented by a user's personal computer (PC), for example. The user relies on hosting and virtualization software to provide the underlying functions and interactions that achieve this operation.
[0018] The term “desktop” herein refers to functionality typically provided by a personal computer operating system such as Windows®, Unix® or Mac OS®, including a graphical user interface employing the “desktop” paradigm in which items (icons, windows) are arrayed on a background. Typically the desktop interface also includes system-level control regions such as task bars, docks, menu bars, etc., with these regions including user-activatable controls such as icons, menus, etc. A “hosted desktop” is a desktop provided to a client computer 14 by another computer, typically a server that is said to “host” the desktop. This can be seen as a type of virtual PC executing in the server computer and presenting its graphical user interface to a separate real PC or other client machine. Known software of this type is sold under the names XenApp™ and XenDesktop™ by Citrix Systems, Inc.
[0019] The terms “primary” and “secondary” with respect to the CCSs 10 , 12 are used as convenient labels for a specific purpose, which is to identify the primary CCS 10 as that which provides the hosted desktop to the client computer 14 . No other meanings are intended. This distinction is necessary for the description of the system and its functionality presented below. Additionally, while in the description below the secondary CCS 12 provides a “separately hosted” application program that is to be integrated into the hosted desktop, in general the separately hosted application program need not be provided by a separate CCS or even by a cloudlike system. For example, it may be provided by the organization computing system 16 , presumably in a server or other computer separate from the client computer 14 .
[0020] FIG. 2 shows portions of the computing systems 10 , 12 and 16 and their interconnection in pertinent detail. The primary CCS 10 includes a desktop hosting program shown as a hosted desktop 20 , and optionally one or more primary-hosted application programs (apps) 22 . Also included is a desktop delivery program 23 that “delivers” the functionality of the primary-hosted application program(s) 22 and hosted desktop 20 to the client computer 14 as though they were being executed locally by the client computer 14 . One example of a desktop delivery program 23 is software known as Citrix XenApp™. The primary CCS 10 has a hosted desktop interface 24 to the client computer 14 over which the hosted desktop functionality is provided. The primary CCS 10 also includes a launcher 26 that provides functions of starting execution of (“launching”) application programs. Both the hosted desktop 20 and launcher 26 are connected to a control channel 28 to which an agent 30 of the client computer 14 is also connected. The agent 30 also communicates with the desktop delivery program 23 and application delivery program 34 by other connections not shown in FIG. 2 .
[0021] The secondary CCS 12 includes one or more secondary-hosted application programs 32 and a hosted application delivery program 34 that delivers the functionality of the secondary-hosted application program(s) 32 to the client computer 14 as though they were being executed locally by the client computer 14 . One example of a hosted application delivery program 34 is the above-referenced Citrix XenApp™ software. A secondary-hosted application program 32 is also referred to as a “separately” hosted application program herein, referring to the fact that it is hosted outside the hosted desktop 20 .
[0022] The client computer 14 includes hosted-desktop client software (Desktop Client) 36 connected to the application delivery program 34 of the secondary CCS 12 as well as to the hosted desktop 20 via the hosted desktop interface 24 . The desktop client 36 includes functionality referred to as “local access” that enables local client resources to be accessible in the hosted desktop 20 . In one embodiment this local access functionality may be in the form of so-called “reverse seamless” or “virtual desktop extender” software. The client computer 14 may also include locally installed applications (apps) 38 . The client computer also includes some form of storage for data referred to as “application program metadata” (App Prog M-D) 40 that contains information about application programs used by the client computer, as described in more detail below. The application program metadata 40 is accessible by the desktop client 36 as well as the agent 30 .
[0023] FIGS. 3 and 4 depict computer screen displays for two distinct type of client computers 14 . FIG. 3 is a display for a so-called “fat” or “thick” client, which is a client computer 14 having substantial computing resources (memory, processing capability, etc.) and typically a complex, robust operating system capable of supporting a variety of intensive computing tasks. A good example of a fat client computer 14 is a personal computer. FIG. 4 is a display for a so-called “thin” client, which is a client computer 14 usually having more limited computing resources used primarily to provide a graphical user interface to access external computing resources (such as those of a separate server computer). The graphical user interface may be provided, for example, in the form of one or more browser-type windows that display hypertext pages served by external server computers. More detail is provided below.
[0024] Referring to FIG. 3 , the fat client computer 14 provides a user interface in the form of a local desktop 42 having a background and control areas as described above. In particular, FIG. 3 shows a start menu 44 included in the local desktop 42 . The start menu 44 presents a listing of one or more application programs (shown as APP 1 and APP 2 ) that are installed on the client computer 14 (i.e., locally installed applications 38 of FIG. 2 ) or otherwise executable by the client computer via the local desktop 42 . In the present context, the start menu 44 includes one or more entries for the secondary-hosted application program(s) 32 hosted by the secondary CCS 12 . This functionality of integrating application programs of the secondary CCS 12 into the local desktop 42 is provided in part by the application delivery program 34 in concert with the local desktop 42 .
[0025] In the present description, the term “application program metadata” is used to refer to the name, appearance, location and other information about an application program. The entry for an application program in the start menu 44 forms part of the application program metadata for that application program. Also included is underlying information, normally not visible in the user interface, such as the path or location in the file system of the executable image of the application program. Application program metadata may also be included in items referred to as “shortcuts”, which include graphical icons that can be placed on the background of the local desktop 42 . An application program can be executed or “launched” by user selection of the application program name from the start menu 44 and/or user activation of a shortcut icon. It will be appreciated that the start menu 44 s an example of an application-launching interface that is integral to the local desktop 42 .
[0026] Returning to FIG. 3 , also shown is a window (“hosted desktop”) 46 which is the local presentation of the hosted desktop 20 from the primary CCS 10 . Like the local desktop 42 , the hosted desktop 46 has a background and a control area, including its own start menu 48 which is an integral application-launching interface. The items in start menu 48 are those configured in the hosted desktop 20 , which may include for example entries for the primary-hosted application programs 22 . Examples of these items are shown as APP 3 and APP 4 . As shown, the start menu 48 also includes the same entries APP 1 and APP 2 that appear in the local desktop start menu 44 . Thus the user of the client computer 14 has the ability to work entirely within the environment of the hosted desktop 20 (via window 46 ) while also being able to access application programs that are provided from outside that environment. In particular, as described in more detail below, the user is able to access the secondary-hosted application program(s) 32 provided by the secondary CCS 12 . While in FIG. 3 this functionality is shown vis-à-vis the start menus 44 and 48 , it may also be provided using shortcut icons on the respective desktops 42 , 46 or more generally anywhere in an underlying directory or folder structure. Additionally, as described in more detail below, this functionality can be extended to enable a separately-hosted application program to be invoked by opening a data file for which an association with the separately-hosted application program has been established.
[0027] Referring to FIG. 4 , the thin client computer 14 provides a user interface in the form of a window or frame 50 of a browser or similar terminal-like user interface program, where “terminal-like” refers to a primary or exclusive capability for user interface functions (graphical display, user input etc.) on behalf of a separate computer that executes a virtualized computer instance and/or application programs. In particular, FIG. 4 shows a pair of icons or other application-launching controls 52 included in the browser window 50 . In this case, the controls 52 are for one or more application programs (identified as A- 1 and A- 2 ) that are executable by a separate server on behalf of this thin client 14 . Similar to the fat client, the controls 52 include one or more controls for the secondary-hosted application program(s) 32 hosted by the secondary CCS 12 . The functionality of integrating application programs of the secondary CCS 12 into the browser 50 is provided in part by the application delivery program 34 in concert with browser 50 .
[0028] FIG. 4 also shows a window (“hosted desktop”) 54 which is the local presentation of the hosted desktop 20 from the primary CCS 10 . The hosted desktop 54 has a background and a control area, including its own start menu 56 . The items in start menu 56 are those configured in the hosted desktop 20 , which may include for example entries for the primary-hosted application programs 22 . Examples of these items are shown as APP 3 and APP 4 . As shown, the start menu 56 also includes entries APP 1 and APP 2 which correspond to the controls 52 for A- 1 and A- 2 that appear in the browser window 50 . Thus the user of the client computer 14 has the ability to work entirely within the environment of the hosted desktop 20 (via window 54 ) while also being able to access application programs that are provided from outside that environment. In particular, as described in more detail below, the user is able to access the secondary-hosted application program(s) 32 provided by the secondary CCS 12 . Additionally, as described in more detail below, this functionality can be extended to enable a separately-hosted application program to be invoked by opening a data file for which an association with the separately-hosted application program has been established.
[0029] FIG. 5 is a flow chart describing a first aspect of operation of the system of FIGS. 1-2 , in particular for the case of a fat client as described with reference to FIG. 3 . At 60 , the secondary CCS 12 is configured to deliver a secondary-hosted application program 32 to the client computer, meaning that the application program 32 is executed at the secondary CCS 12 on behalf of and under the control of the client computer 14 . As described above, this configuration includes use of the application delivery program 34 .
[0030] For description purposes, an example will be referred to in which the secondary-hosted application program 32 is a specialized program such as AutoCad®, a well known design automation program. It is assumed that the user of the client computer 14 has need for the hosted desktop 20 from the primary CCS 10 , but also has need to run an application program such as AutoCad that is not available in the primary CCS 10 . As mentioned above, one major purpose of the presently disclosed technique is to enable such a user to work within his/her hosted desktop environment and still be able to access such separately-hosted application programs (i.e., those hosted or otherwise provided outside of the hosted desktop environment of the primary CCS 10 ).
[0031] Referring again to FIG. 5 , at 62 the agent 30 at the client computer 14 collects or “aggregates” information about application programs available to the client computer 14 and uses the information to populate the start menu 44 of the fat client. In one embodiment, the agent 30 may be realized using software known by the name Citrix Receiver™, which has a formal user interface and employs a user login to associate cloud computing resources with the user of the client computer 14 . In general, the agent 30 is in communication with some or all cloud computing systems used by the client computer 14 and can obtain information about the application programs that are hosted thereby. These include the delivery programs 23 , 34 of the primary CCS 10 and secondary CCS 12 respectively. Aggregation of the application program information may be by a variety of methods including a web interface or installed services. The application information, which forms part of application program metadata as discussed above, is used to create entries for the Start Menu, shortcut icons, etc. in the user's local desktop 42 . It should be noted that the user's local desktop 42 will also include a control for launching the hosted desktop 20 at the primary CCS 10 .
[0032] At 64 there is a startup phase of operation begun when the user launches the hosted desktop 20 . Once the hosted desktop 20 is launched, as part of the startup process, the hosted desktop 20 sends a message over the control channel 28 to fetch the application program metadata as aggregated by the agent 30 . Upon receiving the application program metadata, the hosted desktop 20 uses it to populate the hosted desktop window 46 with corresponding controls, such as entries in the hosted desktop start menu 48 , shortcuts, etc. These items may appear along with information identifying where the programs are hosted, e.g., “AutoCad on secondary CCS”, to help keep the user oriented.
[0033] At 66 is a use phase, which may start when a user at the client computer 14 activates a control for the application program (such as selecting a start menu entry or clicking on a shortcut icon on the hosted desktop 20 ). When this occurs, the hosted desktop 20 invokes the launcher 26 with information (such as a path specification) for the separately hosted application program 32 , and the launcher 26 sends a command to the client computer 14 over the control channel 28 instructing the agent 30 to launch the application program from the client computer 14 . The agent 30 does so, in communication with both the desktop client 36 and the application delivery program 34 of the secondary CCS 12 . It should be noted that the application program may be delivered by the secondary CCS 12 in either a streamed or hosted manner.
[0034] At 68 , the user interface functions of the application program are provided in the hosted desktop window 46 . For example, if the application program generates a window or accepts user input, the window will appear in the hosted desktop window 46 and input will be accepted from an input device (keyboard, mouse) when that window has the input device focus. This functionality is provided by the local access functionality of the desktop client 36 in conjunction with the hosted desktop 20 .
[0035] Referring back to the aggregating of application programs at 62 , this activity may be performed on the basis of user-subscribed applications (potentially using a “self-service” plug-in module on the client computer 14 enabling a user to obtain application programs via an online service) or system-delivered applications (potentially using an administratively controlled application program delivery system).
[0036] FIG. 6 is a flow chart describing the same aspect of operation as above for the case of a thin client such as described with reference to FIG. 4 . In this case, the functions at 70 , 74 and 76 are similar to their respective fat-client counterparts 60 , 66 and 68 of FIG. 5 . At 72 is the startup phase, which differs in a couple of respects from the combination of functions at 62 and 64 of FIG. 5 . Specifically, at 72 the client computer 14 first initializes into its terminal-like interface represented by browser window 50 , for example ( FIG. 4 ). At this point the user may see a hypertext page provided by a web interface server, which may be a login page for example Once the user logs in, the user sees controls for application programs 32 and the hosted desktop 20 in the browser window 50 . The user then launches the hosted desktop 20 . As part of its startup process, the hosted desktop 20 sends one or more messages over the control channel 28 to cause the agent 30 to obtain and record the application metadata for the application programs available to the client computer 14 , including the secondary-hosted application program(s) 32 . In the case that a program such as Citrix Receiver is being used, the messages may include a command to launch a Receiver logon dialog on the thin client, where this logon dialog appears integrated in the hosted desktop window 46 using the local access functionality. After the logon is completed, Receiver enumerates the application programs available to the client computer 14 including the secondary-hosted application programs 32 . The application metadata for the enumerated application program is stored in a data file, such as an XML or similar hypertext file, in the file system of the client computer 14 . For application programs made available using a delivery service as described above, it may be necessary for Receiver to first authenticate itself to the delivery service in order to obtain information from the delivery service.
[0037] Continuing with the functions at 72 , after a pre-set waiting period (e.g., 1-2 seconds), the hosted desktop 20 sends a command over the control channel 28 to retrieve the contents of the data file (e.g., XML file) in which the application metadata is stored. The retrieved contents are used to populate the start menu 56 of the hosted desktop 54 . It may be desirable to include a retry or polling mechanism to accommodate a case in which the preceding enumeration takes longer than the waiting period.
[0038] Upon completion of the functions at 72 the system is ready for the use phase of 74 and 76 , which as indicated above are similar to their respective counterparts 66 and 68 in the fat-client process of FIG. 5 .
[0039] FIGS. 7 and 8 illustrate another aspect of integrating a separately provided application program (e.g., secondary-provided application program 32 ) into a hosted desktop 20 , namely the ability to launch the separately provided application program when a data file having a file type associated with the application program is opened. Referring to the above example of AutoCad®, this application generates drawing files that have a file extension of DWG (e.g., system.dwg). An operating system (e.g., Windows®) typically maintains an association, referred to herein as a “file type association” or FTA, between a file type as indicated by its file extension and the application program that operates on files of that type. Thus in a Windows environment, for example, an FTA may be established between the file type DWG and the application program AutoCAD®, so that when a file of that type is opened the system automatically launches AutoCAD with the name and location of the file as a parameter to enable AutoCAD to open the file immediately upon being launched. As mentioned above, this functionality becomes complicated in the heterogeneous cloud computing environment such as depicted in FIG. 1 , because the application to be launched (e.g., AutoCAD) may be provided by the secondary CCS 12 while the file is located elsewhere, such as in the hosted desktop 20 .
[0040] FIGS. 7 and 8 depict the function of FTA-based application launching for a fat client and thin client respectively. The differences between the two cases are similar or analogous to the differences between FIGS. 5 and 6 . It should be noted that FIGS. 7 and 8 include the functionality of FIGS. 5 and 6 respectively and add in additional functions for the FTA-based application launching.
[0041] Referring to FIG. 7 , the functions at 80 and 88 are similar to their counterparts at 60 and 68 respectively in FIG. 5 . At 82 the agent 30 performs the same aggregation as at 62 in FIG. 5 , and also fetches existing FTAs that are configured in the secondary CCS 12 and updates the registry of the client computer 14 to record which hosted application program should be used for a specific file type. It is assumed that there is such a specific file type for one or more of the secondary-hosted application programs 32 , such as in the above AutoCAD example. The recording is made in the form of a command line that will be used when a file of a particular type is open. The following is an example of a command line that might be used in association with a file of type DWG (i.e., an AutoCAD file):
[0000]
“C:\Program Files (x86)\Citrix\ICA Client\Agent.exe” /qlaunch
“XenApp6 :AutoCAD” /param:“\\Client\%1”
[0042] The above command line includes a path on the client computer 14 to the agent 30 with an instruction “qlaunch” to perform an application launch function, with the application to be launched identified as AutoCAD on a server farm identified as XenApp6 (in this example located in the secondary CCS 12 ). The agent 30 is also to be invoked with a parameter identified as \\Client\% 1, which refers to a location on the client computer 14 that will be specified at call time (passed in as the value % 1). The use of this command line is described below.
[0043] At 84 , the user launches the hosted desktop 20 . Once the desktop is launched, as part of the startup process, the hosted desktop 20 sends a message over the control channel 28 to fetch the application metadata and uses this to populate the start menu 48 of the hosted desktop window 46 as described above with reference to step 64 of FIG. 5 . As part of this exchange, the hosted desktop 20 also receives details about the file extensions (.cad, .pptx, etc.) that have been configured to be launched with the application programs for which it has obtained the application metadata. The extension information is determined by scanning the registry on the client computer 14 . These details include the recorded command lines as described above. The hosted desktop 20 uses this information to create FTA-like registry entries in the registry of the hosted desktop 20 . In particular, each entry associates a file type extension with a command line for invoking a “handler” routine, which in the present description corresponds to the launcher 26 ( FIG. 2 ). An example of such a command line for a file type of DWG (AutoCAD file) is as follows:
[0000]
″C:\Program Files (x86)\Citrix\Launcher.exe” ″C:\Program
Files (x86)\Citrix\ICA Client\Agent.exe″ /qlaunch
″XenApp6:AutoCAD″ /param:″\\Client\%1″
[0044] This command line includes the above command line for the agent 30 (referred to below as an “inner” command line) preceded by a specification of the path to the launcher 26 in the primary CCS 10 . It indicates that when a file of type DWG is opened, the launcher 26 is to be invoked with the inner command line for the agent 30 as an input parameter. The use and effect of this command line is described below.
[0045] FIG. 7 shows two use cases. The functions at 86 - 1 correspond to the use functions at 66 in the process of FIG. 5 , i.e., the launching of a secondary-hosted application program 32 by activation of a control such as an item in the start menu 48 of the hosted desktop window 46 .
[0046] At 86 - 2 are the functions for the second use case, which is initiated when the user opens a file of a given type in the hosted desktop 20 . The hosted desktop 20 consults its registry and obtains the corresponding command line, then invokes the specified handler routine. Continuing with the above example, the command line causes the hosted desktop 20 to invoke the launcher 26 with the inner command line “C:\Program Files (x86)\Citrix\ICA Cnt\Agent.exe”/qlaunch “XenApp6:AutoCAD”/param:\\Client\% 1 being passed to the launcher 26 as a parameter. The hosted desktop 20 also provides the name and path of the document being opened, which will be passed as the % 1 parameter. Note that the document will generally need to be accessible to both the hosted desktop 20 as well as locally at the client computer 14 .
[0047] Continuing with 86 - 2 , the handler routine (e.g., launcher 26 ) sends a command over the control channel 28 to the client computer 14 to launch the agent 30 with the remaining part of the command line, e.g., “qlaunch “XenApp6:AutoCAD” /param:\\Client\doc-path”, where doc-path refers to the document path provided by the hosted desktop 20 when invoking the launcher 26 . The agent 30 then initiates the application launch (e.g., for AutoCAD on the secondary CCS 12 ) from the client computer 14 with the path to the document. From this point operation is as described above with reference to step 68 of FIG. 5 .
[0048] FIG. 8 describes the thin-client counterpart of the process of FIG. 7 . The functions at 90 and 96 are similar to their counterparts at 70 and 76 in FIG. 6 . The startup functions 92 include the functions at 72 of FIG. 6 augmented in the same manner as described above with reference to step 84 in FIG. 7 . In particular, the hosted desktop 20 also receives details about the file extensions (.cad, .pptx, etc.) that have been configured to be launched with the application programs for which it has obtained the application metadata. In this case the file extension information may be stored as part of the application metadata in the same data file (e.g., XML file) referred to in connection with step 72 of FIG. 6 . The hosted desktop 20 again uses the information to create FTA-like registry entries in the registry of the hosted desktop 20 , and the remaining operation (user cases at 94 - 1 and 94 - 2 can be as described above for the counterpart functions at 86 - 1 and 86 - 2 of FIG. 7 .
[0049] While in the above description of FIGS. 6 and 8 , the hosted desktop 20 uses two separate commands to obtain the application metadata (at both 72 and at 92 ), in alternative embodiments this function may require only one command from the hosted desktop 20 and a compound response by the client computer (i.e., both gathering the metadata and returning it to the hosted desktop 20 in one compound action).
[0050] While various embodiments of the invention have been particularly shown and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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Application programs delivered from one or more cloud computing systems (“clouds” or “CCSs”) are integrated into a desktop being delivered/hosted by another cloud (“primary” CCS). In one respect, the integration includes integration of controls for directly launching a separately hosted application program from a desktop hosted by the primary CCS, such as by selection of a start menu entry or activation of a “shortcut” icon that points to the application program. In another respect, a separately hosted application program is launched based on a user opening or accessing content (e.g. data file) that is specifically associated with the separately hosted application program but residing more locally, such as in the hosted desktop. In this aspect, the content is seamlessly redirected to the other cloud without requiring any direct network connectivity between the clouds.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of Ser. No. 13/507,985, which was filed on Aug. 10, 2012, which was a continuation-in-part patent application which claimed priority to the continuation patent application having Ser. No. 12/806,916, filed on Aug. 24, 2010, which claims priority to the continuation-in-part patent application having Ser. No. 11/899,720, which was filed on Sep. 7, 2007, which claims priority to the non-provisional patent application having Ser. No. 11/190,752, which was filed on Jul. 27, 2005, which claims priority to the provisional patent application having Ser. No. 60/598,013, which was filed on Aug. 2, 2004.
FIELD OF THE DISCLOSURE
[0002] This application relates to cosmetic products and to applicators for cosmetic products, and more particularly to sampling devices for cosmetic products. This application is specifically directed to a cosmetic applicator construction for use in the sampling of cosmetic products, especially individualized personal use by a given user.
[0003] The present cosmetic applicator construction more specifically comprises a distributable sampling packet that is affixable to a carrier substrate, such as a mailing card or printed publication, to permit distribution of the sampling packet to an end location for use thereat by a given user. The cosmetic applicator construction is suitable for use in the mailing of cosmetic samples in separate mailers or the provision thereof on or within a printed publication and includes a sampling packet, which is preferably a two-ply card, and an underlying release liner. The sampling packet is attachable to the mailer or printed publication for distribution to the end location and the upper ply of the sampling packet is thereafter removable from the lower ply at the end location to permit individualized and personal use by the user of the upper ply as an applicator portion for the application of a sample of a cosmetic product.
[0004] A unique aspect of such applicator portion is the provision of an embossed field upon the bottom side of the upper ply of the sampling packet, which embossed field is disposed within a sealed area between the upper and lower plies. Such upper and lower plies are preferably heat sealed to one another so as to maintain the integrity of the sampling packet while the sampling packet is affixed to the carrier substrate during the distribution thereof, with such embossed field configured to be able to collect and hold a sample of a cosmetic and to apply the held sample to the body of the user when the upper ply is removed from the lower ply at the end location.
BACKGROUND OF THE DISCLOSURE
[0005] People have adorned themselves with perfumes, colognes, powders, mascaras, and other cosmetics for centuries. Samples of a cosmetic encourage more sales to discriminating customers. The counter, where the customer may purchase, remains the most effective place to promote cosmetics. Often, retailers and suppliers of cosmetics provide free samples to entice women. However, women approach some cosmetic products skeptically, like lipstick. Women only buy lipstick after sampling it to judge its desirability. Women also know of the health risks in sampling a lipstick from a common sampler. Multiple uses of a cosmetic sampler invite customer complaints. Sampling a lipstick from a common tube by more than one person has become socially and medically frowned upon. Many women insist upon sampling from an unopened tube of lipstick or sample on their hand to avoid medical problems.
[0006] To overcome the health risks in cosmetic sampling, the cosmetic industry has made miniature versions of tubes and other cosmetic dispensers. The miniature versions remain subject to contamination at the retail counter. Further, cosmetic suppliers still incur the cost of producing and distributing the miniature samples for each of the color or product line variations. In addition, cosmetic suppliers and retailers have tried cotton swabs that dab from a common cosmetic source, sample sticks, and test strips. These alternatives when used commercially caused messes, inconvenienced customers, and proved ineffective.
[0007] Beyond test strips, tubes, and pencils, the cosmetic industry seeks an inexpensive applicator for applying a cosmetic sample to skin in a single stroke. Presently, cosmetics such as lipstick have individual applicators that indirectly place lipstick upon the lips of a woman. When applied, the lipstick sample should have the same texture, feel, and characteristics regardless of the applicator. Because of the goal for similarity between a sample and the lipstick for sale, applicators usually are miniature tubes or brushes despite other possibilities.
[0008] Traditionally fragrance samplers were dry pre-scented blotter cards that had to be individually wrapped to contain the fragrance for direct mail or magazine advertising. Beginning in the late 1970's, the micro-encapsulated Scentstrip® style magazine and direct mail insert was introduced. The Scentstrip insert is described in U.S. Pat. No. 5,093,182 to Ross. This product was produced on wide web offset printing equipment and therefore offered significant cost efficiencies for mass marketing. However, this was still a dry sample since the moisture in the deposited fragrance slurry would quickly wick into the paper substrate and leave the product sample dry. In fact, the entire technology depended on this moisture wicking since the wet microcapsules would not bond to the paper and would not break upon opening of the sampler. The microcapsules only break and release the fragrance oil when they are dry and are bonded to the paper. The drawback with this product was that it did not replicate the actual wet perfume product very well. To sample the fragrances in wet form, the moisture wicking of the wet fragrance slurry deposited in the wide web offset printing process required prevention. Preventing moisture wicking occurred most easily by using existing narrow web flexographic label printing technology to create a pressure sensitive product that incorporated a wet fragrance or cosmetic sample material between impervious barrier materials such as plastic films and foil structures.
[0009] Three main fragrance sampler patents guide wet fragrance or cosmetic sampling in magazines and direct mail. One is U.S. Pat. No. 5,391,420 to Bootman, which describes a pressure sensitive label comprising two plies of a film or plastic material: one bottom pressure sensitive ply, a deposit of fragrance material and an overlay of a second ply which traps said fragrance deposit. The sealing is by heat seal. The drawback of this product is that the fragrance material is often forced into and through the seal areas under pressure from the stacking forces of many magazines or inserts in distribution.
[0010] U.S. Pat. No. 5,161,688 to Muchin introduces a center ply material which has a die-cut window. This window ply is introduced onto the bottom pressure sensitive ply and thus creates a well for the fragrance material. The top, third, ply is then added and the result is that stacking forces are distributed on to the widow ply and the fragrance material is exposed to less forces that may lead to seal failures and leakage.
[0011] A modification of this second patent concept is described in U.S. Pat. No. 5,622,263 to Greenland. Greenland uses a liquid polyethylene or other hot liquid plastic material that creates the above-mentioned well and also assists in the heat sealing process. The Greenland concept also adds additional material cost and slows the process as the liquid plastic material needs to be deposited and bonded to the top and bottom ply. Further, the hot liquid plastic material introduces foreign odor and can contaminate the cosmetic or fragrance sampling material.
[0012] There are various other patents that deal with cosmetic sampling. Gunderman U.S. Pat. No. 5,690,130 discloses a sampling device with a unit dose of cosmetic that is screen printed onto a base paper with a perimeter adhesive and clear film overlay. Here, a well area is embossed to receive an integral applicator. The well is not designed as a receptor for the cosmetic product nor is the embossing incorporated into the seal so as to afford strength and allow the seal to withstand pressure better. Also, this sampler uses screen printing and is not capable of delivering a wet liquid dose of cosmetic material.
[0013] Lastly, a pressure sensitive base material is not disclosed which would allow automatic affixing as a label onto magazine or direct mail materials.
[0014] Gunderman U.S. Pat. No. 5,566,693 describes a screen printed sampler that delivers a cosmetic dose under a clear film overlay with pressure sensitive base material allowing affixing as a label. Again, this sampler is not designed to deliver a wet fragrance. The formulation requires fragrance to be mixed in a powder-based vehicle so that it can be screen printed. Further no embossing is envisioned to hold a cosmetic dose or to create seal wall integrity.
[0015] Gunderman U.S. Pat. No. 5,562,112 envisions a lipstick sampler, again with neither a well or an embossed seal wall feature.
[0016] Ashcraft U.S. Pat. No. 5,249,676 describes a multi-layer film with a flavor carrier layer between barrier layers. This does not create a wet fragrance sampler and no seals by embossing that will contain a wet cosmetic sample.
[0017] Moir U.S. Pat. No. 5,192,386 describes a screen printed, two-ply sampler with perimeter adhesive and clear film overlay. The cosmetic is a cosmetic powder, a heated oily, non-liquid waxy material, or a fragrance in a dry powder formulation. The product is not wet and there is no provision for creating heat sealed, embossed or interlocking walls to define a well and create internal seal strength sufficient to withstand stacking forces.
[0018] Szycher et al. U.S. Pat. No. 4,880,690 shows a perfume patch.
[0019] Moir U.S. Pat. No. 4,848,378 discloses a cosmetic screen printed, two-ply sampler that allows a pattern deposit of the cosmetic ingredient in the form of a non-smeary powder. This product is not pressure sensitive has no embossed wells or seal walls and does not deliver a wet sample.
[0020] Dreger U.S. Pat. No. 4,769,264 discloses a label product comprising at least two sheets, bonded by adhesive, with microencapsulated fragrance. The liquid fragrance inside the microspheres is so small that it does not create a wet rendering of the product and is dry to the touch as in current day dry “scentstrips”. There is no mention of any embossing to create an improved seal and resist stacking pressure.
[0021] Moir U.S. Pat. No. 4,751,934 discloses another version of a screen printed cosmetic powder formulation that may include fragrance in a two-ply pressure sensitive label construction. The seals of the two ply layers are by adhesive seal and the product rendering is dry or waxy, as in the lipstick dose version, but not wet as contemplated in the current disclosure. No embossing or debossing is used to create well areas or build wall seals.
[0022] Fraser U.S. Pat. No. 4,720,423 describes using in a multi-layer strip having an adhesive with frangible microcapsules as a package overwrap. This product does not render a wet sample and create wells or seal walls either.
[0023] Charbonneau U.S. Pat. No. 4,606,956 discloses a pressure sensitive two ply label construction with conventional microencapsulated slurry applied wet and then allowed to dry. The product sample is rendered in a dry state, no wells or embossed walls are used to create a more impervious seal that resists stacking forces.
[0024] Several other patents disclose fragrance samplers: Charbonneau U.S. Pat. No. 4,606,956 shows an on page fragrance sampling device. Charbonneau U.S. Pat. No. 4,661,388 shows a pad fragrance sampling device. Fraser U.S. Pat. No. 4,720,423 shows a package opening system. Moir et al. U.S. Pat. No. 4,751,934 discloses a cosmetic sampler. Dreger U.S. Pat. No. 4,769,264 discloses an on page fragrance sampling device. Moir et al. U.S. Pat. No. 4,848,378 discloses a cosmetic sampler. Moir et al. U.S. Pat. No. 5,192,386 discloses a method of making a cosmetic sampler. Ashcraft et al. U.S. Pat. No. 5,149,676 discloses a flavor burst structure and method of making it. Gundermann U.S. Pat. No. 5,562,112 discloses a lipstick sampler. Gundermann U.S. Pat. No. 5,566,693 discloses a fragrance sampler. Gundermann U.S. Pat. No. 5,690,130 discloses a cosmetic sampler with an integrated applicator. Sweeny U.S. Pat. No. 4,493,869 discloses fragrance microcapsules clear substrate. Turnbull U.S. Pat. No. 4,487,801 discloses a fragrance releasing pull-apart sheet. Greenland U.S. Pat. No. 5,622,263 discloses a sampler package and method of making it. Muchin U.S. Pat. No. 5,161,688 discloses a sampler and method of making the sampler. Bootman U.S. Pat. No. 5,391,420 discloses fragrance laden pouch samplers.
[0025] The U.S. patent to Wallschlaeger, U.S. Pat. No. 5,396,913, describes a lipstick applicator of a base support, which does not absorb dry solids and liquids placed thereupon, and has a coating of lipstick of 5 mils or less. The base support is not a tube or brush as is commonly associated with lipstick but rather a planar sheet. The lipstick coating is applied to the base support using screen printing methods.
[0026] The base support may have a cover thereupon to protect the coating from handling.
[0027] The U.S. patent to Wallschlaeger, U.S. Pat. No. 4,995,408, then describes a two ply cosmetic sampler. Wallschlaeger's sampler has projections extending upwardly from the base ply and gravity retains the sample within the projections and upon the base ply. Wallschlaeger presents the sampler as a separate stand alone device with a cover upon the projections of the bottom ply. In use, Wallschlaeger's sampler has the top ply detach, similar to a cover, and separate from the bottom ply so the consumer can use the top ply as an applicator of cosmetic retained in the bottom ply and when finished, the top ply is disposed. In contrast, the present disclosure has projections upon the top ply and retains the sample within the top ply, occasionally against gravity. Additionally, the present disclosure is designed for application as a label onto a card or page of printed material. The base ply remains upon the carrier while the top ply, including the sample, is removed for usage by the consumer.
[0028] The difficulty in providing a removable sampler is shown by the operation of a typical product sample at a cosmetics counter, or department store. The prior art communicates the shade and texture of a particular lipstick. However, most cosmetic suppliers produce about 150 shades of lipstick, making individual counter display and sampling impractical and expensive. Cosmetic suppliers have invested heavily in sampling lipstick tubes and two-ply applicators in use at counters around the world. In addition, lipsticks have a variety of formulae differing in shelf life and compatibility. Lipstick formulae require testing for sample stability during shipping and handling to a retail store. During testing, some samples may render a formula incompatible and deter marketing of a formula. The logistics and expense of testing pose obstacles to cosmetic vendors, raising the cost and time involved in a sampling program. The two ply construction of the prior art, the compatibility and stability testing, shelf space requirements, and packaging make existing applicators more expensive to use in a sampling program.
[0029] Embossing in prior art patents, serving as stilting, protects a cosmetic material, or lipstick, between the base ply and the top cover ply. An embodiment of the present disclosure serves as an aid to shear lipstick from a tube. The present disclosure allows the use of one common card by a woman for all the shades she seeks to sample. The present disclosure reduces the need for numerous pre-printed shade cards. As the woman samples the lipstick immediately after applying it to the present disclosure, stability and compatibility concerns of the lipstick do not arise. The two ply embodiment of the present disclosure has cosmetic sample deposited within the embossing of the top ply.
[0030] The present art overcomes the limitations of the prior art. That is, in the art of the present disclosure, a single use applicator for cosmetic products, receives lipstick from a common bulk container but allows each woman to sample the lipstick individually. The two ply embodiment of the disclosure retains cosmetic samples within embossing or projections upon the top ply that is then heat sealed to a base ply attached to a release liner.
SUMMARY OF THE DISCLOSURE
[0031] The preferred embodiment of the present cosmetic products applicator construction disclosure includes a multi-ply sampling packet upon a release liner that affixes the sampling packet to a card, a magazine, a mail piece, or other means of conveyance. Such construction has an upper, or top, ply, a lower, or base or bottom, ply, and a release liner, each with its own function. The top ply of the sampling packet has a pattern embossed downwardly so that the bosses, or projections, abut the base ply located below the top ply. The top ply is heat sealed upon the perimeter of the base ply of the sampling packet as both the top ply and the base play have the same shape. The base ply of the sampling packet then has an adhesive layer opposite the top ply for placing the sampling packet upon the release liner of the cosmetic applicator construction.
[0032] Following distribution of the sampling packet as affixed to the card, magazine, mail piece, or other means of conveyance, upon removal of the top ply from the bottom ply of the sampling packet at the end location, the top ply and the embossed field thereof define an applicator portion for personalized use by the user in applying a sample of the cosmetic.
[0033] In one alternate embodiment, the applicator portion is a single ply card with an embossed pattern that retains a sample of lipstick. The pattern forms a friction field that shears lipstick when applied directly from a tube onto the applicator. Also, the pattern assists in visually targeting the deposit of a cosmetic upon the applicator.
[0034] At a counter, a woman surveys the samples of lipsticks and selects a few of her choosing. The woman takes an applicator portion according to the present disclosure, with the embossed field down, and moves the embossed field across the lipstick source. The embossed field contacts the lipstick and lipstick collects between the embossing of such field. After selecting and collecting the desired sample, the woman folds the applicator away from her, moves the applicator to her mouth, and transfers the sample of lipstick to her lips. Following use, the woman folds the applicator towards her and encloses the embossed field.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] In referring to the drawings:
[0036] FIG. 1 shows a plan view of an alternate embodiment of the cosmetic products applicator constructed in accordance with the principles of the present disclosure;
[0037] FIG. 2 shows an isometric view of the partially folded applicator of the alternate embodiment;
[0038] FIG. 3 describes an end view of an alternate embodiment of the present disclosure while in flat form;
[0039] FIG. 4 shows an exploded view of the dual plies of the sampling packet of the present disclosure;
[0040] FIG. 5 shows a top view of the present disclosure, with the projections shown in phantom in the view;
[0041] FIG. 6 illustrates a sectional view of the sample packet and release liner ready for mailing;
[0042] FIG. 7 describes an enlarged sectional view of the top ply including the placement of a cosmetic sample within the bosses; and
[0043] FIG. 8 portrays an alternate embodiment having visible printing or advertisements upon the plies.
[0044] The same reference numerals refer to the same parts throughout the various figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0045] The present art overcomes the prior art limitations by providing an applicator construction for cosmetic products that allows multiple consecutive samples to be placed upon a single applicator portion for personalized use by an individual. Turning to FIG. 1 , an alternate embodiment of the applicator portion 1 for cosmetic products has a single ply 2 of material generally rectangular in shape. The ply 2 has scoring with a center fold line 4 and a mechanically embossed lip contour pattern 3 . Upon the longitudinal axis, the applicator portion 1 has a centered fold 4 that generally divides the applicator portion of the present disclosure into halves. As a means to secure the applicator portion 1 when closed, the card 2 has one or more notches 6 upon one or more edges. A die cuts the notches 6 to interlock when one half folds upon the other.
[0046] Generally centered, an embossed pattern 3 rises from the ply 2 . The pattern 3 has the appearance of a pair of lips in a smooth field. In the alternate embodiment, the pattern 3 has a plurality of raised bosses, or dots, in a grid shaped to mimic lips. The dots occupy approximately 25% of the surface area of the ply 2 . In an alternate embodiment, the pattern 3 has a series of parallel lines at a diagonal to the longitudinal axis. The pattern 3 rises from the ply 2 somewhat less than three thicknesses of the ply 2 , approximately 3 mils in height.
[0047] Many methods can form the raised area 3 , such as mechanical embossing or printing. A mechanical embosser uses a roller or flat tool with a positive image of the pattern 3 . The card 2 passes under a roller or flat embossing tool which impresses the pattern 3 upon the material of the card 2 . Printing forms a raised area 3 by its own methods, special inks, and deposition. In general, printing places a pattern 3 of greater height than the card 2 upon the surface of the card 2 . Printing includes the methods of silkscreen, offset, rotogravure, flexography, and deposition. In particular, flexography uses conventional inks, offset inks, flexographic inks, ultraviolet cured inks, and thermographic heat set inks. The inks adhere to the surface of the card 2 and the lipstick collects between portions of the ink. Deposition places material upon the card 2 in a pattern 3 . Deposition involves the methods of thermoforming, vacuum forming, casting, heat treatment, electrostatic treatment, spraying, extruding, adhesives, and cohesives.
[0048] As shown in FIG. 2 , a woman utilizes the applicator portion 1 to transfer a sample of cosmetics, or lipstick, to her lips for viewing and shopping. A woman folds the ply 2 along the fold line 4 with the halves folding away from the woman. Upon the halves, the embossed pattern 3 is ready to transfer a cosmetic once in contact with lips.
[0049] A user, such as a salesperson or the woman desiring to sample the cosmetic, places cosmetic, or lipstick, upon the embossed pattern 3 . The user may either drag the ply 2 across a lipstick tube or drag a lipstick tube across the ply 2 . The pattern 3 retains lipstick between the dots generally at no more depth than the height of a boss or a dot, approximately three mils. With the lipstick upon the ply 2 , the woman applies the sample to her lips for possible purchase. After use, the woman folds the card 2 toward her which encases the raised area 3 . The woman then interlocks the notches 6 to secure the applicator 1 in a closed configuration. The applicator portion 1 can then be carried by the woman with less risk of the sample leaking from the applicator portion 1 .
[0050] Turning to FIG. 3 , an alternate embodiment of the applicator portion of the present disclosure has two or more sub-plies 5 . The first sub-ply 5 a forms the base of the applicator portion 1 . The first sub-ply 5 a extends for the complete width and length of the card 2 . The first sub-ply 5 a folds longitudinally along the line 4 . Upon both sides of the fold line 4 , the applicator portion 1 has a second sub-ply, formed from two sub-ply halves 5 b . The second sub-ply halves 5 b have less width than half of the card 2 and less length than the card 2 . The second sub-ply halves 5 b provide the field 3 as manufactured by the methods previously described in FIG. 1 . The second sub-ply halves 5 b are generally symmetrically arranged about the fold line 4 .
[0051] Another version of this applicator portion may be made of material that does not feature a raised or embossed area, as previously described, but may be made of material, or exhibits a coating on a material, that renders the applicator portion or area receptive to the cosmetic sample, and which, at the same time, is relatively impervious to the cosmetic sample so that it does not absorb into or through the applicator before usage. The applicator portion will still fold over on a pre-creased, printed, or perforated line, so that it may function as the original applicator portion as described herein. Another version may include either a raised or embossed area, or a non-raised applicator area, with an overlay cover material that is removed prior to usage, to maintain a hygienic deposit area for the cosmetic sampler, when applied.
[0052] FIG. 4 now shows one preferred embodiment of the present disclosure of the cosmetic products applicator construction as it is assembled. The applicator construction 7 has an upper, or top, ply 8 above a lower, or bottom or base, ply 9 , forming a sampling packet, which affixes to a release liner 10 . The top ply is generally planar in extent and has a generally oval shape, a top surface 8 a exposed to the user of the sampling packet of the applicator construction, and an opposite bottom surface 8 b with a pattern of integral bosses, or projections 11 . The projections extend away from the top ply and towards the base ply. The individual projections can have varying patterns and shapes as is known in the art. The projections can be formed by embossing, de-bossing, thermoforming, cohesives, other adhesives, printing, laminated secondary plies, and like methods.
[0053] Beneath the top ply, the base ply 9 is generally a planar oval shape similar to that of the top ply. The base ply 9 has a top surface 9 a and an opposite bottom surface 9 b . The top surface 9 a of the base ply receives the projections depending from the top ply. The top ply is joined to the bottom ply upon their mutual perimeter generally by heat sealing and like methods. The bottom surface 9 b then has a layer of adhesive 13 , as later shown in FIG. 6 , preferably pressure sensitive, applied thereon for affixing the assembled plies of the applicator to the release liner 10 . Though shown here as rectangular, the release liner can be of any useful shape for placing the applicator as a label upon a mail piece, magazine page, or like material. The release liner then permanently adheres to a carrier, card, magazine page, and like material. Alternatively, the release liner 10 can be removed from the bottom of the sampling packet and the sampling packet can then be directly adhered to the mail piece, magazine page, and like material by the pressure sensitive adhesive remaining on the bottom surface 9 b of the bottom ply 9 . In use, the top ply 8 is ultimately removed from the fixed bottom ply 9 and the top ply carries the sample of cosmetic for the consumer to use as desired.
[0054] When the top ply 8 is placed upon the bottom ply 9 to form a sampling packet and both are then affixed to the release liner 10 , the applicator construction 7 appears from the top as shown in FIG. 5 . The top ply and the base ply have a similar shape, with the negative image of the pattern of projections 11 being apparent in the top ply. The release liner holds the compact form of the two plies including a cosmetic sample therein.
[0055] The assembled sampling packet with attached release liner then appears in layers as shown in the sectional view of FIG. 6 . The top ply 8 has a pattern where the integral projections 11 extend downwardly from the bottom surface 8 b . The projections are spaced apart on two axes and retain a sample 12 of cosmetic placed or collected therein. The shaping of individual projections, surface tension of the sample, and static charge retain the sample proximate to the bottom surface 8 b of the top ply until used. In the preferred embodiment, the projections are bosses or round knob like hubs. The height of the boss from the top surface 8 a is enough to retain the cosmetic sample between adjacent bosses and shallow enough to avoid perception by a woman during usage. The projections then abut the top surface 9 a of the bottom ply 9 . The projections generally rest upon the top surface without penetrating or deflecting into it. Upon the bottom surface 9 b , a layer of adhesive 13 is applied that affixes the base ply along with the top ply to the release liner.
[0056] Looking more closely at the sample 12 within the top ply 8 , FIG. 7 shows cosmetic sample retained between adjacent projections 11 here shown as bosses. The sample is retained side to side by adjacent projections and retained upon the top ply against gravity by surface tension and friction with the material of the top ply. The bosses each appear as a round swelling, similar to a smooth mound or knob. The bosses contact the skin of a woman on a minimum of surface area thus avoiding an adverse perception of bosses scraping across her skin. The knob or hub like shape retains the cosmetic sample during manufacturing and transport yet readily releases the sample upon the woman's skin when the woman grips the top ply 8 and moves the bottom surface 8 b with the bosses upon her skin. The cosmetic sample is generally less than 5 mils thick. The present disclosure retains the sample in the top ply during packaging and handling of the applicator by printers and eventually by end users.
[0057] FIG. 8 illustrates an alternate embodiment of the present disclosure. The top ply 8 has its top surface 8 a with a pattern of projections 11 thereon. The projections extend downwardly as before. The projections leave a limited appearance of a negative image upon the top surface that permits printing 14 , advertising, or other indicia to be placed thereupon. The top surface can display a message or printing visible to the user before removing the top ply for application of the cosmetic sample contained therein. With the top ply removed during usage, the top surface 9 a of the bottom ply 9 is exposed upon the release liner affixed to a carrier. In this alternate embodiment, the top surface of the bottom ply can be seen by the user and thus printing 14 , advertising, or other indicia can be placed there as well. This alternate embodiment provides at least two surfaces capable of receiving and then displaying printing for viewing by the end user.
[0058] From the aforementioned description, a cosmetic products applicator has been described. The applicator portion is uniquely capable of individual sampling of lipstick from bulk containers and for retaining a cosmetic in the removable top ply. The projections or bosses of the top ply do not create an adverse perception upon the skin of the woman users. The applicator may be manufactured from many materials, including but not limited to, paper, polymers, polyester, polyethylene, polypropylene, polyvinyl chloride, nylon, Teslin, Saran, ferrous and non-ferrous metal foils and their alloys, and composites.
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A cosmetic applicator construction that includes a distributable sampling packet that is affixable to a carrier substrate, such as a mailing card or printed publication, to permit distribution of the sampling packet to an end location for use thereat by an individual user. The cosmetic applicator construction is suitable for use in the mailing of cosmetic samples in separate mailers or the provision thereof on or within a printed publication and includes a sampling packet, which is preferably a two-ply card, and an underlying release liner. The upper ply of the sampling packet includes an embossed field formed on the underside of the upper ply, disposed between the upper ply and the lower ply, and configured to hold a cosmetic sample.
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REFERENCE TO RELATED APPLICATION
[0001] Cross reference is made to copending U.S. patent applications Ser. No. ______ entitled “Adjustable Ground Anchor” (Attorney Docket No. 445-4555-U; 60137-630 PUS1); Ser. No. ______ entitled “Support Arm Positioning Tab” (Attorney Docket No. 445-3448-U; 60137-631 PUS1) and Ser. No. ______ entitled “Slide in Locking Newspaper Box” (Attorney Docket No. 445-3447-U; 60137-633 PUS1).
BACKGROUND OF THE INVENTION
[0002] Some rural and suburban areas utilize curbside mailboxes. Mailboxes generally have a large metal box mounted on a support designed primarily to receive quantities of incoming mail. Some rural curbside mailboxes may be grouped together at property boundaries or road/driveway intersections, depending upon conditions.
[0003] Mailboxes evolved to reduce the time required for a mail carrier to complete delivery when the front door of a residence is some distance from the street. Mail boxes are mounted curbside on suitable posts or other supports and may be fitted with a signal flag or semaphore arm—usually red or fluorescent orange that is raised by the resident of the property to notify the postman of outgoing mail and by the postman to inform the recipient that incoming mail had been delivered.
[0004] Mailboxes exist under harsh conditions and are subject to extreme stresses: people back into them and run them over; snow plows pack tons of ice and snow against them; the sun bakes them; storms pelt them and can rip them from the ground; lawn mowers and string trimmers attack their supporting posts; animals and insects like wasps live in them; and vandals blow them up, paint-ball them and attack them with bats; among other things. Mailboxes need to be replaced frequently.
[0005] Moreover, new home construction continues in rural and suburban areas and new mailboxes are in demand.
SUMMARY OF THE INVENTION
[0006] A non-limiting embodiment of a support for a mailbox includes an arm, a first bracket for attaching to the arm and having a first projection, a second bracket for attaching to the arm and having a second projection, wherein the first projection and the second projection cooperate to achieve a desired dimension on the arm to support a desired dimension of the mailbox.
[0007] Another non-limiting embodiment of a support for a mailbox includes an arm having a tab, a first bracket for attaching to the arm and having an L-shaped projection, a second bracket for attaching to the arm and having a second projection having a brim and a bottom, wherein the L-shaped projection cooperates with the tab and the second projection brim cooperates with the L-shaped projection to achieve a desired dimension to support a desired dimension of the mailbox.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
[0009] FIG. 1 is a perspective, disassembled view of an embodiment of a mailbox support.
[0010] FIG. 2 is an assembled, cutaway view of the mailbox support of FIG. 1 including a mailbox.
[0011] FIG. 3 is a perspective view of an upper support of FIG. 1 .
[0012] FIG. 4 is a cutaway view of an installed upper support.
[0013] FIG. 5 is a top perspective view of the upper support of FIG. 1 .
[0014] FIG. 6 is a perspective, cutaway view of the upper support of FIG. 1 .
[0015] FIG. 7 is a perspective view of the upper support of FIG. 6 .
[0016] FIG. 8 is a perspective, cutaway view of an installed mailbox on the upper support of FIG. 2 .
[0017] FIG. 9 is a perspective view of a newspaper box of FIG. 2 .
[0018] FIG. 10 is a perspective view of the newspaper box of FIG. 9 and the lower support of FIG. 2 .
[0019] FIG. 11 is a perspective, cutaway view of an installed newspaper box of FIG. 9 installed in the lower support of FIG. 2
[0020] FIG. 12 is a perspective view of the mounting system of FIG. 1 .
[0021] FIG. 12A is a perspective side view of the mounting system of FIG. 12 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Referring to FIGS. 1 and 2 the mailbox support of the invention is shown. The mailbox support 10 has a post 15 , an upper support 20 , a lower support 25 , a newspaper box 30 , a mailbox 35 and an anchoring system 40 . The post, the upper mailbox support, the mailbox, the newspaper box and the lower mailbox support may be extruded or molded from any suitable material such as PVC or aluminum. The post, which is extruded, may have a pair of decorative stanchions 45 that hide a bottom portion 50 of post and the anchoring system 40 .
[0023] Referring now to FIGS. 1-5 , the upper support 20 is shown. The upper support has an injection molded rectangular body 55 that has a top 60 , a bottom 65 , and a downwardly extending rectangular portion 70 that looks like a downspout of a gutter. The rectangular portion 70 is designed to fit over the post 15 (see FIG. 4 ) and be anchored thereon. The rectangular portion has a friction tab 75 that extends downwardly from the bottom 65 and extends inwardly along its length into an opening 80 within the rectangular portion 70 . The friction tab 75 has a rounded raised portion 85 to enable a user to manipulate the friction tab if installing the lower support 20 . Because of the nature of the material of the friction tab, the friction tab is flexible and if moved, the friction tab tends to move back to its original position.
[0024] The bottom 65 of the upper support 20 has a plurality of reinforcing ribs 90 and openings 95 (see FIG. 3 ) that receive screws (not shown) to attach the lower support 25 as will be discussed hereinbelow. During installation of the upper support 20 , the rectangular portion 70 is slid down the post 15 . US Postal Service regulations require that the upper support and the mailbox 35 placed thereon (see FIG. 2 ), be disposed between 41 and 45 inches above the ground. This height enables a mail person to easily insert mail (not shown) into the mailbox. An installer may slide the upper support 20 to an approximate height, and the friction tab engages the post 15 (see FIG. 4 ) so that the upper support 20 tends to stay in place while the installer looks for a tape measure (not shown) to install the upper support at the proper height. This way the installer does not need “three hands” to do the job. Once the upper support is in position, the installer drives screws (not shown) through holes 105 disposed in the rectangular portion 70 of the upper support to secure the upper support to the post 15 . If the upper support is not in the proper position, the installer simply lifts the friction tab 70 by means of raised portion 85 and slides the upper support to the proper height for installation.
[0025] Referring now to FIGS. 5 , 6 and 7 , the top 60 of the upper support 20 is shown. The top has a plurality of raised races 110 molded therein. The races have straight-aways 115 that each have a pair of tabs 120 extending parallel to the top 60 therefrom.
[0026] A left bracket 125 and a right bracket 130 are disposed on the top 60 and cooperate with the tabs 120 so that the brackets may be manipulated by an installer user to adjust inwardly or outwardly to fit the width of the mailbox (see FIGS. 2 and 8 ).
[0027] The left bracket 125 has an inner longitudinal wall 140 and an outer longitudinal wall 145 that are connected by end walls 150 . The inner longitudinal wall 140 has a plurality of inverted top-hat shaped extensions 155 extending therefrom towards the right bracket 130 . The top hat has a top 160 that has a slot 165 that extends from a middle 170 of the extension through an end 175 distal from the inner longitudinal wall 140 (see FIG. 5 ). The top-hat shaped extensions 155 also have brims 177 . Each top hat is cut away (see FIGS. 5 and 7 ) to allow brim extensions 178 to extend into the right bracket as will be discussed hereinbelow.
[0028] The right bracket 130 has an inner longitudinal wall 185 and an outer longitudinal wall 190 that are connected by end walls 195 . The inner longitudinal wall 140 has a plurality of alternating L-shaped extrusions 200 and horizontally flipped L-shaped extrusions 205 extending therefrom towards the left bracket 125 . Each L-shaped extrusion and horizontally flipped L-shaped extrusion has a rectangular vertical side portion (see FIGS. 6 and 7 ) 215 extending upwardly from the bottom portion 210 . The inner longitudinal wall 185 has a cut-out portion 187 to hold the top hat extensions 178 .
[0029] To install the left bracket 125 and right bracket 130 on the top 60 of the upper support 60 , the bottom portions 210 of each alternating L-shaped extrusions 200 and horizontally flipped L-shaped extrusions 205 are inserted between the top 60 and the tabs 120 extending from the straight-aways 115 . The brims 177 of each top hat shaped extension 155 engage the top of the vertical side portions 215 . At this point the left and right brackets may slide laterally to approximate the width of a mailbox (See FIG. 8 ). Once the left and right brackets are in the desired position, screw 220 is driven through the slot 165 through washer 225 into the top portion 20 to anchor the left bracket 125 to the top 60 and to have the brims 177 of each top hat shaped extension 155 engage the top of the vertical side portions 215 so that the left bracket is also anchored to the top 60 . The brim extensions 178 allow the left bracket 125 and the right bracket 130 to be engaged even if the brackets are pulled apart widely to accommodate a wider mailbox 35 .
[0030] Referring to FIG. 8 , once the left bracket 125 and the right bracket 130 are anchored to the top 60 , the mailbox 35 is inserted over the outer longitudinal wall 145 of the left bracket 125 and the outer longitudinal wall 190 of the right bracket 130 , screw(s) 230 are inserted through the mailbox into the outer longitudinal wall 190 thereby anchoring the mailbox to the upper support 20 .
[0031] Referring to FIGS. 1 , 9 and 10 , the lower support 25 is shown. The lower support has a pair of side arms 235 , each side arm having a plurality of molded support ribs 240 (see FIG. 10 ), a top portion 245 , a rectangular downwardly extending portion 247 that fits over the post 15 and the downwardly extending rectangular portion 70 of the upper support 20 , and a plurality of holes 248 through which screws (not shown) are driven to attach the lower support 25 to the upper support 20 .
[0032] To attach the lower support 20 to the upper support 25 , the lower support is slid over the post 15 before the upper support and then is raised into contact with the installed upper support 20 as described above. The lower support 25 is then screwed into the upper support 20 to join the upper and lower supports together.
[0033] The newspaper box 30 is rectangularly shaped with an open end 250 for the insertion of newspapers (not shown). The newspaper box 30 has a top wall 255 , a pair of sidewalls 257 , each sidewall having a groove 260 , a back wall 265 and a bottom wall 270 . The grooves 260 are adapted to receive the molded support ribs 240 on the lower support 25 side arms 235 .
[0034] Referring to FIGS. 1 , 9 and 11 , a locking tab 275 extends from the back wall 265 of the newspaper box 30 parallel to the top wall 255 (see FIG. 9 ). The locking tab 275 has a chamfered extension 280 that increases in slope from the back wall towards a front of the newspaper box 30 and a lower portion 285 that is parallel to the top wall 255 but not in plane therewith. The chamfered extension fits in rectangular opening 290 in the top portion 245 of the lower support (see also FIG. 1 ) 25 .
[0035] To install the newspaper box 30 , grooves 260 are slid over the molded support ribs 240 until the chamfered extension 280 clicks into place in the rectangular opening 290 in the top portion 245 of the lower support 25 . Because the lower locking tab 275 is flexible, if the removal of the lower mailbox from the newspaper box is desired, the user simply pushes down the lower portion 285 of the locking tab 275 until the chamfered extension 280 releases itself from the opening 290 and the newspaper box 30 may be slid out of the lower support 25 .
[0036] Referring now to FIGS. 12 and 12A , the anchoring system 40 is shown. the anchoring system includes a screw 295 , a circular lower plate 300 , a circular upper plate 305 and a plurality of receiving fixtures 310 . The upper and lower plates, the screw and the receiving fixtures 310 are made of a tough, long-lasting material such as steel or rugged plastic.
[0037] The upper plate 305 is designed to rotate about the lower plate and has three circular slots 312 extending therethrough. The slots extend far enough around the plate to enable an installer to properly orient the post 15 as will be discussed herein below. The receiving fixtures are welded to the upper plate 305 .
[0038] The lower plate 300 has a plurality of bolts 315 that extend upwardly therefrom through the slots 312 in the upper plate 305 . The bolts 315 extending through the slots in the upper plate have threaded top portions 320 . The screw 295 is fixedly attached, such as by welding, to a bottom 325 of the bottom plate.
[0039] To install the anchoring system 40 , an installer screws the screw into the ground (not shown). This can be achieved by joining the upper plate 305 with the lower plate 300 by fitting bolts 315 through the upper plate slots 312 and inserting a pry bar (not shown), in between the receiving fixtures 310 so that rotation of the pry bar around the axis of the screw 295 causes the upper plate to rotate about the lower plate until the lower plate bolts 315 hit the end of the slots 312 . Once the ends of the slots are hit, the lower plate 300 rotates with the upper plate 305 causing the screw to drive into the ground. Installation continues as the screw digs into the ground until the lower plate 300 touches the earth. Once the earth is touched, continuing to drill would compromise the soil beneath the lower plate that might, in turn, compromise the anchoring system 40 .
[0040] In other systems, to get the proper orientation of their post, a user might let the screw dig into the ground farther thereby compromising the soil or too little, leaving the screw 295 open to the elements. In the non-limiting embodiment shown, once the lower plate 300 reaches the ground, the upper plate 305 and the receiving fixtures 315 can be properly oriented to hold the post 15 in the proper position by rotating the upper plate 305 about the lower plate 300 within the slots 312 until the proper position is obtained. Because of the orientation of the slots 312 and the number of receiving fixtures 310 , the plate does not need to be rotated more than 90 degrees, though other numbers and shapes of receivers, extent of the slots and numbers of bolts are contemplated by this invention.
[0041] Once the upper plate is properly oriented, nuts 320 are torqued on the bolts 315 to prevent further rotation of the upper plate 300 relative to lower plate 295 thereby completing the construction. The receiving fixtures 315 are spaced on the upper plate 300 so that they can receive a 4×4 piece of wood (not show) or the like within the confines of the receiving fixtures or the post 15 is slipped down and over the receiving fixtures 315 and attached thereto from the outside by screws (not shown).
[0042] Although a combination of features is shown in the illustrated examples, not all of them need to be combined to realize the benefits of various embodiments of this disclosure. In other words, a system designed according to an embodiment of this disclosure will not necessarily include all of the features shown in any one of the Figures or all of the portions schematically shown in the Figures. Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments.
[0043] The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.
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An adjustable support for a mailbox includes an arm, a first bracket for attaching to the arm and having a first projection, a second bracket for attaching to the arm and having a second projection, wherein the first projection and the second projection cooperate to achieve a desired dimension upon the arm to support a desired dimension of the mailbox.
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